M424_FAILURE ANALYSIS
2025 SEMESTER 2 EXAMINATIONS PREPARATIONS
EXAM QUESTIONS AND ANSWERS
PART I_MULTIPLE COICE
QUESTION 1
A material capable of large amount of energy before fracture is known as
A. Ductility
B. Toughness
C. Shock proof
D. Plasticity
Answer: Toughness – ability to absorb energy before fracture.
QUESTION 2
Corrosion is the deterioration of a substance or its properties due to
A. Mechanical overload
B. Reactions with its environment
C. Fatigue
D. Wear
Answer: Reactions with its environment – corrosion occurs from chemical/electrochemical reactions.
QUESTION 3
The energy absorbed in a body, when it is strained within the elastic limits, is known as
A. Strain energy
B. Proof resilience
C. Modulus of resilience
D. Toughness
Answer: Strain energy – energy stored within the elastic region.
QUESTION 4
Corrosion accelerated by an oxygen concentration cell will occur
A. Within a crevice
B. Outside a crevice
C. Both inside and outside a crevice
D. Everywhere
Answer: Within a crevice – low oxygen inside causes anodic reaction and corrosion.
QUESTION 5
Crevice corrosion. It may occur on the following except:
A. Washers
B. Under barnacles and sand grains
C. Flat surfaces
D. U7nder applied protective films, and at pockets formed by threaded joints
Answer: Flat surfaces – crevice corrosion happens in confined or shielded areas.
QUESTION 6
In the tensile test, the phenomenon of slow extension of the material, i.e. stress increasing with the time at the
constant load is called
A. Yielding
B. Breaking
C. Creeping
D. Plasticity
Answer: Creeping – time-dependent deformation at constant stress
QUESTION 7
Two forms of localized attack are:
A. Erosion and crevice corrosion
B. Pitting and intergranular corrosion
C. Stress cracking and high temperature corrosion
D. Pitting and crevice corrosion
Answer: Pitting and crevice corrosion – both are localized corrosion types.
QUESTION 8
Pitting corrosion can be controlled by
A. Materials selection
B. Protective Coatings
C. Cathodic protection
D. All the above
Answer: All the above – all these methods prevent pitting.
QUESTION 9
In tensile test of mold steel specimen, the breaking stress as compared to ultimate tensile stress is
A. More
B. Less
C. Same
D. More/less depending on the composition
Answer: Less – because of necking and reduced cross-sectional area before fracture.
QUESTION 10
During a tensile test on a specimen of 1 cm cross-section, a maximum load observed was 8 tons and area of
cross section at neck was 0.5 c m2. Ultimate tensile strength of the specimen is
A. 4 tons/ c m2
B. 8 tons/ c m2
C. 16 tons/ c m2
D. 22 tons/ c m2
Answer: 8 tons/cm² – strength = load ÷ original area.
QUESTION 11
The impact strength of the material is the index of its
A. Tensile strength
B. Capability of being cold worked
C. Toughness
D. Hardness
Answer: Toughness – measures ability to absorb impact energy.
QUESTION 12
The tensile strength of the material is obtained by dividing the maximum load during the test by
A. Area at the time of fracture
B. Original-cross sectional area
C. Average of (a) and (b)
D. Minimum area after fracture
Answer: Original cross-sectional area – standard basis for stress calculation.
QUESTION 13
In designing equipment and facilities, it is important to consider the various factors that make up the service
conditions, these factors including the following except:
A. Temperature
B. Material
C. Velocity
D. Pressure
Answer: Material – it is a design factor, not a service condition.
QUESTION 14
Corrosion inhibitors generally control corrosion by:
A. Forming thin films that modify the environment at the metal surface
B. Removing the oxygen from the system
C. Changing the pH
D. Changing the temperature
Answer: Forming thin films – inhibitors form protective barriers on the surface.
QUESTION 15
Ultimate tensile stress of the mild steel compared to ultimate compressive stress is
A. More
B. Same
C. Less
D. More or less depending on other factors
Answer: Less – mild steel has higher compressive than tensile strength.
QUESTION 16
Stainless steels are normally classified based on their microstructure, and usually are defined as iron-based
alloys having at least
A. 11% Lead
B. 11% Carbon
C. 11% Copper
D. 11% Chromium
Answer: 11% Chromium – provides corrosion resistance by forming a passive oxide film.
QUESTION 17
Problems associated with welds that may affect their corrosion resistance include:
A. Brittle failures
B. Heat-affected zones
C. Porosity
D. B and C
Answer: B and C – heat-affected zones and porosity reduce corrosion resistance.
QUSTION 18
…………………….. is often the result of the wearing away of a protective scale or coating on the metal
surface.
A. Corrosion stress cracking
B. Pitting and intergranular corrosion
C. Pitting and Crevice corrosion
D. Stress cracking and high temperature corrosion
Answer: Pitting and crevice corrosion – begin when protective coating is damaged.
PART II_SOLVE THE FOLLOWING PROBLEMS
1. A ceramic matrix composite contains internal flaws as large ass 0.001 cm length. The plane strain
fracture of the composite is 45 and the tensile strength 550 MPa. Will the flaw composite to fail before
the tensile strength is reached? Assume f = 1
Solution:
σ c =KIC /(Y √ (πa))=45/√ (3.14 ×10 ⁻ ⁵)≈ 254 MPa .
Answer: The composite will fail before reaching 550 MPa since 254 MPa < 550 MPa.
2. Of those metals listed on the table
Metals Yield Tensile Strain at Fracture Elastic
strength Strength fracture strength Modulus
MPa MPa MPa MPa GPa
A 310 340 0.23 265 210
B 100 120 0.40 105 150
C 415 550 0.15 500 310
D 700 850 0.14 720 210
E Fracture before yielding 650 350
a) Which will experience the greatest percentage reduction in area?
Why?
Metal B: Highest strain at fracture (0.40), that is most ductile.
b) Which is the strongest? Why?
Metal D: Highest tensile strength (850 MPa).
c) Which is the stiffest? Why?
Metal C: Highest elastic modulus (310 GPa).
d) Which is the hardest? Why?
Metal D: High strength usually means high hardness