Code No: R05322002 Set No.

1
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY AND WELDING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. A mechanized ductile iron captive foundry has to be set up with a capacity of 250
tons/day of output metal. It must have sections for core making, two automated
mold making and handling lines, a melting and casting bay, two induction melting
furnaces, separate scrap yards for returns, automated sand preparation and supply
and sand reclamation system, degating yard, a cleaning and grinding unit, a quality
control and inspection wing and an administrative block. Provide a schematic
sketch of foundry plant layout which, you think, provides for minimum material
handling and redundant work. [16]

2. (a) Define permeability of molding sand. How is it tested? Why this property is
important for molds and cores?
(b) What are the molding clays? How do you classify them?
(c) Explain how binding clay forms bridges between the sand grains and the water
and consequently develops strength. [6+4+6]

3. (a) What laboratory tests that are routinely done for cupola melt control? What
is the relevance of these tests?
(b) How is melt rate and liquid metal temperature and composition are controlled
in Cupola? What process parameter the operator has in control on adjusting
these? [8+8]

4. (a) Sketch schematically a gating system and explain the geometry, design con-
siderations and role of different elements of it.
(b) Differentiate between progressive and directional solidification of castings.
[10+6]

5. (a) Explain the submerged arc welding process with a neat sketch.
(b) Differentiate between TIG welding and MIG welding processes. [8+8]

6. (a) Explain the ‘friction welding’ process used for welding of plastics giving details
about
i. Principle of operation
ii. Equipment used
iii. Surface preparation
(b) Write down the advantages, limitations and applications of the above process.
[10+6]

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Code No: R05322002 Set No. 1
7. Explain why for the following

(a) Bakelite scrap is useless, while polyvinylchloride scrap can be recycled.

(b) thermoplastic polymers are flexible, where as thermosetting polymers are not.
(c) Polyethylene is harder and more rigid than phenol formaldehyde.
(d) During condensation polymerization water molecules are formed as by-product.
[4+4+4+4]

8. (a) Describe the atomization process for the production of metal powders. Differ-
entiate between water and gas atomization techniques.
(b) Briefly classify and describe various powder metallurgical compaction processes
enlisting their suitability for specific application. [8+8]

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Code No: R05322002 Set No. 2
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY AND WELDING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) When does metal casting become attractive against a wrought product of same
shape?
(b) When do you use a sweep pattern?
(c) Differentiate between an automated foundry and mechanized foundry.
(d) Define permeability of molding sand? How is it tested? Why molds and cores
need to be permeable. [3+3+5+5]

2. (a) Discuss the use of polymer resins as binder of molding and core sands.
(b) Explain how strength is conferred in sodium silicate bonds. [10+6]

3. (a) Sketch cross section of cupola furnace and label different zones. What physical
and chemical changes occur in these zones when cupola is operated?
(b) What measures do you suggest to improve the thermal efficiency of a cold
blast cupola. [10+6]

4. (a) Explain how alloys solidify?

(b) Explain how microshrinkage and microsegregation are developed in solidified
parts?
(c) What are the pros and cons of using several ingates instead of single ingate in
feeding a mold cavity, when total ingate area is same in both cases? [4+6+6]

5. (a) Sketch the neutral flame for oxy acetylene welding and explain the chemical
reactions taking place in various zones of the flame. Also compare this with
oxidising and carburising flames.
(b) Explain how acetylene gas is stored in the cylinder with a sketch, showing the
cross section of the cylinder. Discuss the safety devices incorporated on the
cylinder. [10+6]

6. (a) What is prime? What are the various types of primers used in adhesive bond-
ing process. Explain them.
(b) Explain why primers are used in adhesive bonding process.
(c) Explain the following with regard to adhesive bonding process.
i. Surface preparation
ii. Curing the assembly which is adhesive coated. [6+5+5]

7. (a) What effects does a plasticizing agent have on a polymer? Explain in detail.

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Code No: R05322002 Set No. 2
(b) Give applications for which flammability of plastics would be of major impor-
tance. Also explain why?
(c) What properties do elastomers have that thermoplastics in general do not
have. Discuss. [8+4+4]

8. (a) Explain the following in detail:

i. Apparant density
ii. Sedimentation
iii. Compressibility
iv. Permeability
v. Flow rate.
(b) The property of the final sintered compact depends on the physico-chemical
characteristics of the metal powders used. Discuss. [10+6]

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Code No: R05322002 Set No. 3
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY AND WELDING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What are the common materials used for making patterns? Why some mate-
rials are preferred to others in making patterns used in a mechanized foundry?
(b) Explain why the following allowances are provided: draft allowance, shrinkage
allowance, and machining allowance.
(c) What are the common pattern making methods? [6+6+4]

2. (a) What are the property requirements of cores? How the required property set
is obtained by adjusting the composition of core sands?
(b) What are stock cores? How are they made?
(c) Differentiate between the composition, properties, shelf live of oil, sand and
shell sand cores [6+4+6]

3. (a) What is liningless cupola? How is cupola shell is water cooled?

(b) Draw a sketch of water cooled cupola and its accessories. [6+10]

4. Lay out an algorithm based on the principles of gating system design to feed an
arbitrary mold cavity with liquid metal. [16]

5. (a) Name two gas welding techniques and explain their principle and applications.
(b) Discuss various types of flames used in gas welding process. Suggest their
specific applications. [8+8]

6. Write an essay on ‘Testing of adhesive bonded joints’. [16]

7. With the help of a neat sketch, describe the working of a ram injection molding
process. List out the advantages and disadvantages of the process over other meth-
ods of processing of plastics. Also give the important applications of this process.
[16]

8. (a) Why is particle size is of great importance in powder metallurgy? What do

you know about different classes of powders in powder metallurgy? Explain.
(b) Discuss the electrolytic method of copper powder production indicating its
advantages, the principle on which the method is based, the main variables
affecting the properties of the powder and technology of the process. [6+10]

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Code No: R05322002 Set No. 4
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY AND WELDING
(Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Explain how rapid prototyping methods are cutting lead times of proving the
new casting designs?
(b) Explain how rapid prototyping methods can build master patterns very rapidly?
[8+8]

2. (a) Discuss the suitability of zircon, quartz, olivine, alumino-silicate, and chromite
sands in a ferrous industry based on their properties.
(b) What the role of following additives to sand mixes: Carbonaceous additions,
cellulose, and cereals? [10+6]

3. (a) What are the problems associated with feeding a vertical centrifugal casting
machine? How the molds are fed from the ladle in practice?
(b) Explain the causes of the following casting defects in centrifugally cast parts:
raining, and banded segregation. [10+6]

4. (a) What is the function of sprue well? How do you eliminate the possibility of
sand abrasion at the bottom of sprue well?
(b) Sketch a drag runner and cope ingates in a gating system.
(c) What are the disadvantages of bottom gating? [6+6+4]

5. (a) How does straight polarity differ from reverse polarity. Explain them in detail.
(b) What are the principle sources of current supply for arc welding process. With
the help of neat sketches and circuit diagram, explain their working procedure.
(c) What is meant by penetration? Explain its relevance in welding process.
[5+7+4]

6. (a) Compare brazing and braze welding. What are their specific applications?
Explain.
(b) What are the different costs considered in various welding processes? Explain
them in detail. [8+8]

7. (a) Describe the advantages of cold forming of plastics over other processing meth-
ods.
(b) Describe the methods used to make tubular plastic products. [7+9]

8. (a) Discuss the important properties and various testing methods of metal pow-
ders.

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Code No: R05322002 Set No. 4
(b) Describe isostatic and continuous compaction techniques. [8+8]

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