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Casting
By S K
IES-2001
The main purpose of chaplets is
(a) Aluminium
(d) Copper. C
GATE-1999
Which of the following materials requires
the largest shrinkage allowance, while
making a pattern for casting?
(a) Aluminium
(b) Brass
(c) Cast Iron
(d) Plain Carbon Steel D
IES-1999
In solidification of metal during
casting, compensation for solid
contraction is
D
GATE-2008
While cooling, a cubical casting of side 40
mm undergoes 3%, 4% and 5% volume
shrinkage during the liquid state, phase
transition and solid state, respectively. The
volume of metal compensated from the
riser is
(a) Wood
(b) Rubber
(c) Metal
(d) Polystyrene D
IES-2008
The pattern adopted for those castings
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) Skelton pattern
(d) Single piece pattern B
GATE 2012 (PI)
In sand casting, fluidity of the molten
metal increases with
(A) increase in degree of superheat
(B) decrease in pouring rate
(C) increase in thermal conductivity of the
mould
(D) increase in sand grain size A
ISRO-2011
Fluidity in casting (CI) operation is
greatly influenced by
[2 marks]
IES-2002
Assertion (A): In CO2 casting process, the
mould or core attains maximum strength.
Reason (R): The optimum gassing time of
CO2 through the mould or core forms Silica Gel
which imparts sufficient strength to the mould
or core.
(a) Both A and R are individually true and R
is the correct explanation of A
(b) Both A and R are individually true but R
is not the correct explanation of A
(c)A is true but R is false
(d) A is false but R is true A
GATE 2008 (PI)
In sand casting of a hollow part of lead, a
cylindrical core of diameter 120 mm and height
180 mm is placed inside the mould cavity. The
densities of core material and lead are 1600
kg/m3 and 11,300 kg/m3 respectively. The net
force (in N) that tends to lift the core during
pouring of molten metal will be
(a) N = 2n
(b) N = 2n-l B
(c) N = 2n + 1
(d) N = 2n + 1
IES 2011
In light metal casting, 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 volume of flow through each
gate
takes place
(a) 1 and 2 only (b) 1 and 3 only
(c) 2 and 3 only (d) 1, 2 and 3 C
GATE 2010 (PI)
During the filling process of a given sand mould
cavity by molten metal through a horizontal runner
of circular cross-section the frictional head loss of
the molten metal in the runner will increase with the
A
GATE-2002
The primary purpose of a sprue in a
casting
mould is to
(a)Feed the casting at a rate consistent with
the rate of solidification
(b)Act as a reservoir for molten metal
(c)Feed molten metal from the pouring basin
to the gate
(d)Help feed the casting until all
solidification takes place C
IES-1998
Which of the following are the requirements of an
ideal gating system?
1. The molten metal should enter the mould cavity
with as high a velocity as possible.
2. It should facilitate complete filling of the mould
cavity.
3. It should be able to prevent the absorption of air
or gases from the surroundings on the 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
IES-2009
Consider the following statements:
1.The actual entry point through which the
molten 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 the above statements is/are correct?
(a) 1 only (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
B
GATE-2001
The height of the down-sprue is 175 mm
and its cross-sectional area at the base is
200 mm2. The cross-sectional area of the
horizontal runner is also 200 mm2.
Assuming no losses, indicate the correct
choice for the time (in seconds) required to
fill a mould cavity of volume 106 mm3. (Use
g = 10 m/s2).
(a)2.67 (b)8.45 (c)26.72 (d)84.50 A
GATE-2007
A 200 mm long down sprue has an area of
cross section of 650 mm2 where the pouring
basin meets the down sprue (i.e. at the
beginning of the down sprue). A constant head
of molten metal is maintained by the pouring
basin. The Molten metal flow rate is 6.5 105
mm3/s. Considering the end of down sprue to
be open to atmosphere and an acceleration
due to gravity of 104mm/s2, the area of the
down sprue in mm2 at its end (avoiding
aspiration effect) should be C
(a)650.0 (b)350.0 (c)290.7 (d)190.0
Contd
IES-2003
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
The correct sequence of the above elements
in the ratio 1: 2: 4 is
(a) 1, 2 and 3
(b) 1,3 and 2
(c) 2, 3 and 1
(d) 3, 1 an 2 A
IES-2005
The gating ratio 2: 8: 1 for copper in gating
system design refers to the ratio of areas
of:
(a) Sprue: Runner: Ingate
(b) Runner: Ingate: Sprue
(c) Runner: Sprue: Ingate
(d) Ingate: Runner: Sprue A
GATE-2010
In a gating system, the ratio 1:2:4 represents
(b) 20 seconds
(d) 40 seconds D
GATE-2003
With a solidification factor of 0.97 x 106
s/m2, the solidification time (in seconds) for
a spherical casting of 200 mm diameter is
B
IES-2006
According to Chvorinov's equation, the
solidification time of a casting is
proportional to:
(a) v2
(b) v
(c) 1/v
(d) 1/v2
D
GATE -2011 (PI)
In a sand casting process, a sphere and a
cylinder of equal volumes are separately cast
from the same molten metal under identical
conditions. The height and diameter of the
cylinder are equal. The ratio of the solidification
time of the sphere to that of the cylinder is
(a) 1.14
(b) 0.87
(c) 1.31
(d) 0.76 C
GATE-2009 (PI)
A solid cylinder of diameter D and height equal to D, and a
solid cube of side L are being sand cast by using the same
material. Assuming there is no superheat in both the cases,
the ratio of solidification time of the cylinder to the
solidification time of the cube is
(a) (L/D)2
(b) (2L/D)2
(c) (2D/L)2
(d) (D/L)2 D
IES - 2012
The ratio of surface area of volume for a unit
volume of riser is minimum in case of
18 CM [10 - Marks]
Conventional Question IES-2007
Calculate the size of a cylindrical riser
A
IES-1997
Assertion (A): Steel can be melted in hot blast
cupola.
Reason (R): In hot blast cupola, the flue gases are
used to preheat the air blast to the cupola so that
the temperature in the furnace is considerably
higher than that in a conventional cupola.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not
the correct explanation of A
(c)A is true but R is false
(d) A is false but R is true A
IES - 2012
Statement (I): Cupola furnace is not employed for
melting steel in foundry
Statement (II): The temperatures generated
within a cupola are not adequate for melting Steel
(a) Both Statement (I) and Statement (II) are
individually true and Statement (II) is the correct
explanation of Statement (I)
(b) Both Statement (I) and Statement (II) are
individually true but Statement (II) is not the
correct explanation of Statement (I) D
(c) Statement (I) is true but Statement (II) is false
(d) Statement (I) is false but Statement (II) is true
GATE-1996
Light impurities in the molten metal are
prevented from reaching the mould cavity
by providing a
(a) Strainer
(b) Button well
(c) Skim bob
(d) All of the above C
GATE-2005
A mould has a downsprue whose length is 20
cm and the cross sectional area at the base
of the downsprue is 1cm2. The downsprue
feeds a horizontal runner leading into the
mould cavity of volume 1000 cm3. The time
required to fill the mould cavity will be
(a)4.05 s (b)5.05 s (c)6.05 s (d)7.25 s
B
GATE-2006
In a sand casting operation, the total liquid head is
maintained constant such that it is equal to the
mould height. The time taken to fill the mould with a
top gate is tA. If the same mould is filled with a
bottom gate, then the time taken is tB. Ignore the
time required to fill the runner and frictional effects.
Assume atmospheric pressure at the top molten
metal surfaces. The relation between tA and tB is B
(A) tB 2 t A
(B) tB 2 t A
tA
(C) tB
2
(D) tB 2 2 t A
GATE 2007 (PI) Linked S-1
In a sand casting process, a sprue of 10
mm base diameter and 250 mm height
leads to a runner which fills a cubical
mould cavity of 100 mm size
The volume flow rate (in mm3/s) is
(a) 0.8 x 105 (b) 1.1 x 105
(c) 1.7 x 105 (d) 2.3 x 105
C
GATE 2007 (PI) Linked S-2
In a sand casting process, a sprue of 10
mm base diameter and 250 mm height
leads to a runner which fills a cubical
mould cavity of 100 mm size
The mould filling time (in seconds) is
(a) 2.8 (b) 5.78
(c) 7.54 (d) 8.41
B
IES 2009
2 marks
IAS-2011 Main
Sketch a mould for two hollow components
to be cast. On the diagram, indicate
runner, gate, riser, core, cope, sprue,
pouring basin, sprue well, drag, parting
line.
[10-Marks]
GATE-2004
Misrun is a casting defect which occurs due
to
(b) Swell
(c) Sand wash
(d) Scab A
IES-2001
Scab is a
D
IAS-2001
Which of the following pattern-materials are
used in Precision Casting?
1. Plaster of Paris
2. Plastics
3. Anodized Aluminium Alloy
4. Frozen Mercury
Select the correct answer using the codes given
below:
(a) 1 and 2 (b) 2 and 4 (c) 3 and 4 (d) 1 and 3
B
IAS-2004
Which one of the following gating
systems is best suited to obtain
directional solidification?
(a) Top grating
(b) Part-line grating
(c) Bottom grating
(d) Stepped grating
D
IES 2011
In the designation of Aluminium casting A514.0
indicates :
(a) Aluminium purity
(b) Aluminium content
(c) Percentage of alloy element
(d) Magnesium Content
Ans. (d)