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CASTING PROCESS
1. What is casting?
Casting is obtained by pouring of molten metal into mould and allows solidifying.
2. What do you meant by moulding?
The process of making mould is called moulding. It includes filling of moulding
sand around the pattern, ramming, removing the pattern, making runner, riser,
gate and vent holes.
3. Name the types of pattern?
Single piece pattern.
Split pattern.
4. What is meant by loose piece pattern?
Some pattern cannot be removed from mould as a single piece. So loose piece
patterns are used with solid pattern for easy removal
5. When split patterns are used?
Some pattern cannot be removed from mould as a single piece. So split patterns
are used with solid pattern, it is made of two parts.
6. Name the materials used for making pattern?
Wood
Metal
Plaster
Plastic
Wax.
7. State two advantages of Aluminium as pattern material?
Aluminium is light in weight
It melts at low temperature.
It does not get rusted.
8. Why plastic is used as a pattern material?
It is not affected by moisture
The dimensional accuracy is more
It has light weight but strong.
9. What is master pattern?
For making a metal pattern, a wooden pattern is used. The wooden pattern used to
make a metal pattern is called master pattern.
10. State any two factors for selecting pattern material?
Quantity of casting to be produced
Quality
Casting and moulding method adopted.
Intricacy (complexity) of the castings to be produced.
11. What is pattern allowance?
Patterns are not made to correct sizes of the castings. Patterns are made slightly
larger than the required castings. This extra size given in pattern is called pattern
allowance.
12. List out the types of pattern allowances?
Shrinkage allowance
Machining or Finishing allowance
Draft allowance
Distortion or Camber allowance
Rapping allowance.
13. What is the purpose of shrinkage allowance is given in pattern making?
When Molten Metal is poured in to the mould it will solidify and cool. During cooling,
the metal will shrink and reduce in size. To avoid this extra size is given on required Casting.
14. What is finishing allowance?
Machining is done on the casting to remove the excess metal to get smooth
surface finish. This extra size give to the pattern is called machining allowance.
Machining allowance is also called finishing allowance.
15. Define draft allowance.
The edges of mould may be damaged while the pattern is removing from mould.
To avoid this, pattern is made with slight taper on vertical surfaces. This taper is
called draft allowance. It is expressed in degrees or mm.
16. Why distortion allowance is given?
The shape of some castings may be distort during cooling, (It depends upon size,
shape and thickness of casting). To avoid this distortions the pattern is made with
slight bent in opposite direction. E.g., U-shape casting.
17. What are all the operations are done by moulding?
Preparing moulding sand
Filling moulding box with moulding sand
Placing pattern in proper position
Ramming the sand
Cutting the gate
Making runners and risers holes
Introduce the core if necessary.
18. State three constituents of moulding sand.
Silicon sand grains, Clay, Moisture.
19. List out the merits of synthetic moulding sand?
It has High refractoriness.
Less amount of binder is sufficient.
The properties can control easily
20. Mention two properties of good moulding sand.
Porosity/ Permeability
Collapsibility
Adhesiveness
Refractoriness
Cohesiveness
Plasticity/ flow ability.
21. Define porosity?
Porosity is the property of moulding sand, which permits steam and gases to
escape through it, if not casting defects may occur. E.g., blow holes.
22. Define collapsibility?
Collapsibility is the property of moulding sand by which the mould collapses and
prevents the formation of cracks in casting.
23. What is cohesiveness in moulding sand?
Cohesiveness is the property of moulding sand by which the sand particles will
stick together. Due to this, mould remains strong.
24. Define tempering of moulding sand.
Tempering is the process of adding sufficient water to the sand moulding sand.
25. What is the purpose of gate?
The main purpose of gate is to create a way to pour a moulten metal. It connects
the runner hole and the mould cavity.
26. What are all the steps involved in preparation of moulding sand.
Mixing of sand
Tempering of sand &
Conditioning of sand.
27. List out the ingredients of Moulding sand?
Sand
Binder &
Additive
28. What is the purpose of binder used in moulding sand? List the types of binders used.
Binder is used to obtain cohesiveness in sand. Clay, organic and inorganic is the
types of binders.
29. What is additive used in moulding sand?
Additives are used to improve the properties like strength, porosity, and
refractoriness.
30. How the moulding sands are classified?
Natural or green sand
Synthetic sand
Special sand
(I) Olivine sand
(II) Zircon sand
(III) Chromite sand
31. When pit moulding is used?
Pit moulding is used for very large and heavy castings like machine bodies.
32. List out the types of Moulding machines.
Squeezer machine
Jolt machine
Sand slinger.
33. State any two reasons for using moulding machine.
Producing moulds at faster rate
Producing accurate moulds
Reducing the production cost
Getting better quality castings
34. What is core?
Core is a sand mass used to make a cavity or a hole in casting.
35. Enumerate the operations carried out in core making.
Core sand preparation
Core Moulding
Baking
Finishing
Coating
36. When strickle core box is used?
It is used when a core of irregular shape is required.
37. Write the requirements of good core?
It should have high refractoriness to withstand the high temperature of molten
metal.
It should have good collapsibility for easy removal of sand from casting.
38. Why it is so called CO2 process of core making
The core sand is filled up in the core box and rammed. Then CO2 gas is passed
through the core for 30seconds at pressure of 1.5kg/cm2. Then the CO2 reacts with
sodium silicate to form a silica gel to get the core as very hard.
39. Define casting.
Casting is obtained by pouring of moulten metal into the mould and allowing it to
solidify.
40. What do you meant by pressure die casting?
Die casting is the process in which molten metal is forced under pressure into a
permanent metal mould. The metal mould is called die.
41. Mention any-2 limitations of gravity die casting.
The cost of die is more.
Removal of casting is difficult
It is not suitable for produce complicate castings.
It is suitable only for mass production.
42. Which metals suits for Die casting
Lead, magnesium, tin and lead.
43. Mention the types of die casting.
Hot chamber die casting
Cold chamber die casting
44. Write down the advantages of die casting.
Very high rate of production
The die has long life
Metal wastage is low
Casting defects are less.
45. Why centrifugal casting is called so?
In centrifugal casting a metal mould is made to rotate on trolley by means of
centrifugal force the molten metal is thrown out to the walls of the mould. So the
hollow casting is produced without core.
46. List out the types of melting furnaces.
Cupola furnace
Crucible furnace
(I) Pit type furnace
(II) coke fired stationary furnace
(III) oil fired tilting furnace
Electric furnace
(I) Direct arc furnace
(II) In Direct arc furnace
(III) Induction furnace
47. What purpose tumbling operation is carried out in casting?
It is used for the purpose of removing sand and other impurities from the surface
of small castings.
48. Define pickling
The surface of small casting can be cleaned by dipping the castings in weak acid
solutions .This is called pickling.
49. List out the methods used for cleaning the castings?
i.Brushing v.Sawing
ii.Shearing vi.Flame cutting
iii.Chipping vii.Sand blasting
iv. Flogging viii.Shot blasting
50. What is the use of pyrometer? Name the types of pyrometer.
It is used to measuring high furnace temperature.
i) Thermo electric pyrometer
ii) Optical pyrometer
UNIT-II
JOINING PROCESS
1. Define welding
Welding is a process of joining similar metals by the application of heat. It can be
done with or without application of pressure.
2. Enumerate two basic types of welding
Plastic welding
Fusion welding
3. Define arc welding
Arc welding is process of joining two metal pieces by melting their edges by an
electric arc.
4. State the expansion of TIG welding & MIG welding
TIG – Tungsten inert gas welding
MIG – Metal Inert gas welding
5. List some advantages of plasma arc welding
All metals can be welded in this process.
No need of filler rod
Welding speed is high
6. When electro slag welding is applied?
This welding is used to weld thick plate of 25 mm or more.
7. Write down the equipments used in gas welding?
Gas cylinders
Regulators
Pressure gauges
Hoses
Welding torch
8. Name any two types of gas flames
Neutral flame
Carburising flame
Oxidising flame
9. State two advantages of gas welding
Cost of welding equipment is less.
The maintenance cost is low.
The amount of filler metal deposit can be controlled easily.
10. Mention any two application of Carburising flame
It is used for welding steel, alloy steels, non-ferrous metals, nickel and Monel metal.
11. What is meant by resistance welding?
In resistance welding, the metal is heated to plastic stage due to heat generated by the
resistance.
12. What is oxy-acetylene cutting?
In this method, the metal is heated by an oxy-acetylene flame and cut by passing
oxygen jet.
13. What is brazing
It is the process of joining two similar or dissimilar metals by using a high melting
alloy called brazing
14. Name any two types of brazing
Torch brazing
Induction brazing
Dip brazing
Furnace brazing
15. What is the application of Thermit welding?
Thermit welding is used for joining heavy parts, rails, pipes, shafts, and cables and
worn out machines frames.
16. Define diffusion welding
In this method, welding is done by the inter atomic bond with the application of heat
and pressure.
17. What is edge preparation of plates in weld joints
Edge preparation is the process of making the edges to be joined to correct shape.
This gives a good welded joint
18. What type of shape the edges will be prepared for joining plates of more than
20mm thick?
Single U and Double U butt welds are used to prepare for joining plates more than
20mm thick
19. Name some of welding defects
Porosity
Blow holes
Undercut.
20. What is the main difference between destructive and non-destructive testing?
In destructive testing method, the test is conducted by destroying the welded
joint. So the tested work piece cannot be used.
In non-destructive testing method, the test is conducted without destroying
the welded joint.
21. Mention any two safety measures during gas welding
The gas cylinders should not be kept near the heat sources
Fire extinguishing equipment is necessary
Quality hoses should be used.
22. List out the safety features of arc welding
A specific voltage and current should be maintained
The electrode holder should be properly insulated
Welding should be done in safer place.
UNIT-III
.UNIT –V