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21-Mat-A2 Materials Transport Phenomena: December 2018

Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)

  1. Question 1 General Knowledge — True / False / Ambiguous
  2. Question 2 Continuous-Caster Tundish Grade Change (PFR + CSTR in Series)
  3. Question 3 Direct Steelmaking — Gas-Film-Controlled FeO Reduction
  4. Question 4 Scale-Up of Regenerator Stoves — Dimensional Analysis
  5. Question 5 Hot-Strip-Mill Transfer-Bar Radiative Cooling — Maximum Slab Thickness and Annual Capacity
  6. Question 6 Liquid-Metal Flow Over a Flat Plate — Penetration-Theory Heat Transfer
  7. Question 7 Pump Power for a Direct-Chill Casting Mold Water Circuit
  8. Question 8 Hydrostatic Casting Forces on a Spherical Die-Cast Mold with a Fill Riser

Start with Question 1 →

National Exams — December 2018 — Met-A2 Metallurgical Rate Phenomena. Three-hour, open-book exam; any Casio or Sharp approved calculator permitted. Candidates answer Question 1 (compulsory) plus any four of Questions 2–8; the five answered count equally (20 marks each). All eight are solved below for completeness. Candidates were told to state any interpretive assumptions where doubt exists.

Reference texts: Geiger, G. H. & Poirier, D. R., Transport Phenomena in Materials Processing (TMS) — the primary reference for the momentum-, heat- and mass-transfer analyses in Questions 3, 5, 6, 7 and 8; Szekely, J., Evans, J. W. & Sohn, H. Y., Rate Phenomena in Process Metallurgy — reactor-network and interfacial mass-transfer modelling (Questions 2, 3); Welty, J. R. et al., Fundamentals of Momentum, Heat and Mass Transfer — dimensional analysis and pipe-friction data (Questions 4, 7); Gaskell, D. R., Introduction to the Thermodynamics of Materials — Fe–C phase relations (Question 1h).

Note on the questions
Question 8 specifies a fill hole of explicit length $L$ and asks whether to increase $L$, and it is solved below from first principles. Question 5 asks for the maximum thickness of slab and adds an explicit instruction to justify the four simplifying assumptions rather than merely state them.