Casting

Short questions (each 2 marks)

1 Name the casting method that is used for casting large cylindrical pipes. (2008
BPUT)
2 Name of the bonding agents in core sands. (2008
BPUT)
3 Distinguish between shrinkage cavity and shrinkage porosity . (2008
BPUT)
4 In casting process weight vof the casting is 54kg and weight of the material in the
gating system is 18kg. Find out the casting yield.
(2009 BPUT)
5 What is the role of clay in moulding sand. (2009 BPUT)
6 Write the difference between progressive solidification and directional solidification.
(20098 BPUT)
7 Name a casting method in which expandable pattern is used and method where
permanent mould is used .
(2010 BPUT)
8 Mention the role of risers in a sand casting method. (2010
BPUT)
9 In sand casting ,sprue or pouring gate designed tapered-Why? (2010
BPUT)
10 Name at least 4 characteristics suitable for making a sound mould in sand casting
methods (2011 BPUT)
11 Name of a pattern material which is expandable and also a product casted by thish
method. (2011 BPUT)
12 What is CO@ moulding used for making cores? (2011 BPUT)
13 What is meant by skin dried mould? Explain its applications.
14 What is the various elements that comprise of the gating system?
15

Marks : 10 x 3 = 30
1. What are the common materials used for pattern-making-
2. Draw a sketch of a typical mould and name its principal parts.
3. Classify different types of moulds.
4. Name the common materials used for forging.
5. Describe press forging.
6. What is the difference between the hammer and press forging-
7. What are the common forging defects-
8. List out the applications of welding
9. What are the functions of coatings on shielded electrodes-
10. Describe resistance welding.
11. What is meant by hot spinning.
12. Specify the merits of different kinds of rolling mills.
13. What is a press- Where it is used-
14. Name various parts of power press.
15. What is meant by Sintering-
LONG QUESTIONS

1. Compare the solidification time of two optimum side risers of the same
volume with one has cylindrical shape and other is parallopiped.
2.

Chapter -2: Casting Process

1. Define the terms Casting and Foundry.

2. Why casting is preferred over other methods of manufacturing? Discuss.
3. What are the common basic features to various casting process.
4. What is a pattern?
5. What are the basic features common to various casting processes? Discuss their
relative merits and demerits.
6. What considerations are necessary while designing a pattern?
7. How is layout of a pattern made? State the procedure for pattern construction.
8. Discuss briefly various types of pattern materials.
9. List the types of factors on which the various types of patterns depend.
10. Enumerate the various types of commonly used patterns.
11. With neat sketches explain briefly solid pattern, skeleton pattern and loose piece
pattern.
12. With neat sketches explain briefly the following patterns:
(a) Segmental pattern (b) Cope and drag pattern (c) Sweep
pattern.
13. List the various types of allowances which are usually provided in a pattern.
14. Explain briefly the following pattern allowances:
(a) Shrinkage allowance (b) Machining allowance
(c) Rapping or shaking allowance (d) Distortion allowance
 Chapter -3: Mould Making

1. What are the main characteristics which a good moulding sand should posses?
2. How does the characteristics of moulding sand influence the performance during
moulding and casting?
3. Discuss briefly the materials which are added to moulding sand to improve their
moulding properties.
4. Explain how the grain size and shape affect the performance of foundry sand.
5. Discuss briefly the influence of water-content on moulding sand properties.
6. Explain the process of sand preparation and sand conditioning.
7. What is Stop-off? Explain briefly.
8. Explain briefly, parting sand, facing sand and backing sand.
9. What are mould surface coatings? Explain.
10. Explain the process of sand preparation and sand conditioning.
11. Why testing of foundry sand is necessary? What are the common tests performed
on foundry sands?
12. What are the main characteristics of a good core sand?
13. What are the main core binders? Discuss their uses in making core sand.
14. Classify the different types of moulds and state their advantages.
15. Draw the sketch of a typical mould and name its principal parts.
16. What is stack moulding?
17. Sketch and describe the following techniques, stating clearly their advantages
and special applications :
(a) use of false cope, (b) use of dry sand cores, (c) use of drawbacks,
(d) bedding-in, (e) coping down.
18. How does machine moulding differ from hand moulding? List the advantages and
disadvantages of moulding machines.
19. Discuss briefly moulding machines.
20. State the advantages of the following
(a) Dry sand mould over green sand mould,
(b) Loam mould over dry sand mould,
 (c) Permanent mould over dry sand mould.
21. With a neat sketch explain briefly the construction and working of a cupola
furnace.
22. With a neat sketch explain briefly the electric furnace.

Chapter -4: Gating Systems

1. What is a gate and list the functions of a gating system.

2. With a neat sketch explain the different parts of a gating system.
3. How a gate is designed?
4. What is meant by risering? State the advantages that are provided by a riser.
5. What is the best shape and size of a riser? Why?
6. Write short notes on
(a) Use of padding (b) Use of exothermic materials, and
7. With neat sketches explain the different types of gating systems.
8. What is gating ratio? Explain.

Chapter -5: Cooling and Solidification

1. Explain briefly the process of crystallization of pure metals.

2. What is dendritic solidification? Explain.
3. What is the critical size of nucleation that nucleates from melt?
4. Deduce the expression for free energy concept in solidification.
5. Explain the following:
(a) Normal segregation, (b) Gravity segregation, (c)
Micro-segregation and (d) Macro-segregation.
6. What is the scope of chills in obtaining directional solidification? Explain.

Chapter -6: Casting Processes

1. What are the steps involved in preparation of a casting?

2. State the advantages and disadvantages of casting process.
3. What are the basic rules for good casting design?
4. List the different types of casting processes.
5. With a neat sketch explain the sand casting process.
6. Write short notes on:
(a) Shell-mould casting, (b) Plaster-mould casting, (c)
Ceramic-mould casting, (d) Vacuum casting and (e)
Evaporative pattern casting.
7. With neat sketchs explain the investment casting process. List its advantages,
disadvantages and applications.
8. Explain briefly slush casting, electroslag casting, precision casting, semi solid
metal forming and pressed casting.
9. What is centrifugal casting? For what type of jobs would you recommend this
casting process?
10. Explain briefly true centrifugal casting, semi-centrifugal casting and centrifugal
casting.
11. What is continuous casting? Explain the process of continuous casting with a
neat sketch.
12. List the advantages claimed by permanent mould casting over sand casting.
13. Describe the pre-design consideration in the design of castings.
14. List the factors which influence the choice of the proper casting method.
15. Enumerate the methods of repairing and salvaging defective castings.
16. What are the common defects of casting? State their causes and remedies.
17. Explain briefly the different types of cleaning operations performed on castings.
18. Discuss briefly the various methods employed to inspect the castings.

Unit I

1. State any four types of patterns.

Ans: The various types of patterns which are commonly used are as follows:
i) Single piece or solid pattern

ii) Two piece or split pattern

iii) Loose piece pattern

iv) Cope and drag pattern

 v5) Gated pattern

2. Mention any two advantages and disadvantages of die casting.

Ans:
Advantages:
It is a very fast process.
Moulds have longer life.
Better surface can be obtained.
Limitations:
Moulds are much costlier.
This method is not suitable for small quantity production.
Shape and weight of the casting is limited.

3. What function of core ?

Ans: Functions of core are:

Core provides a means of forming the main internal cavity for hollow casting.
Core provides external undercut feature
Cores can be inserted to obtain deep recesses in the casting.
Cores can be used to increase the strength of the mould.

4 What are the advantages and applications of ceramic moulds?

Ans:
Advantages:
It is less expensive
Intricate objects can be casted.
Castings of thin sections and which do not require machining can be produced.
Applications:
It is mainly used for all material using better ingredient in slurry.

5. What are the pattern materials? (Dec. 2008)

Ans: 1) Wood

2) Metal
3) Plastic
4) Plaster
5) Wax

6. Explain the term fettling.

Ans: Fettling is the name given to cover all those operations which help the casting to give a good
appearance. It includes the removal of cores, sand, gates, risers, runners and other unwanted projections
from the casting.

7
What is the purpose of flux?
Ans: 1) It acts as shield to weld.
 2) To prevent atmospheric reaction of molten metal with atmosphere.

8) How can slag inclusions in welding be avoided?

Ans:
Avoid multi layer welding
Reduce arc length
Increase electrode angle
Avoid using large electrode

9)
Why is flux coated on filler rods?
Ans:
The coating improves penetration and surface finish.
Suitable coating will improve metal deposition rates.

10)
What is the application of carburizing flame?
Ans:
Carburizing flame is generally used for:
1.steel rods
2. Welding of low alloy
3. Non-ferrous metals

4. High carbon steel

11)
What are the diameter and length of the electrodes available in the market? (Dec.
2009)
Ans:
Standard length of electrodes are 250 mm, 300 mm and 450 mm.
Standard diameters of electrodes are 1.6,2 ,2.5, 3.2, 4,5,6,7,8, and 9 mm.

12) List the various alloys and metal used in pattern.

Ans: The various metals and alloys employed for making patterns ate :
(a) Aluminium and its alloys
(b) Steel
(c) Brass
(d) Cast iron
(e) White metal
13 List the three forms of contraction.
Ans: Contraction takes place in three forms
(1) Liquid contraction
(2) Solidifying contraction
(3) Solid contraction

14 Shrinkage of metal depends on what factors ?

Ans: The shrinkage of metal depends on the following factors :
(1) The metal to be cast
(2) Pouring temperature of the molten metal
(3) Dimensions of the casting
(4) Method of moulding

15 Define permeability.
Ans : The sand must be porous to allow the gases and steam generated within the moulds to be
removed freely. This property of sand is known as permeability or porosity.

16 Explain the principle of oxy-actelyene welding.

Ans: When acetylene, in correct proportion, is mixed with oxygen in a welding torch and ignited,
then the flame resulting at the tip of the torch is sufficiently hot to melt and join the parent metals.
17.
1 Name the steps involved in making a casting.
Ans: Steps involved in making a casting are
(1) Pattern making
(2) Sand mixing and preparation
(3) Core making
(4) Melting
(5) Pouring
(6) Finishing
(7) Testing