A pipe can be manufactured as (a) seamless (cold rolled and extruded) or (b) hot rolled and welded. (i) Describe the process for manufacturing each type of pipe: (a) Seamless (cold rolled and extruded) pipe; (b) Hot rolled and welded pipe. (ii) Why might a cold rolled seamless pipe be better suited to drilling operations than a hot rolled and welded pipe? A particle reinforced composite (containing flakes) has particles evenly distributed throughout the matrix where the rule of mixtures applies. (i) State THREE effects that a larger volume of carbon particles within the matrix produces. A drill bit is a cutting tool on the end of a rotary subsea drill. A Thermally Stable Polycrystalline (TSP) drill bit can be used to drill a subsea well. TSP bits are man-made polycrystalline structures consisting of a multitude of synthetic diamond crystals sintered together at high pressure and temperature, used to aid cutting into hard rock formations. (i) Describe THREE reasons why this type of bit may be better suited than steel. (ii) State TWO failure mechanisms of the bit. How would you determine the mechanical properties of a carbon steel pipe at ambient temperature? List THREE relevant properties and the corresponding THREE tests to determine the properties for each. One of the failure mechanisms for a drill pipe is fatigue. (i) Describe the meaning of the word “fatigue” directly referring to a drilling operation. (ii) State FOUR ways this fatigue failure can be mitigated. A domestic window frame can be manufactured from a variety of materials including uPVC plastic or aluminium. (i) Describe FOUR mechanical or chemical properties that are important. (ii) Based on these properties in Q2(c)(i), state which material would be the most suitable choice and the reason for your selection. (d) (i) Why is the tensile strength of ceramics much lower than the compressive strength? (ii) What would you do to increase the tensile or bending strength of a concrete beam? A ceramic has a strength of 300 MPa and a fracture toughness of 3.6 MPa.m0.5. A crack has been found with a total length of 2 x 10-5m. Can this ceramic support this size hole without fracturing? Support your answer using a calculation. Most types of metal corrosion are galvanic in nature. What are the fundamental requisites for galvanic corrosion to occur? How is electricity generated and conducted through a corrosion circuit? MCS Ltd designs and produces armour plates for the defence industry, under working conditions, these armour plates are subjected to blast and ballistic missiles, and so need to be resistant to penetration. (a)List and explain three types of tests that you would use to measure the hardness of these plates. (b)Ceramics are known for their electrical properties. Name 4 electrical properties and describe 3 with any relevant example of application. (c) Describe thermoset plastics and thermoplastics, explaining the main differences between them The grids covering the drains in the streets of most British cities are made of ductile cast iron (also known as spheroidal graphite iron). As you know, it rains frequently in Britain and the streets can stay wet for some time. In wintertime salt is frequently spread on the roads and the colour of the iron changes to a bright yellow-brown. Once winter is over, they return to their usual brown-black colour. Using your knowledge of materials and corrosion, explain why they last so long (many decades) and what the colour changes signify. Comment on the suitability of the following combinations of materials for oxygenated seawater service. You may refer to the RGU Galvanic Series for Metals and Alloys in Seawater for this question. (i) 17-4 PH flange and graphite gasket (2) (ii) CDA 675 flange and 410 stainless steel sealing ring (2) (iii) Inconel 825 tube and Inconel 625 connector (2 (iv) 316L stainless steel pipe and 90-10 Copper-nickel sprinkler (2) (b) Define ’’hot-dip galvanising’’ and explain how it works. (6) (c) (i) Explain how a film forming inhibitor protects a carbon steel pipeline from CO2 corrosion. A sketch would assist the explanation. (2) (ii) Name TWO key factors that affect the ability of a film forming inhibitor to adhere to the surface of the pipeline. (2) (d) Discuss the effects of solution resistance on the Evans diagram. (2) (a) Describe with illustrations and equations the following forms of corrosion: (i) Crevice corrosion; (3) (ii) Intergranular corrosion. (3) (iii) What steps can be taken to mitigate against crevice corrosion occurring? (2) Calculate the tendency for corrosion to occur in the following metal electrolyte systems, identifying the anodic and cathodic reactions: (i) silver in cupric acid; (3) (ii) nickel in silver nitrate. (3) E0 Ag/Ag+ = -0.799V vs SHE, E0 Cu2+/Cu = -0.377V vs SHE, E0 Ni/Ni2+ = 0.250V vs SHE
A pipe can be manufactured as (a) seamless (cold rolled and extruded) or (b) hot rolled and welded.
(i) Describe the process for manufacturing each type of pipe:
(a) Seamless (cold rolled and extruded) pipe;
(b) Hot rolled and welded pipe.
(ii) Why might a cold rolled seamless pipe be better suited to drilling operations than a hot rolled and welded pipe?
A particle reinforced composite (containing flakes) has particles evenly distributed throughout the matrix where the rule of mixtures applies.
(i) State THREE effects that a larger volume of carbon particles within the matrix produces.
A drill bit is a cutting tool on the end of a rotary subsea drill. A Thermally Stable Polycrystalline (TSP) drill bit can be used to drill a subsea well. TSP bits are man-made polycrystalline structures consisting of a multitude of synthetic diamond crystals sintered together at high pressure and temperature, used to aid cutting into hard rock formations.
(i) Describe THREE reasons why this type of bit may be better suited than steel.
(ii) State TWO failure
How would you determine the mechanical properties of a carbon steel pipe at ambient temperature? List THREE relevant properties and the corresponding THREE tests to determine the properties for each.
One of the failure mechanisms for a drill pipe is fatigue.
(i) Describe the meaning of the word “fatigue” directly referring to a drilling operation.
(ii) State FOUR ways this fatigue failure can be mitigated.
A domestic window frame can be manufactured from a variety of materials including uPVC plastic or aluminium.
(i) Describe FOUR mechanical or chemical properties that are important.
(ii) Based on these properties in Q2(c)(i), state which material would be the most suitable choice and the reason for your selection.
(d) (i) Why is the tensile strength of ceramics much lower than the compressive strength?
(ii) What would you do to increase the tensile or bending strength of a concrete beam?
A ceramic has a strength of 300 MPa and a fracture toughness of 3.6 MPa.m0.5. A crack has been found with a total length of 2 x 10-5m. Can this ceramic support this size hole without fracturing? Support your answer using a calculation.
Most types of metal corrosion are galvanic in nature. What are the fundamental requisites for galvanic corrosion to occur?
How is electricity generated and conducted through a corrosion circuit?
MCS Ltd designs and produces armour plates for the defence industry, under working conditions, these armour plates are subjected to blast and ballistic missiles, and so need to be resistant to penetration.
(a)List and explain three types of tests that you would use to measure the hardness of these plates.
(b)Ceramics are known for their electrical properties. Name 4 electrical properties and describe 3 with any relevant example of application.
(c) Describe thermoset plastics and thermoplastics, explaining the main differences between them
The grids covering the drains in the streets of most British cities are made of ductile cast iron (also known as spheroidal graphite iron). As you know, it rains frequently in Britain and the streets can stay wet for some time. In wintertime salt is frequently spread on the roads and the colour of the iron changes to a bright yellow-brown. Once winter is over, they return to their usual brown-black colour. Using your knowledge of materials and corrosion, explain why they last so long (many decades) and what the colour changes signify.
Comment on the suitability of the following combinations of materials for oxygenated seawater service. You may refer to the RGU Galvanic Series for Metals and Alloys in Seawater for this question.
(i) 17-4 PH flange and graphite gasket (2)
(ii) CDA 675 flange and 410 stainless steel sealing ring (2)
(iii) Inconel 825 tube and Inconel 625 connector (2
(iv) 316L stainless steel pipe and 90-10 Copper-nickel sprinkler (2)
(b) Define ’’hot-dip galvanising’’ and explain how it works. (6)
(c) (i) Explain how a film forming inhibitor protects a carbon steel pipeline from CO2 corrosion. A sketch would assist the explanation. (2)
(ii) Name TWO key factors that affect the ability of a film forming inhibitor to adhere to the surface of the pipeline. (2)
(d) Discuss the effects of solution resistance on the Evans diagram. (2)
(a) Describe with illustrations and equations the following forms of corrosion:
(i) Crevice corrosion; (3)
(ii) Intergranular corrosion. (3)
(iii) What steps can be taken to mitigate against crevice corrosion occurring? (2)
Calculate the tendency for corrosion to occur in the following metal electrolyte systems, identifying the anodic and cathodic reactions:
(i) silver in cupric acid; (3)
(ii) nickel in silver nitrate. (3)
E0 Ag/Ag+ = -0.799V vs SHE, E0 Cu2+/Cu = -0.377V vs SHE, E0 Ni/Ni2+ = 0.250V vs SHE
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