Casting E Book

Tailor made module for various exams like HPCL, ISRO, BARC etc.
PRODUCTION TECHNOLOGY
(MENTAL CASTING PROCESSES)
1. The main purpose of chaplets used in foundry practice are :
(a) To provide efficient venting (b) To ensure directional solidification
(c) To support the core (d) To align the mould boxes
2. Core prints are used to:
(a) Strengthen core
(b) Form seat to support and hold the core in place
(c) Fabricate core
(d) All of the above
3. Due to the shake allowance:
(a) The fillets are provided on pattern
(b) The pattern is made slightly bigger than required size
(c) The tapper is provided on vertical faces of pattern
(d) The pattern is made slightly smaller than required size
4. The property of moulding sand which does not provide any resistance to contraction
of the solidified casting is called?
(a) Collapsibility (b) Refractoriness (c) Adhesiveness (d) Permeability
5. Chills are:
(a) Mixed in sand to enhance its collapsibility
(b) Metallic objects to provide very high heat extraction capability of sand mould
(c) Metallic objects to provide strength of sand mould
(d) Metallic objects to provide very low heat extraction capability of sand mould
6. Shrinkage allowance on the pattern is provided to take care of
(a) Liquid shrinkage (b) Solid shrinkage
(c) Liquid and solid shrinkage (d) Any one, liquid or solid shrinkage
7. Decreasing the clay content in the moulding sand increases the
(a) Permeability (b) Refractoriness
(c) Green strength (d) Flowability
8. Refractoriness of the moulding sand can be increased by
(a) Increasing the grain size (b) Decreasing the grain size
(c) Increasing the water content (d) Increasing the clay content
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9. "Bell" shapes are generally made by

(a) Single piece patter (b) Gated pattern
(c) Cope and drag pattern (d) Sweep pattern
10. The properties of moulding sand that allows the gases to be escaped from the mould is
called
(a) Hot strength (b) Permeability (c) Refractoriness (d) Plasticity
11. Which of the following processes is suitable for making hollow parts with thin
sections?
(a) Thermoforming (b) Blow molding
(c) Injection molding (d) Reaction injection molding
(e) Extrusion
12. A taper provided on the pattern for its easy and clean withdrawal from the mould is
known as
(a) Shrinkage allowance (b) Distortion allowance
(c) Machining allowance (d) Draft allowance
13. Draft angle is provided for forged parts–
(a) to arrange fiber lines in a favorable way (b) to avoid unbalanced forced
(c) to reduce stress concentration (d) for easy removal from die cavities
14. The main advantages of using CO2 moulding is that
(a) Much hardened mould is obtained

(b) Gases can be made to escape more easily
(c) Gases formed react with CO2 to form a colloidal solution
(d) Carbon % in the molten metal can be increased

15. In a casting process, a mould of dimension 60 cm × 30 cm × 14 cm is to be filled by
liquid the top pouring. The liquid metal height above the top surface of the mould is
2
14 cm and the area of the gate is 6 cm . The time taken to fill the mould will be :
(a) 32 s (b) 12 s (c) 25.34 s (d) 28.28 s

16. In a gating system desing, a down sprue of 180 mm length has a diameter of 20 mm at
its top end. The liquid metal in pouring cup is maintained up to 60 mm height. The
diameter, in mm. of the down sprue at its lower end to avoid aspiration will be :
(a) 11.11 (b) 14.14 (c) 25 (d) 17.32
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17. Investment casting is used for

(a) Mass production
(b) Shapes that are made with difficulty using complex patterns in sand casting
(c) Stainless steel parts
(d) Shapes which are complex, intricate and cannot be cast by any other method
18. According to Chvorinov, following is the correct formula for solidification time (Ts),
where k = Mould casting constant, V = volume of casting, SA = surface area.
2 2 2 2
 SA   SA   V   k 
(a) Ts =V   (b) Ts =k   (c) Ts =k   (d) Ts =V  
 k   V   SA   SA 
19. Cold chamber die casting is suitable for which of the material listed below?
(a) Brass (b) Tin (c) Zinc (d) Lead
20. Sand and oxide layers adhering to the casting are removed by which of the following
processes?
(a) Heating (b) Shot blasting (c) Gas cutting (d) Air cooling
21. Which of the following is the best suited for production of hollow pipes?
(a) Centrifugal casting (b) Investment casting
22. If the proportional of oxygen is less than the proportion of acetylene in oxy acetylene
gas welding, the flame produced is ______ .
(a) Plasma arc (b) Carburizing flame
(c) Oxidizing flame (d) Neutral flame
23. The gating ratio refers to the cross sectional areas of:
(a) Sprue : In-gate : Runner (b) Spure : Runner : In-gate
(c) In-gate : Runner : Sprue (d) Runner : Spure : In-gate
24. "A reservoir of molten metal provided in the casting so that hot metal can flow back
into the mould cavity due to the reduction in volume of metal due to solidification" is
known as:
(a) Spure (b) Runner (c) Riser (d) Core
(e) Chills
25. The ability of casting material to fill the mould cavity is described by...................
(a) Cohesiveness (b) Reactiveness (c) Fluidity (d) Permeability
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26. For Gating system of casting, choke are (A) may be written as (where, m = mass of
casting, ρ = density of molten metal, H = effective metal height, C = efficiency factor,
t = pouring time):
m m m 2 gH tm
(a) A  (b) A  (c) A  (d) A 
 tC 2 gH tC 2 gH  tC  C 2 gH
27. Which of the following is not the casting defect?
(a) Hot tears (b) Stop-off (c) Run out (d) Blow holes
28. If a cube of 100 mm dimension is to be made of Aluminium (shrinkage allowance =
10 mm/m). What will be the dimension of wooden pattern?
Assume only shrinkage allowance.
(a) 101mm × 101mm × 101mm (b) 100mm × 99mm × 98mm
(c) 99mm × 99mm × 99mm (d) 102mm × 101mm × 100mm
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29. A casting of size 100 × 100 × 100 mm solidifies in 20 minutes. Find out the
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solidification time for casting of size 100 × 100 × 50 mm under same condition.
(a) 16.3 minutes (b) 14.3 minutes (c) 12.3 minutes (d) 11.3 minutes
30. In sand-casting, when it is not possible to get very fine details on the surface then
some modifications are done in a pattern termed as:
(a) Pattern allowance (b) Shrinkage allowance
(c) Machine allowance (d) Core prints
(e) Elimination of details
31. The ability of the molding material to withstand the high temperatures of molten
metal so that it does not cause fusion is known as:
(a) Refractoriness (b) Green strength
(c) Dry strength (d) Hot strength
(e) Permeability
32. ______ is not the slag trap method used in sand molding.
(a) Bottom gate (b) Pouring basin
(c) Strainer core (d) Runner extension
(e) Whirl gate
33. Cylinder blocks of internal combustion engine are made by
(a) Forging (b) Extrusion (c) Casting (d) Drilling
(e) Broaching
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34. In shell moulding, the dimensional accuracy that can be expected is

(a) 0.001 to 0.002 mm/mm (b) 0.003 to 0.005 mm/mm
(c) 0.1 mm to 0.3 mm/mm (d) 0.3 mm to 0.5 mm/mm
35. The disadvantage of die casting process is
(a) High production rates are not possible (b) Surface finish is poor
(c) Heavy sections cannot be easily cast (d) Cost is less
36. True centrifugal casting is used to
(a) Cast objects symmetrical about an axis (b) Get accurate castings
(c) Get dynamically balanced castings (d) Get statistically balanced castings
37. A sprue is
(a) A sprue is the passage through which liquid material is introduced into a mold A
process of cleaning castings
(b) A chemical added to molten materials to get sound castings
(c) A special type of non-ferrous core used in centrifugal castings only
(d) A process of cleaning casting
38. The fuel used in pit furnace is generally
(a) Wood (b) Charcoal (c) Oil (d) Coal
39. Riser is generally located
(a) Near the deepest section of the mould (b) Near the parting line
(c) On the upper most section of the casting (d) Opposite to the pouring end
40. Pouring basing is provided in sand moulds
(a) To reduce the turbulence in the liquid metal
(b) To maintain high temperature of liquid metal
(c) To increase fluidity
(d) To improve properties of sand
41. In die casting the moulds are made of
(a) Metal (b) Ceramic (c) Sand (d) Glass
42. The riser is designed in such way that
(a) It solidifies before the casting
(b) It solidifies after the casting
(c) Both riser and casting solidifies at the same time
(d) There is no relation between solidification of casting and riser
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43. Which of the following is not a part of gating system?

(a) Pounng basin (b) Sprue (c) Gates and riser (d) Vents
44. Ornaments are cast by
(a) Die casting (b) Continuous casting
(c) Pressed casting (d) Centrifugal casting
45. Die cast parts are used when–
(a) Material of the parts has low melting point
(b) Parts have small size
(c) All three objectives are desired
(d) Parts are made on large scale
46. In die casting process
(a) Any metal can be cast (b) Any size of casting can be prepared
(c) The cost of dies is generally insignificant
(d) Very high production rates are possible
47. The main advantage of investment casting is–
(a) Raw materials required are cheap
(b) No special tooling is required
(c) There is no sophisticated technology involved
(d) It can be conveniently adopted for heavy castings
48. The molten metal is not introduced directly into the mould Cavity as it will cause:
(a) Erosion of the mould cavity (b) Corrosion of the mould cavity
(c) Crack in the bottom surface (d) Breakage of the mould
49. Which one does not form a part of the gating system for a casting:
(a) Pouring basin (b) Spure (c) Choke (d) Pattern
50. Shrinkage allowance is added to pattern dimensions to take care of :
(a) Liquid shrinkage (b) Liquid and solid shrinkage
(c) Solid shrinkage (d) None of these
51. Fine grains size during the solidification of a metal is achieved by:
(a) Lower nucleation rate
(b) Higher nucleation rate with lower growth rate
(c) Higher nucleation rate with higher growth rate
(d) Larger growth rate
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52. Which is not a casting defect?

(a) Misruns (b) Cope and Drag
(c) Lifts and shifts (d) sponginess
53. A casting process in which molten metal is poured in a mould and allowed to solidify
while the mould is revolving is known as:
(a) Die casting (b) Investment casting
(c) Centrifugal casting (d) Continuous casting
54. A zone of cupola furnace which starts from above the melting zone and extends upto
bottom of charging door is known as:
(a) Stack zone (b) Well
(c) Preheating zone (d) Combustion zone
55. Gray cast iron blocks 200 × 100 × 10 mm are to be cast in sand moulds. Shrinkage
allowance for pattern making is 1%. The ratio of the volume of pattern to that of the
casing will be
(a) 0.97 (b) 0.99 (c) 1.01 (d) 1.03
(e) 0.96
56. Shift is a casting defect which
(a) Results in a mismatching of the top and bottom parts of a casting
(b) Results in general enlargement of a casting
(c) Occurs near the ingrates as rough lumps on the surface of a casting
(d) Occurs as sand patches on the upper surface of a casting
57. The property of sand due to which the sand grains stick together is called :
(a) Collapsibility (b) Permeability
(c) Cohesiveness (d) Adhesiveness
58. The purpose of gate is used to :
(a) Deliver molten metal into the mould cavity
(b) Act as a reservoir for the molten metal
(c) Feed the molten metal to the casting in order to compensate for the shrinkage
(d) Deliver molten metal from the pouring basin to gate
59. Hot tear is a
(a) Hot working process (b) Welding defect
(c) Casting defect (d) Forging defect
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60. A cylindrical blind riser with diameter’d’ and height 'h' is placed on the top of mold
cavity of a closed type sand mold. If the riser is of constant volume, then the rate of
solidification in the riser is the least when the ratio h/d is
(a) 1 : 2 (b) 2 : 1 (c) 1 : 4 (d) 4 : 1
61. An aluminium cube of 12 cm side has to be cast along a cylindrical riser of height
equal to its diameter. The riser is not insulated on any surface. If the volume
shrinkage of aluminium during solidification is 6 percent, calculate shrinkage volume
on solidification
3 3 3 3
(a) 72 cm (b) 103.68 cm (c) 1728 cm (d) 1624.32 cm
62. Dye penetration inspection is generally used to locate

(a) Temporary defects (b) Surface breaking defects
(c) Artificial defects (d) Core defects
63. Sweep patterns are used for moulding parts having the shape of
(a) Rectangular (b) Complex shape
(c) Square (d) Symmetrical
64. Chills are not used in the following application
(a) Directional solidifications
(b) Smaller casting for eutectic alloy
(c) Change in crossections
(d) Complex geometry
65. Zinc alloys are preferentially cast by
(a) Investment casting (b) Die casting
(c) Centrifugal casting (d) Shell-mould casting
66. Consumable patterns are made of
(a) Polystyrene (b) Wax
(c) Plaster of Paris (d) Any of the above
67. Shell patterns are often used for
(a) Pipe work (b) Bends
(c) Drainage fittings (d) All of the above
68. Cohesiveness of sand depends on
(a) Grain size and shape of the sand particles
(b) Bonding materials
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(c) Moisture content

(d) All of the above
69. A casting defect which results in general enlargement of a casting is known as
(a) Shift (b) Sand wash (c) Swell (d) Scab
70. Which one of the following materials will require the largest size of riser for the same
size of casting?
(a) Aluminium (b) Cast iron (c) Steel (d) Copper
71. Directional solidification in casting can be improved by using:
(a) Chills and chaplets (b) Chills and padding
(c) Chaplets and padding (d) Chills, chaplets and padding
72. Green sand is a mixture of
(a) 30% sand, 70% clay (b) 50% sand, 50 % clay
(c) 70% sand, 30% clay (d) 90% sand, 10% clay
73. A casting defect which occurs due to improper venting of sand is known as
(a) cold shuts (b) blow holes (c) shift (d) swell
74. Loam sand comprises of
(a) 40% of clay and 10% moisture (b) 50% of clay and 10% moisture
(c) 80% of clay and 20% moisture (d) 50% of clay and 18% moisture
75. When V is the volume and A is the surface area of the casting, then according to
Chvorinov's equation, solidification time of a casting is proportional to
2 3 4
V V  V  V 
(a) (b)   (c)   (d)  
A A  A  A 
76. In sand casting lower part of the moulding flask is called:
(a) cope (b) riser (c) drag (d) none of these
77. The process of making hollow castings of desired thickness by permanent mould
without the use of cores is known as :
(a) Die casting (b) Slush casting
78. The colour marked on the surface of a pattern to be machined is :
(a) Black (b) Green (c) Red (d) Blue
79. Hot tears results in castings due to:
(a) Too much shrinkage of molten metal
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(b) High content of sulfur in molten metal

(c) Less moisture in mould
(d) Both (a) and (b)
80. Which of the following materials requires the largest shrinkage allowance, while
making a pattern for casting?
(a) Cast iron (b) Brass
(c) Aluminum (d) Plain carbon steel
81. Coal dust, is added to moulding sounds for improving of the casing:
(a) Surface finish (b) Collapsibility (c) Hot strength (d) Dry strength
82. Match the following manufacturing processes with the manufactured products:
(a) Investment casting (1) Turbine rotors
(b) Die casting (2) Turbine blades
(c) Centrifuged casting (3) Connecting rods
(d) Drop forging (4) Gl pipes
(e) Extrusion (5) Cl Pipes
(f) Shell moulding (6) Carburetor body
(a) 1, 6, 5, 3, 2, 4 (b) 1, 6, 5, 3, 4, 2
(c) 6, 1, 5, 3, 2, 4 (d) 1, 6, 3, 5, 4, 2
83. Swab is
(a) A welding defect (b) A gear cutter
(c) A tool used in foundry (d) A forging die
84. Match list-I (Process) with -II (Products or raw material) and Select the correct
Ans.wer using the codes given below the list:
List-I List-II
(a) Die casting 1. Phenol formaldehyde
(b) Shell moulding 2. C.I. pipes
(c) CO2 moulding 3. Non-ferrous alloys
(d) Centrifugal casting 4. Sodium silicate
Codes:
A B C D
(a) 3 1 4 2
(b) 1 3 4 2
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(c) 1 3 2 4
(d) 3 1 2 4
85. Which one of the following moulding processes does not require use of core?
(a) Sand moulding (b) Shell moulding
(c) Centrifugal casting (d) Plaster moulding
86. Plastic parts are generally made by
(a) Investment casting (b) Injection moulding
(c) Shell moulding (d) Continuous casting
87. In centrifugal casting, the impurities are
(a) Uniformly distributed (b) Forced towards the outer surface
(c) Trapped near the mean radius of the casting
(d) Collected at the centre of the casting
88. Moulding sand should posses which property
(a) Collapsibility (b) Flow ability
(c) Cohesion (d) All of the above
89. A pattern is made slightly larger in dimension to give:
(a) Rapping allowance (b) Shrinkage allowance
(c) Draft allowance (d) None of the above
90. Which of the following is a casting defect?
(a) Blow hole (b) Slag inclusion
(c) Pour short (d) All above are casting defects
91. According to Chvorinov's rule, the solidification time of casting is proportional to
(Volume/surface area)n. The value of the exponent 'n for metal is equal to :
(a) 2 (b) 3 (c) 2.5 (d) 1.5
92. Gate in a mould connects
(a) Sprue base with mould cavity (b) Riser with mould cavity
(c) Pouring basin with mould cavity (d) Pouring basin with runner
93. Principal materials used in soldering are
(a) Tin and lead (b) Copper and tin
(c) Zinc and copper (d) Copper and lead
94. The brazing process is carried out temperature range
(a) 600-150°C (b) 350 - 500 °C
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(c) 180- 250°C (d) 600 - 75°C

95. During MIG welding, the metal is transferred in the form of
(a) Continuous flow of molten metal (b) A fine spray of metal
(c) Electron beam (d) Solution
96. The material used for coating the electrode is called :
(a) Protective layer (b) Slag (c) Deoxidizer (d) Flux
97. The 'flyer plate' is used .......... welding.
(a) Ultrasonic (b) Explosive (c) Electron beam (d) Laser beam
98. Consider the following processing methods for Plastics :
(a) Transfer moulding (b) Extrusion
(c) Themnoforming (d) Calendering

99. Consider that the following materials are usable for manufacturing dies, moulds in
investment casting process for the purpose of large-scale production :
1. Aluminium alloy 2. Magnesium alloy
3. Brass 4. Low-carbon steel
Which of the above are correctly usable?
(a) 1 , 2 and 3 only (b) 1 , 2 and 4 only
(c) 3 and 4 only (d) 1, 2, 3 and 4
100. The occurrence of casting defect 'rat tail' is possible because of
1. Soft ramming of sand
2. Continuous large flat surface on the mould
3. Excessive hardness of the mould
Which of the above reasons are correct?
(a) 1 and 2 only (b) 2 and 3 only
(c) 1 and 3 only (d) 1 , 2 and 3
101. Consider the following statements: In shell moulding
1. a single parting plane should be provided for mould
2. detachable pattern parts and cores could be included
3. minimum rounding radii of 2.5 mm to 3 mm should be used
4. draft angles of not less than 1° should be used
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Which of the above statements are correct?

(a) 1,3 and 4 only (b) 1,2 and 3 only
(c) 2, 3 and 4 only (d) 1, 2, 3 and 4
102. In hot die forging, thin layer of material all around the forging is
(a) Gutter space, which fills up hot gases
(b) Flash, the width of it is an indicator of the pressure developed in the cavity
(c) Coining, which indicates the quality of the forging
(d) Cavity, which is filled with hot impurities in the material
103. When an alloy solidifies over a range of temperature, the resulting casting structure is
(a) Wholly equiaxed (b) Wholly columnar
(c) Partially columnar partially equiaxed (d) dendritc
104. The process of making hollow castings of non circular shape and desired thickness by
permanent mould without the use of cores is known as
(a) Die casting (b) Slush casting
105. The ratio of surface area to volume for a unit volume of riser is minimum in case of
(a) Cylindrical riser (b) Spherical riser (c) Hemispherical riser (d) Cuboids riser
106. The relationship between total freezing time t, volume of the casting V and its surface
area A, according to Chvorinov's rule is
2 2
V A A V
(a) t = K   (b) t = K   (c) t = K   (d) t = K  
A V V A
107. Consider the following statements
1. Hot chamber machine is used for casting zinc, tin and other low melting alloys.
2. Cold chamber machine is used for die casting of ferrous alloys.
3. Rapid cooling rate in die casting produces high strength and quality in many alloys.
Which of these statements are correct?
(a) 1, 2 and 3 (b) 1 and 2 only (c) 2 and 3 only (d) 1 and 3 only
108. Consider the following advantages of die casting over sand casting
1. Rapidity of the process
2. Smooth surface
3. Strong dense metal structure
Which of the statements are correct?
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(a) 1.2 and 3 (b) 1 and 2 only (c) 2 and 3 only (d) 1 and 3 only
109. The proper sequence of investment casting steps is
(a) Slurry coating-Pattern melt out-Shake-out-Stucco coaling
(b) Stucco coating- Slurry coating-Shake-out-Pattern melt out
(c) Slurry coating-Stucco coating-Pattern melt out-Shake-out
(d) Stucco coating- Shake-out-Slurry coating-Pattern melt out
110. The methods of casting for producing ornamental pieces are
(a) Such and gravity casting (b) Pressed and slush casting
(c) Gravity and semi permanent mould casting
(d) Semi permanent mould and pressed casting
111. In light metal castings, runner should be so designed that
1. It avoids aspiration
2. It avoids turbulence
3. The path of runner is reduced in area so that unequal volumes of flow through each
gate take place.
(a) 1 and 2 only (b) 1 and 3 only (c) 2 and 3 only (d) 1. 2 and 3
112. Match List-I with List-ll and select the correct answer using the code given below the
lists:
List-I
A. Top gate
B. Bottom gate
C. Parting gate
D. Step gate
List-ll
1. Heavy and large castings
2. Most widely used and economical
3. Turbulence
4. Unfavourable temperature gradient
Codes:
A B C D
(a) 3 4 2 1
(b) 1 4 2 3
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(c) 3 2 4 1
(d) 1 2 4 3
113. Consider the following advantages of shell mould casting:
1. Close dimensional tolerance
2. Good surface finish
3. Low cost
4. Easier
(a) 1.2 and 3 only (b) 2, 3 and 4 only (c) 1. 2 and 4 only (d) 1, 2, 3 and 4
114. Which of the following are the most suitable materials for die casting?
(a) Zince and its alloys (b) Copper and its alloys
(c) Aluminium and its alloys (d) Lead and its alloys
115. Which one of the following casting processes is best suited to make bigger size
hollow symmetrical pipes?
(a) Die casting (b) Investment casting
(c) Shell moulding (d) Centrifugal casting
116. Which of the following are the most likely characteristics in centrifugal casting? '
(a) Fine grain size and high porosity (b) Course grain size and high porosity
(c) Fine grain size and high density (d) Course grain size and high density
117. Consider the following statements:
1. The actual entry point through which the rnoltet metal enters the mould cavity is
called ingate
2. Bottom gate in case of a mould creates unfavourable temperature gradient.
3. Sprue in case of a mould is made tapered to avoid air inclusion
Which of these statements is/are correct?
(a) 1 only (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
118. In which one of the following furnaces most of the nonferrous alloys are melted?
(a) Reverberatory furnace (b) Induction furnace
(c) Crucible furnace (d) Pot furnace
119. Match List (Article) with List-ll (Processing Method) and select the correct answer
using the code given below the lists:
List-I
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A. Disposable coffee cups

B. Large water tanks
C. Plastic sheets
D. Cushion pads
List-ll
1. Rotomoulding
2. Expandable bead moulding
3. Thermoforming
4. Blow moulding
5. Calendering
Codes:
A B C D
(a) 3 5 1 2
(b) 4 5 1 2
(c) 4 3 2 1
(d) 3 1 5 2
120. Bottom gating system is sometimes preferred in casting because
(a) It enables rapid filling of mould cavity
(b) It is easier to provide in the mould
(c) It provides clener metal
(d) It reduces splashing and turbulence
121. The pattern adopted for those casting where there are some portions which are
structurally weak and are likely to break by the force of ramming are called
(a) Loose piece pattern (b) Follow board pattern
(c) Skeleton pattern (d) Single piece pattern
122. Which of the following casting processes does not/do not require central core for
producing pipe?
1. Sand casting process
2. Die casting process
3. Centrifugal casting process Select the correct answer using the code given below:
(a) 1 and 2 (b) 2 only (c) 2 and 3 (d) 3 only
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123. Small amount of carbonaceous material sprinkled on the inner surface of mould cavity
is called
(a) Backling sand (b) Facing sand
(c) Green sand (d) Dry sand
124. Which one of the following is the correct statements? Gate is provided in moulds to
(a) Feed the casting at constant rate (b) Give passage to gases
(c) Compensate for shrinkage (d) Avoid cavities
125. Which one of the following is the correct statement? In a centrifugal method
(a) No core is used (b) Core may be made of any metal
(c) Core is made of sand (d) Core is made of ferrous metal
126. Which of the following are employed is shell moulding
1 Resin Dinder 2. Metal pattern
3. Heating coils
Select the correct answer using the code givon below
(a) 1 and 2 only (b) 1 and 3 only (c) 2 and 3 only (d) 1. 2 and 3
127. Match List-l (Casting Process) with List-ll (Principled and select the correct answer
using me code given below the list.
List-l
A. Die casting
B. Investment casting
C. Shell moulding
D. Centrifugal casting
List-ll
1. The metal solidifies in a rotating mould
2. The pattern cluster is repeatedly dipped into a ceramic slurry and dusted will
refractory
3. Molten metal is forced by pressure into a metallic mould
4. After cooling, the invest is removed from the casting by pressure jetting or
vibratory cleaning
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Codes:
A B C D
(a) 2 1 3 4
(b) 3 4 2 1
(c) 2 4 3 1
(d) 3 1 2 4
128. According to Chovrinov's equation, the solidification time of a casting is proportional
to
2
(a) v (b) v (c) 1/v (d) 1/v2
(where, v = volume of casting)

129. Shell moulding can be used for
(a) Producing milling cutters (b) Making gold ornaments
(c) Producing heavy and thick walled casting
(d) Producing thin casting
130. Which of the following materials are used for making patterns in investment casting
method?
1. Wax
2. Rubber
3. Wood
4. Plastic
Select the correct answer using the codes given below:
(a) Only 1 and 3 (b) Only 2 and 3
(c) Only 1, 2 and 4 (d) Only 2, 3 and 4
131. In which of the following are metal moulds used?
(a) Greensand mould (b) Dry sand mould
(c) Die casting process (d) Loam moulding
132. A gating ratio of 1 : 2 : 4 is used to design the gating system for magnesium alloy
casting. This gating ratio refers to the cross-section areas of the various gating
elements as given below:
1. Down sprue
2. Runner bar
3. Ingates
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The correct sequence of the above elements the ratio 1 : 2 : 4 is

(a) 1,2 and 3 (b) 1, 3 and 2 (c) 2, 3 and 1 (d) 3, 1 and 2
133. In gating system design, which one of the following is the correct sequence in which
choke area pouring time, pouring basin and sprue sizes are calculated?
(a) Choke area - Pouring time - Pouring basin-Sprue
(b) Pouring basin - Sprue - Choke area - Pouring time
(c) Choke area - Sprue - Pouring basin - Pouring time
(d) Pouring basin - Pouring time - Choke area-Sprue
134. In shell moulding, how can the shell thickness be accurately maintained?
(a) By controlling the time during which the pattern is in contact with mould
(b) By controlling the time during which the pattern is heated
(c) By maintaining the temperature of the pattern in the range of 175°C - 380°C
(d) By the type of binder used
135. The centrifugal casting method is used for casting articles of
(a) Symmetrical shape about vertical axis
(b) Symmetrical shape about horizontal axis
(c) Irregular shape (d) Non-ferrous metal only
136. Which one of the following processes produces a casting when pressure forces the
molten metal into the mould cavity?
(a) Shell moulding (b) Investment casting (c) Die casting (d) Continuous casting
137. Match List-I (Products) with List-ll (Casting process) and select the correct answer
using the codes given below the lists:
List-I
A. Hollow statutes
B. Dentures
C. Aluminium alloy pistons
D. Rocker arms
List-ll
1. Centrifugal casting
2. Investment casting
3. Slush casting
4. Shell moulding
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5. Gravity die casting

Codes:
A B C D
(a) 3 2 4 5
(b) 1 3 4 5
(c) 1 2 3 4
(d) 3 2 5 4
138. Scab is a
(a) Sand casting defect (b) Welding defect
(c) Welding defect (d) Forging defect
139. The main purpose of chaplets is
(a) To ensure directional solidification
(b) To provide efficient venting
(c) For aligning the mould boxes
(d) To support the cores
140. Match List (Type of casting) with List-II (Working Principles) and select the correct
answer using the codes given below the lists:
List-I
A. Die casting
B. Centrifugal casting
C. Centrifugal
D. Continuous casting
List-ll
1. Molten metal is forced into the die under pressure
2. Axis of rotation doesnot coincide with axis of mould
3. Metal solidifies when mould is rotating
4. Continuously pouring molten into mould
Codes:
A B C D
(a) 1 3 2 1
(b) 4 3 2 l
(c) 1 2 3 4
(d) 4 2 3 1
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141. Match List-I (Process) with List-ll (Products/ Materials) and select the correct answer
using the codes given below the lists:
List-I
A. Die casting
B. Shell molding
C. CO. molding
D. Centrifugal casting
List-ll
1. Phenol formaldehyde
2. C.I. pipes
3. Non-ferrous alloys
4. Sodium silicate
Codes:
A B C D
(a) 1 3 4 2
(b) 3 1 4 2
(c) 3 1 2 4
(d) 1 3 2 4
142. In solidification of metal during casting. compensation for solid contraction is
(a) Provided by the oversize pattern
(b) Achieved by properly placed risers
(c) Obtained by promoting direction solidification
(d) Made by providing chills
143. A sand casting mould assembly is shown in the given figure. The elements marked A
and B are respectively
(a) Sprue and riser (b) Ingate and riser

(c) Drag and runner (d) Riser and runner
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144. Which of the following are the requirements of: ideal eating system?
1 The molten metal should enter the mould cavity with as high a velocity as possible.
2. Is should facilitate complete filling of the mould cavity.
3. It should be able to prevent the absorption air or gases from the surroundings on t
molten metal while flowing through it.
Select the correct answer using the codes given below:
(a) 1,2 and 3 (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
145. A spherical drop of molten meal of radius 2r was found to solidify in 10 seconds. A
similar drop of radius 4mm would solidify in
(a) 14.14 seconds (b) 20 seconds (c) 18.30 seconds (d) 40 seconds
146. Which one of the following pairs is not correctly matched?
(a) Aluminium alloy... Pressure die casting Piston
(b) Jewellery ...Lost wax process
(c) Large pipes -Centrifugal casting
(d) Large bells ...Loam moulding
147. Consider the following ingredients used in moulding
1. Dry silica sand
2. Clay
3. Phenol formaldehyde
4. Sodium silicate
Those used for shell mould casting include
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1 and 3 (d) 1, 2, 3 and 4
148. Which of the following methods are used for obtaining directional solidification for
riser design?
1. Suitable placement of chills.
2. Suitable placement of chaplets
3. Employing padding
(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2, and 3
149. Misrun is a casting defect which occurs due to
(a) Very high pouring temperature of the metal
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(b) Insufficient fludity of the molten metal

(c) Absorption of gases by the liquid metal
(d) Improper alignment of the mould flasks
150. Which of the following pairs are correctly matched?
1. Pit moulding .. for large jobs
2. Investment moulding….. Lost was process
3. Plaster moulding…… Mould prepared in gypsum
(a) 1 ,2 and 3 (b) 1 and 2 (c) 1 and 3 (d) 2 and 3
151. Match List-I with List-II (Process of Manufacture) and select the correct answer using
the codes given below the lists:
List-I (Product)
A. Automobile piston in aluminium alloy
B. Engine crankshaft in spheroidal graphite Iron
C. Carburettor housing in aluminium alloy
D. Cast lithium blades
List-II (Process of Manufacture)
1. Pressure de-casting
2 Gravity de casting
3. Sand casting
4. Precision investment casting
5. Shell moulding
Codes
A B C D
(a) 2 3 1 5
(b) 3 2 1 5
(c) 2 1 3 4
(d) 4 1 2 3
152. Directional solidification in castings can be improved by using
(a) Chils and chaplets
(b) Chils and padding
(c) Chaplets and padding
(d) Chils chaplets and padding
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PRODUCTION TECHNOLOGY (CASTING)

SOLUTIONS
1. Solution : (c) The main purpose of chaplets used in foundry practice are to support
the core .
Chaplet: - A Core chaplet is a metal location piece inserted in a mould either to
prevent a core shifting its position or to give extra support to a core. The molten metal
melts the chaplet, which then forms part of the Cast material.
2. Solution: (b) Core prints are used to form seat to support and hold the core in place.
Core prints:- Generally core prints are provided in cores. These core prints are a sort
of projection at the end of core and these support the core in position in a mould.
Design should provide space for core prints sufficiently large to locate the core
accurately, prevent sagging, and resist the hydrostatic molten-metal pressure.
3. Solution(d) : Due to the shake allowance the pattern is made slightly smaller than
required size.
4. Solution. (a) : Collapsibility which is the property of moulding sand which does not
provide any resistance of contraction of the solidified casting. Adhesiveness—
Adhesiveness is the property of sand due to which the sand particles sticks to the sides
of the moulding box. Adhesiveness of sand enables the proper lifting of cope along
with the sand. Refractoriness—Refractoriness is the property of sand to withstand
high temperature of molten metal without fusion or soften.
5. Solution. (b) : Chills are metallic objects to provide very high heat extraction
capability of sand mould. Normally the metal, in the mould cools at a certain rate
relative to thickness of the casting.
6. Solution. (c) : Shrinkage allowance on the pattern is provided to take care of both
liquid and solid shrinkage.
7. Solution. (a) : Decreasing the clay content in the moulding sand increase the
permeability. The addition of clay in sand increase the optimum moisture content.
The addition of clay reduces the hydraulic conductivity of sand. The effect is very
prominent upto 10% clay content and beyond that reduction in permeability is
gradually decrease.
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8. Solution. (a) : Refractoriness –Refractoriness is the ability of the moulding material

to withstand the high temperatures of the molten metal to be poured so that it does not
get fused with the metal. The refractoriness of the silica sand is highest.
Refractoriness is measured by the sinter point of the sand. Refractoriness of the
moulding sand can be increased by increasing the grain size.
9. Solution. (d) : Sweep pattern is used to "Bell" shapes or 3-D symmetrical object
casting.
10. Solution (b) : Permeability—The properties of moulding sand that allows the gases
to be escaped from the mould is called Permeability. Refractoriness—It is the
property of mould sand to withstand high temperature of molten metal.
11. Solution. (b) : Blow Molding–Blow molding is a specific manufacturing process by
which hollow plastic parts are formed and can be joined together. It is also used for
forming glass bottles or other hollow shapes. The blow molding process begins with
melting down the plastic and forming it into a parison or, in the case of injection and
injection stretch blow molding, perform. The parison is a tube-like piece of plastic
with a hole in one end through which compressed air can pass. The parison is then
clamped into a mold and air is blown into it.
12. Solution. (d) : Draft allowance–It is a taper which is given to all the vertical walls of
the pattern for easy and clean withdrawal of the pattern from the sand without
damaging the mould cavity. It may be expressed in millimeters per meter on a side or
in degrees. The amount of taper varies with the type of patterns. The wooden patterns
require more taper than metal patterns because of the greater frictional resistance of
the wooden surfaces.
13. Solution. (d) : Draft angle is provided for forged parts for easy removal from die
cavities.
14. Solution. (a) : The main advantages of using CO2 moulding is that much hardened
mould is obtained.
3
15. Solution (c) : Given - Volume of mould = 60 × 30 × 14 cm Liquid metal height ht =
2
14 cm Ag = 6 cm time filling (tf) =
Am hm Vm 60  30  14
   253.419sec
AgVg Ag  2 gh 6  2  9.81 14
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16. Solution. (b) : Given
hS= 180 mm
D2 = 20 mm
hC = 60 mm
Applying continuity equation (2) to (3)

section -
Q = A2 V2 = A3 V3
A2 V 2 ght  A2  ht
= 3=  =
A3 V2 2 ghc  A3  h c

 (D 2 )2 240  D2 
2
4  2 , 
  2
(D3 ) 2 60  D3 
4
(20)2 400
2
2 ,  (D3 )2
 D3  2
D3  200 D3 = 14.14 mm
17. Solution (d) : Investment casting is used for- • Complex shapes which are difficult to
produce by any other method are possible since the pattern is withdrawn by melting it.
• Very fine details and thin section can be produced by this process.
• Very close tolerance and better surface finish can be produced.
18. Solution (c) : According to Chvorinov rule
2
 V 
Solidification time k  
 SA 
Where V = volume of casting
S.A. = surface area of casting
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19. Solution (a) : Cold chamber die casting : In this the furnace is separated from
casting unit. It is used to produce high melting point material casting. Force required
to move the liquid metal into the die will be high when compare to hot chamber die
casting. Brass, Copper Aluminium and Magnesium is commonly cold die casting
metals.
20. Solution (b) : Shot blasting is a post-production finishing service that is processed
through the rapid impacting of a part’s surface with a defined amount of abrasive
material. It helps in removing sand and oxide layer.
21. Solution (a) : Centrifugal casting is used for making bigger size hollow symmetrical
pipes. For producing a hollow part, the axis of rotation is placed at the center of the
desired casting. The speed of rotation is maintained as high as to produce a centripetal
acceleration of the order of 60g to 70g. It should be noted casting of hollow parts need
no core in this process.
22. Solution. (b) : A carburizing flame is one in which the supply of acetylene is in
excess as compared to the oxygen. If the supply of acetylene is less than the supply of
oxygen than the flame is known as oxidizing flame. If both acetylene and oxygen are
in the ratio of 1 : 1 then flame is called neutral flame.
23. Solution (b) : Gating ratio = Sprue area : Runner area : Ingate area.
24. Solution (c) : Riser- A reservoir of molten metal provided in the casting so that hot
metal can flow back into the mould cavity due to the reduction in volume of metal due
to solidification. Riser compensate two type contraction—
1. Liquids 2. Solidification.
25. Solution (c): The ability of casting material to fill the mould cavity is described by
fluidity.
Fluidity—Fluidity an ability of metals and alloys to flow through the getting system
filling the cavity of the casting mould and conforming its shape.
Factor determining fluidity Solidification interval—The wider solidification
interval of an alloy, the lower fluidity of the alloy. Viscosity—Viscosity of the alloy,
the lower viscosity of an alloy, the better its fluidity.
26. Solution. (a) : Choke area,
m
A
 tC 2 gH
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27. Solution (b): Stop-off is not the casting defect. Hot-tears—Hot tears, also known as
hot cracking, are failures in the casting that occur as the casting cools.
Run-out—A run-out is caused when the molten metal leaks out of the mould caused
by faulty mould making or faulty flask. Blow holes—When gases entrapped on the
surface of the casting due to solidifying metal, a rounded or oval cavity is formed
called as blow holes.
28. Solution (a) : Shrinkage allowance = 10 mm/m = 1 mm/100 mm
Then dimension of wooden pattern

= (100 + 1) × (100 + 1) × (100 × 1)
3
= 101 × 101 × 101 mm
3
29. Solution (d) : Casting size = 100 × 100 × 100 mm
Solidifies time = 20 minutes
Solidification time = t2
3
For size = 100 × 100 × 50 mm
2
V 
Solidification time t2  K  
 A
where
K - Solidification area
A - surface area
For same condition
2
100 100 100 
ts1  K  2 
 6 100
2
100 
ts1  K  
 6 
20
K 2
 0.072 min t / mm
 100 
 6 
 
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2
 100 100  50 
ts 2  K  
 2  100  100  2 100  50 100  50 
2
 500000 
ts 2  0.072  
 40000 
ts 2  0.072 156.25
ts 2  11.25 11.3 min

30. Solution (e): In sand-casting, when it is not possible to get very fine details on the
surface then some modification are done is known as Elimination of details. Pattern
allowance, shrinkage allowance and machine allowance are provided on the pattern if
the casting is to be machined whereas core print is an open space provided in the
mould for locating, positioning and supporting core.
31. Solution (a) : Refractoriness is the ability of the molding material to withstand the
high temperature of molten metal so that it does not cause fusion. Molding sands with
poor refractoriness may burn when the molten metal is poured into the mould cavity.
Usually sand moulds should be able to withstand upto 1650°C.
32. Solution (a) : Bottom gate is not the slag trap method used in sand molding.
33. Solution (c) : Manufacturing of engine blocks are mainly done using sand casting,
although die casting also used it is more cost effective as the die wear out easily due
to the high temperature of the molten metal. The casted engine block is then machined
to get the surface finish and coolant passages.
34. Solution (b) : Shell moulding is a process that uses a risk covered sand to form the
mold. It has better dimensional accuracy of the order of 0.002 to 0.003 mm. Shell
mold requires less floor space for casting.
35. Solution (c) : Disadvantage of die-casting process are :-
1) All metal & alloy cannot be cast.
2) Cost of machines, dies and other equipment is high
3) Heavy casting cannot be cast.
36. Solution (a) : True centrifugal casting is generally used for the making of hollow
pipes and tubes, which are axisymmetric with a concentric hole.
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37. Solution (a): A sprue is the passage through which liquid material is introduced into a
mold, a process of cleaning castings. Main purpose of sprue is feed molten metal from
the pouring basin to the gate.
38. Solution (d): The fuel used in pit furnace is generally coal.
39. Solution (c): Riser is generally located on the upper most section of the casting.
40. Solution (a): Pouring basing is provided in sand moulds to reduce the turbulence in
the liquid metal.
41. Solution (a): In die casting, the mould is made by metallic material. Metallic mould is
used in die-casting which result for the extraction of heat from the molten metal will
not be easy. So, water cooling channels is used near the castings. This made the
proper solidification of the castings.
42. Solution (b): Riser is designed in such a way that the solidification in the riser take
place after the solidification of the casting.
43. Solution (d): Vents is not a part of gating system.
44. Solution (c) : Slush casting is a traditional method of permanent mold casting
process, where the molten metal is not allowed to completely solidity in the mold.
When the desired thickness is obtained the remaining molten metal is poured out.
45. Solution (d) : Die cast parts are used when
1. material of the parts has low melting point.
2. Parts have small size
3. Parts are made on large scale
46. Solution (d): In die casting process a high production rates are possible.
47. Solution (d): Investment casting is suitable for both small cost part & heavy or large
casting.
48. Solution (a) : The molten metal is not introduced directly into the mould Cavity as it
will cause erosion of the mould cavity.
49. Solution (d): Pouring basin, spure, and choke are the parts of gating system for a
casting whereas pattern is not a part of gating system.
50. Solution (c): Shrinkage allowance is added to pattern dimensions to take care of solid
shrinkage.
51. Solution (b): Fine grains size during the solidification of a metal is achieved by
higher nucleation rate with lower growth rate.
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52. Solution (b) : Casting defects-

• Blow holes • Air inclusions
• Pinhole porosity • Cuts and washes
• Fusion • Drop
53. Solution (c) : Centrifugal casting a casting process in which molten metal is poured in
a mould and allowed to solidify while the mould is revolving is called centrifugal
process. The casting produced under this centrifugal force is called centrifugal
casting. This process is especially employed for casting articles of symmetrical shape.
The ferrous and nonferrous metal can be casted by this process have dense and fine
grained structure.
54. Solution (c) : A zone of cupola furnace which starts from above the melting zone and
extends upto bottom of charging door is known as preheating zone.
55. Solution : (d) Vcasting  200  100  10
 1   1   1 
VPattern   200  200    100  100     10  10 
 100   100   100 
 202 10110.1
Then
Vpattern 202 10110.1
  1.03
Vcasting 200 100 10
56. Solution (a) : Shift is a casting defect which results in a mismatching of the top and
bottom parts of a casting.
57. Solution (c) : The property of sand due to which the sand grains stick together is
called cohesiveness.
58. Solution (a) :
Gate is provided to feed mould cavity to feed casting at desired flow rate.
Airvents may be provided for escape of gases.
Riser and shrinkage allowance is provided to compensate the shrinkage.
59. Solution (c) : Hot tears, also known as hot cracking, are failures in the casting that
occur as the casting cools. This happens because the metal is weak when it is hot and
the residual stresses in the material can cause the casting to fail as it cools. Proper
mold design prevents this type of defects.
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60. Solution (a) : Optimum condition for top blind riser solidification time (ts) ↑ and
surface are A ↓
 2
A d   dh
4
 2
V d h
4
 2 4V
A d d
4 d2
dA
0
d (d)
 4V
2 d  (1) 2  0
4 d
2 4V
d 2
4 d
 3  2
V d  d h
8 4
h 1

d 2
61. Solution (b) : Data given as, a = 12 cm Volume shrinkage of aluminium during
Solidification = 6% × V
3 3 3
V = a = (12) = 1728 cm
Then, shrinkage volume on solidification

6
 1728 
100
3
= 103.68 cm
62. Solution (b) : Dye penetration inspection is generally used to locate Surface breaking
defects.
63. Solution (d) : Sweep patterns are used for moulding parts having the shape of
symmetrical.
64. Solution (b): Chills are used in the application of directional solidifications, change
in cross section and complex geometry not for smaller casting for eutectic alloy.
65. Solution (b) : Die casting- The die casting (also known as pressure die casting) may
be defined as that casting which uses the permanent mould (called die) and the molten
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metal is introduced into it by means of pressure. Even though lead zinc and its alloys
also can be casted but they are not used commonly in engineering hence aluminum
and its alloys are the most commonly used materials in the die casting.
66. Solution (a) : Consumable patterns are made of polystyrene.
67. Solution (d) : Shell patterns are often used for
_ Pipe work
_ Bends
_ Drainage fittings
68. Solution (d) : Cohesiveness- It is the property of sand due to which the sand grain
slick to together during ramming. It is defined as the strength of the moulding sand.
Cohesiveness of sand depend on- _ Grain size and shape of the sand particles. _
Bonding materials _ Moisture content
69. Solution (c) : Swell- A casting defect which results in general enlargement of a
casting is known as swell.
70. Solution (a) : Aluminium will require the largest size of riser for the same size of
casting.
• Liquid shrinkage maximum for aluminium→65%.
• Liquid and solidification shrinkage is max for aluminium which required more
volume of riser.
• Solid shrinkage is maximum for brass which required large size of pattern.
• Total shrinkage maximum for steel.
71. Solution (b) Directional Solidification:- Directional Solidification can be ensured by
chills and padding
72. Solution (c) Green sand is a mixture of 70% sand, 30% clay. Green sand:- When
sand is in its natural state, it is referred to an green sand. It is a mixture of silica sand,
with 18 to 30% clay and 6 to 8% water. The clay and water gives bonding strenght to
green sand is generally used for casting small or medium sized moulds.
73. Solution (b) A casting defect which occurs due to improper venting of sand is known
as blow holes.
Blow holes:- It is an excessively smooth depression on the outer surface of a casting.
A casting defect which occurs due to improper venting of sand is known as blow
holes.
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74. Solution: (d) Loam sand contains upto 50% clay and dries hard. It also contains fire
clay. It must be sufficiently adhesive to hold on to the vertical surface of the rough
structure of the mould. Chopped stray and manure are commonly used to assist in
binding. The moisture content is from 18 to 20%
75. Solution : (b) Chvorinov's Rule:- It states that the freezing time of a casting
2
V 
ts  K  
 A
K= solidification constant
V
= ratio of volume of the casting to its surface area
A
2
V
Best riser is one whose   is 10 to 15% larger than that of the casting
A
76. Solution : (c)
In sand casting lower part of the moulding flask is called drag

77. Solution: (b) The process of making hollow costing of desired thickness by
permanent mould without the use of cores is known as slush casting. Slush Casting:-
This method is a special application of permanent mould casting in which hollow
casting are produced without the use of cores. Molten metal is poured into the
metallic mould and allowed to solidify upto the required thickness. The mould is then
turned over so that the remaining liquid metal falls out and casting of desired
thickness can be obtained. Normally small thickness casting of lead zinc and law
melting alloy are obtained by slush casting method.
78. Solution: (c) The colour marked on the surface of a pattern to be machined is red.
79. Solution: (a) Hot tears results in castings due to, too much shrinkage of molten metal.
Hot tear: It is an internal or external ragged discontinuity in the metal costing
resulting from hindered contraction occurring Just after the metal has solidified.
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80. Solution : (d)

Pattern Materials Shrinkage allowance (mm/meter)
Cast iron 7-10.5
White cast iron 21
Malleable CI 15
Steel 20
Brass 14
Aluminium 18
Aluminium alloy 13–16
Bronze 10.5–20
81. Solution: (a) Coal dust, is added to moulding sands for improving surface finishing of
the casting. Composition of green synthetic sand for steel casting is an under. New
Silica sand–25%, old sand–70%, Bentonite–1.5%, Dextrine–0.25% and moisture–3 to
3.5%.
82. Solution : (b)
Manufactured Manufactured Products
Process
(i) Investment casting (i) Turbine rotors
(ii) Die casting (ii) Carburetor body
(iii) Centrifuged (iii) CI pipes
casting
(iv) Drop forging (iv) Connecting rods.
(v) Extrusion (v) GI pipes.
(vi) Shell moulding (vi) Turbine blades.
83. Solution: (c) Swab is a tool used in foundry. swab:- It is made of flax or hemp and is
used for applying water to the mould around the edge of the pattern. This prevents the
sand edges from crumbling, when the pattern is removed from the mould.
84. Solution : (a) List-I (Products) List-II (Process)
None - ferrous alloys Die casting
Phenol formaldehyde Shell moulding
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Sodium silicate CO2 Moulding
C.I. pipes. Centrifugal casting

85. Solution: (c) Centrifugal casting moulding processes does not require use of core.
Centrifugal Casting:- In this process the molten metal is poured in a mould and
allowed to solidify while the mould is revolving. the metal Solidifies under the
pressure of centrifugal force. The Centrifugal forces cause the metal to take up the
impression of the mould cavity.
86. Solution: (b) Plastics parts are generally made by injection moulding.
Injection moulding:-
It makes use of heat softening characteristics of thermoplastics materials. These
materials soften when heated and reharden when cooled. No chemical change takes
place when the material is heated or cooled, the change being entirely physical.
87. Solution: (d) In centrifugal casting, the impurities are collected at the centre of the
casting. Centrifugal casting:- In centrifugal casting no core is needed to form the
hole in the middle. Centrifugal casting finds its best use in mass production, The use
in machinery and equipment for centrifugal casting can be justified only when a large
quantity of identical casting are required.
88. Solution: (d) Property of moulding sands.:-
i) Permeability v. Refractoriness
ii) Cohesivness vi. Chemical resistivity
iii) Adhesivness vii. Binding Property
iv) Plasticity viii. Flowability
89. Solution : (b) A pattern is made slillghtly lorger in dimension to give shrinkage
allowance
shrinkage allowance:-
1-2 :- Liquid shrinkage

2-3 :- Solidification shrinkage
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3-4 :- Solid shrinkage

Liquid shrinkage > Solid shrinkage > Phase transfer motion shrinkage.
90. Solution : (d) Casting defects:-
i) Blow hole and open blow ii) Pin hole porosity
iii) Cuts and washes iv) Metal penetration
v) Fusion vi) Runout
vii) Misruns and Cold shuts viii) Slag inclusion
ix) Hot tear x) Hot spot
91. Solution. (a) : Given –
n
V
Solidification Time    ...(1)
A
According to chvorinov's rule -
2
V
solidification time t    ...(2)
A
comparing equation (1) and (2)
2 n
V V
   
A A
so, n = 2
92. Solution: (a) Gate in a mould Connects sprue base with mould cavity. The actual
entry point through which molten metal enters the mould cavity.
93. Solution: (a) : Soldering is a method of joining similar or dissimilar metals by means
of a filler metal whose liquids temperature is below 450oC. Solder is an alloy of tin
and lead used to create electrical joints.
94. Solution : (b) Brazing process:-
(i) The melting point temperature of filler material is more than 430°C but less than
the melting point temperature of base material
(ii) Filler material is an alloy of copper zinc and silver
(iii) The flux used in borax and boric acids.
(iv) Used in pipe fitting where leak proof joints are required for intricate light weight
components.
95. Solution: (b) During MIG welding, the metal is transferred in the form of a fine spray
of metal.
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96. Solution: (d) The material used for coating the electrode is called flux.
Fluxes:- In welding of certain metals, the fusion of the weld does not take place very
readily. Particularly when the oxides of the base metal have a higher melting point
than the metal it self. Thus these oxides remain on the surface and become entrapped
in the solidifying metal instead of flowing from the welding zone. This oxide can be
removed from the weld location by use of certain fluxes which react chemically with
the oxides of most metals and form fusible slag at welding temperature.
97. Solution : (b) The flyer plate is used Explosive welding.
α = initial stand-off angle.

Explosive welding:- In this process, the metals to be joined are placed at an angle to
each other. The energy derived from an Explosion forces the plates together at high
velocity causing surface ripples in the metal. As the force is dissipated the ripples lock
or weld the two metals.
98. Solution: (b)
In transfer moulding, calculated amount of plastic material is placed in moulding pot.
The material is heated, pressure forces and transfers the material to mould cavity and
final product comesout.
In extrusion raw plastic is melted and formed into continuous profile such as pipe
tubes. Calendaring on the other hand is finishing process for high quality plastic film.
99. Solution-: (d)
Aluminium alloy, magnesium alloys, brass are used for manufacturing dies, mouldsin
investment casting as dies requires high carbon steels due to high hardness.
100. Solution : (b)
Rat tail casting defect is a long, shallow angular depression on the surface of casting.
It is due to excessive hardness of mould which leads to insufficient hot deformation of
sand, it may also result due to design problems such as providing large flat surface on
the mould.
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101. Solution: (a)

• In shell molding
• Single parting plane should be provided
• Detachable pattern parts & cores should be avoided.
• Minimum rounding radii is 2.5 to 3 mm
• Draft angle should not be less than 1°.
102. Solution: (b)
In hot die forging, some of the material flows outward and forms a thin layer all
around the forging, is called flash. The thin flash cools rapidly and because of its
frictional resistance, it subjects the material in the die cavity to high pressures, there
by encouraging filling of the die cav/ty. Its width indicates (he pressure developed in
the cavity.
103. Solution :(d)
Pure metals and alloys give different structure on solidification pure metals give a
columnar structure, which is not desired due to inferior mechanical properties because
of large grains Alloys gives dendritic structure on solidificaton which is a more
desirable structure.
104. Solution: (b)
Slush casting is the process for making hollow non circular shape and desired
thickness by permanent mould. Centrifugal casting makes circular shapes. While die
casting and pressed casting requires a core to make hollow shapes
105. Solution : (b)
Ratio of surface area to volume i.e. A/V is minimum for a spherical riser. The
sequence is ascending order of A/V sphere  cylinder  square (cube)  plate.
Also, if (V/A) ratio of asked, reverse the above order.
106. Solution : (d)
Chvorinov’s rule is
2
V
tr = K  
A
107. Solution : (d)
Hot chamber die casting is used for low melting points metals such as zinc and lead.
However, cold chamber die casting is not used to cast ferrous metals but non-ferrous
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metals such as aluminium, alloys of copper etc. Also rapid cooling leads to formation
of fine grains, thus giving high strength of fine grains, thus high strength and quality
to die casted components.
108. Solution : (a)
All three i.e., Mass production, high surface finish and strong dense metal structure
are advantages of die casting over sand casting.
109. Solution : (c)
Sequence of investment casting is
Slurry coating  Stucco coating (also called repealed coating)  wax pattern melt
out shake out.
110. Solution : (b)
Ornamental pieces are produced by slush casting and pressed casting.
111. Solution (a)
Any runner that is designed for a casting should avoid aspiration of air and
turbulence. Also it should be so designed equal flow that should pass through each
gate.
112. Solution (a)
Top gate: It causes turbulences due to high velocity.
Bottom gate: Causes unfavourable temperature gradient.
Parting gate: Most commonly used gats
Step gate: Used for heavy and large casting
113. Solution : (c)
Shell mold casting is no. a low cost process because it uses a metallic mould and
tender and heating elements. Though .Its gives good surface finish and close
dimensional tolerances.
114. Solution : (c)
Aluminium and its alloys are cast by diecasting process
115. Solution : (d)
Centrifugal casting is used to produce large sized hollow symmetrical pipes.
116. Solution : (c)
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As centrifugal casting produces hollow pipes, the metal near the walls cools faster
producing fine grains. Also, due to centnfugal force. density of the product is very
good
117. Solution : (d)
Although all options are correct but the bottom gate may or may not unfavourable
temperature gradient it is the weakest argument
118. Solution : (b)
Cupola - Cast iron
Reverberate/ - Non ferrous alloys
Induction - Ferrous 4 Non-ferrous alloys
Arc furnace - Iron and steel
Induction furnace is most commonly used for melting non ferrous alloys
119. Solution : (d)
Disposable Coffee cups: Thermoforming
Large water tanks: Rolomoulding
Plastic sheets: Calendering
Cmshion pads Expandsible bead mculdirq
120. Solution : (d)
Bottom gating system is preffered to reduce splashing and turbulance its disadvantage
is that it does not promote directional solidification On the other hand top gate gives
highest turbulence but promotes directional solidification
121. Solution : (b)
Follow board s a wooden board that is used as a support to structurally weak sections
of casting
122. Solution : (d)
Centnfugal casting does not require a core for producing pipe as metal is distributed
towards walls of mould by centrifugal force Rest two process require cores to produce
a cavity.
123. Solution : (b)
Facing sand is the sand that comes in contact with molten metal first It bears the brunt
of high temperature and protect the sand behind it (called backing sand) from burning.
Facing sand also helps in acheiving smooth finish on casting
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124. Solution : (a)

• Gate is provided to feed mould cavity to feed casting at desired flow rate.
• Airvents may be provided for escape of gases.
• Riser and shrinkage allowance is provided to compensate the shrinkage.
125. Solution : (a)
No core is required in centnfugal casting. When the desired thickness of casting is
reached, the rotation of mould is stopped. Core is used in semi-centrifugal casting.
126. Solution (d)
Phenol formaldehyde (thermosetting resin) is used as a binder (2-4% quantity) mixed
with sand in a metal pattern (either ferrous metal or aluminium) heated to 175 -
370°C.
127. Solution : (b)
Die Casting: Molten metal forced by pressure into metallic mould.
Shell: The pattern cluster is repeatedly dipped into ceramic slurry and dusted with
refractory.
Investment Casting: After cooling, the invest is removed from the casting by Jetting
or vibratory cleaning.
Centrifugal Casting: Metal solidifies in rotating mold.
128. Solution : (a)
Chvorinov's equation is
ts = k(V/A)2
where ts is solidification time

k is a mold constant, it depends on mould material.
V = volume of casting and A = surface area of casting.
So, tsaV2.
129. Solution : (d)
Milling cutters: Sand cooling followed by machining.
Gold ornaments: Investment casting
Thick walled casting: Slush casting
Thick castings: By shell moulding typically the thickness of casting in shell
moulding is limited to 10 mm.
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130. Solution : (c)

In investment casting, all materials wood can be used (i.e. wax, rubber plastic because
wood cannot be melted.
131. Solution : (c)
Die casting process uses metal moulds is why it is called permanent mould process
All other process uses sand moulds
132. Solution : (a)
1:2:4 is total sprue area: total runner area total ingate area.
133. Solution : (a)
• Initially, choke area or in gate area is calculated from discharge required and
velocity.
• This is followed by calculating the pouring time as
Volume of mould
tp =
Rate of flow
• Then design of pouring basin is done
• Finally sprue is designed depending on height of pouring basin.
134. Solution : (a)
Shell thickness depends on the time during which the pattern is in contact with the
mould. Higher the contact time, larger will be thickness of mold.
135. Solution : (a)
Centrifugal casting is used to produce symmetrical shape about vertical axis. There is
a constraint in using centrifugal casting about horizontal axis as molten metal would
flow out of mould while pouring.
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136. Solution : (c)

Die casting process produces a casting by pressurizing molten metal into cavity.
137. Solution : (d)
Hollow Statues: Slush casting
Dentures: These are teeth replacements made by investment casting
Aluminium alloy piston: Gravity die casting.
Rocker aims: Shell moulding
138. Solution : (a)
Scab is a sand casting defect wherein sand shears from cope surface and a layer a
metal is protruded from main casting.
139. Solution : (d)
Chaplet are used to support the core inside »» casting. The core may displace from its
desired position due to buoyancy forces of the molten metal To support the core at
proper position chaplets and core prints are used.
140. Solution (a)
Die Casting: Molten metal is forced in die under pressure
Centrifugal Casting: Metal solidifies in rotating mold
Centrifuging Axis of rotation is offset from mould axis
Continuous Casting: Continuous pouring of metal into mould
141. Solution : (c)
Die Casting: Non ferrous alloys.
Shell moulding: Phenol formaldehyde used as thermosetting bunder
CO2 moulding: Sodium silicate is used as mould binder instead of phenol
formaldehyde
Centrifugal Casting: Cast Iron pipes mad. due to rotational symmetry
142. Solution : (a)
In solidification of metal during casting, solid contraction is compensated by
providing a "Shrinkage allowance' Here an oversize pattern equal to solid shrinkage is
made.
143. Solution : (a)
A is sprue as it tapering down to avoid any aspiration of air into mould cavity B is
riser which acts as reservoir of molten for directional solidification.
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144. Solution : (c)

An ideal gating system should maintain an optimum velocity. High velocity will lead
to turbulence and erosion of mould and low pouring velocity may result in premature
cooling of molten metal.
145. Solution : (d)
Solidification time of casting
2
ts = k(V/A)
V = 4/3r3
A= 4r2
V r t s1 (V/ A) 2 r12
So  =  
A 3 t s2 (V/ A) 22 r22
2
1 1
  
2 4
t s 2  4  t s1  4  10  40 sec
146. Solution : (a)

Aluminium pistons are made by gravity die casting and not pressure die casting.
147. Solution : (c)
In shell mold casting dry silica sand is mixed with phenol formaldehyde, which is a
thermosetting binder. It is to be noted here that sodium silicate is used in a similar
casting process called "CO2" casting process.
148. Solution : (b)
Chills and padding is used for obtaining directionalo solidification. Chaplets are used
to support core inside the casting.
149. Solution : (b)
Misrun is a casting defect that occur insufficient fluidity of molten due to less. fluidity
metal is unable to completely fill the mold cavity. Main reason for insufficient
fluidlty is low pouring temperature. Due to this ^ metal starts solidifying before
filling the mould cavity.
150. Solution (a)
All pairs are correctly matched.
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151. Solution : (a)

• Automobile piston in aluminium alloy is made by gravity die casting.
• Engine crankshaft in spheroidal graphite iron is made by simple sound casting as
iron has very good castability.
• Carburettor housing in aluminium alloy is made by pressure die casting (i.e. cold
chamber die casting).
• Cast titanium blades are made by shell mouldings
152. Solution : (b)
• Directional solidification in castings is achieved by
• Chills that are metallic pieces used to increase thermal conductivity of thicker
sections in casting:
• Padding is of insulating material around the riser to reduce heat loss from riser, that
it solidifies last. Chaplets are used support cores inside the casting and | has nothing to
do with direction solidification.
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Tailor made module for various exams like HPCL, ISRO, BARC etc.

9. "Bell" shapes are generally made by

14. The main advantages of using CO2 moulding is that

(a) Much hardened mould is obtained

(c) Gases formed react with CO2 to form a colloidal solution

(d) Carbon % in the molten metal can be increased

(a) 32 s (b) 12 s (c) 25.34 s (d) 28.28 s

17. Investment casting is used for

34. In shell moulding, the dimensional accuracy that can be expected is

43. Which of the following is not a part of gating system?

52. Which is not a casting defect?

62. Dye penetration inspection is generally used to locate

(c) Moisture content

(b) High content of sulfur in molten metal

(c) 180- 250°C (d) 600 - 75°C

(c) Themnoforming (d) Calendering

Which of the above statements are correct?

A. Disposable coffee cups

(where, v = volume of casting)

The correct sequence of the above elements the ratio 1 : 2 : 4 is

5. Gravity die casting

(a) Sprue and riser (b) Ingate and riser

(b) Insufficient fludity of the molten metal

PRODUCTION TECHNOLOGY (CASTING)

8. Solution. (a) : Refractoriness –Refractoriness is the ability of the moulding material

16. Solution. (b) : Given

Applying continuity equation (2) to (3)

Then dimension of wooden pattern

Solidifies time = 20 minutes

ts 2  11.25 11.3 min

52. Solution (b) : Casting defects-

Then, shrinkage volume on solidification

In sand casting lower part of the moulding flask is called drag

80. Solution : (d)

Sodium silicate CO2 Moulding

C.I. pipes. Centrifugal casting

1-2 :- Liquid shrinkage

3-4 :- Solid shrinkage

α = initial stand-off angle.

101. Solution: (a)

124. Solution : (a)

where ts is solidification time

130. Solution : (c)

136. Solution : (c)

CO2 moulding: Sodium silicate is used as mould binder instead of phenol

144. Solution : (c)

146. Solution : (a)

151. Solution : (a)

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