IEGR 363: Manufacturing Processes

Fall 2004
M. Salimian
Test# 1 (October 6, 2004)

1. Please write your initials and the last 4 digits of your student ID
number on all pages.
2. Read the questions carefully before answering them. Your quick
interpretation of a question may lead to answering it incorrectly.
3. Support your answers by sketches.
4. Do not attempt to fill out pages for answer for a question that can be
answered in a couple of sentences. Your answer as a whole will be
graded including the parts that are correct as well as those assertions
that may be incorrect.
5. Make sure to pay attention to selection of questions and choices that
you have. Answering more questions that is allowed in one section
does not earn you points and will waste your time.

Part I: 15 point questions Select ONLY 2 questions of your choice.
Question #1 (15 Points)
Explain the different steps of investment casting. Make sure to explain for each
step why that step is performed, what is a desirable method of doing that step
and what happens if you do not perform it in its desirable way.
Question #2 (15 Points)
Explain 8 different types of casting defects. Why are they generated and how you
can avoid them.
Question #3 (15 Points)
Discuss two steps of the sand casting process that can be automated and
explain how the automation has affected those steps. Explain the automated
methods involve in those steps.
Question #4 (15 Points)
From one of the following processes, pick the one of your choice and explain it in
details with sketches.
Shell molding or V process
Page 1 of 3
IEGR 363: Manufacturing Processes
Fall 2004
M. Salimian
Test# 1 (October 6, 2004)

Question #5 (15 Points)
Describe and illustrate design considerations for corners, angles, section
thickness and flat areas.

Part II: 10 point questions Select ONLY 2 questions of your choice.
Question #6 (10 Points)
Illustrate and explain cold shut and hot tear defects in casting and the ways to
reduce them and why they work.
Question #7 (10 Points)
Describe and illustrate how single crystal turbine blades are cast.
Question #8 (10 Points)
Name 5 practices that can improve the quality of cat parts and for each practice
name two example used in different casting processes.
Question #9 (10 Points)
What are hot spots, shrinkage allowance, and machining allowance?

Part III: 5 point questions Select ONLY 6 questions of your choice.
Question #10 (5 Points)
Explain the reasons why heat transfer and fluid flow are important in metal
casting.
Question #11 (5 Points)
What is the function of a core?
Question #12 (5 Points)
Name the important factors involved in the economics of casting operations.

Question #13 (5 Points)
Which of the following considerations is/are important for a riser to function
properly? Must is: (a) have a surface area larger than the part being cast, (b)
be3 kept open to atmospheric pressure, and/or (c) solidify first? Why?
Page 2 of 3
IEGR 363: Manufacturing Processes
Fall 2004
M. Salimian
Test# 1 (October 6, 2004)
Question #14 (5 Points)
How are dissolved gasses removed from molten metal?
Question #15 (5 Points)
Why is the investment-casting process capable of producing fine surface detail
on castings?
Question #16 (5 Points)
What are the advantageous and limitations of die castings?
Question #17 (5 Points)
Explain the different identification scheme, terminology, and classifications of the
threads.
Question #18 (5 Points)
What would you do to improve the surface finish in expendable mold castings
process?

Part IV: Answer both questions.
Question #19 (10 Points)
What is rubber molding? Explain as much as you can about the steps.
Question #20 (10 Points)
Explain different parts of the report based on the course guideline.

Page 3 of 3