MANUFACTURING TECHNOLOGY-1

UNIVERSIT QUESTION BANK WITH ANSWERS

UNIT –I
METAL CASTING PROCESS

1 State any four types of patterns. (May 2006)

Ans: The various types of patterns which are commonly used areas follows:
1) Single piece or solid pattern
2) Two piece or split pattern
3) Loose piece pattern
4) Cope and drag pattern
5) Gated pattern

2 Mention any two advantages and disadvantages of die casting. (May=2006)

Ans: Advantages:
• It is a very fast process.
• Moulds have longer life.
• Better surface can be obtained.
Limitations:
• Moulds are much costlier.
• This method is not suitable for small quantity production.
• Shape and weight of the casting is limited.

3 Write the requirements of good pattern. (May 2007)

Ans: Simple in design
• Cheap and readily available
• Light in mass
• Surface id smooth
• Have high strength
3. What is core venting? (May 2007)
Ans: While pouring the mould with molten metal mould walls and cores heat up rapidly and releases large
amount of gases. In order to prevent casting defects these gases must be vented out. For this purpose core
venting are used. Core venting are incorporated in the core box itself.
4. What function of core ? (May 2008)
Ans: Functions of core are:
• Core provides a means of forming the main internal cavity for hollow casting.
• Core provides external undercut feature.
• Cores can be inserted to obtain deep recesses in the casting.
• Cores can be used to increase the strength of the mould.

5. Which process is called lost waxing method? Why? (May 2008)

Ans: Investment casting process is also known as Lost-wax process. The term investment
refers to a clock or special covering apparel. In investment casting, the clock is a refractory mould which
surrounds the precoated wax pattern.

6. What is the function of core prints? (Dec. 2008)

Ans:
 1. Core prints are basically extra projections provided on the pattern.
2. They form core seats in the mould when pattern is embedded in the sand for mould
making.
3. Core seats are provided to support all the types of cores.
4. Though the core prints are the part of pattern, they do not appear on the cast part.

7. What are the advantages and applications of ceramic moulds? (Dec. 2008)
Ans: Advantages:
• It is less expensive
• Intricate objects can be casted.
• Castings of thin sections and which do not require machining can be produced.
Applications:
• It is mainly used for all material using better ingredient in slurry.

8. What are the pattern materials? (Dec.

2008) Ans:1) Wood 2) Metal 3)
Plastic
4) Plaster 5) Wax

9. Explain the term fettling. (Dec. 2009)

Ans: Fettling is the name given to cover all those operations which help the casting to
give a good appearance. It includes the removal of cores, sand, gates, risers, runners and
other Unwanted projections from the casting.

10. What are the applications of casting?

Ans: Transportation vehicles (in automobile engine and tractors)
• Machine tool structures
• Turbine vanes and power generators
• Mill housing
• pump filter and valve

11. what are the different types of furnaces used for casting.
1.Cupola Furnace.
2.Open Hearth furnace
3.Crucible Furnace.
4.Pot Furnace.
5.Electric Furnace.
12. State the main functions of tuyeres in cupola furnace.
The tuyers are used to supply air to the coke bed for complete burning.

Part-B (16 Marks)

1. What are the pattern allowances? Explain briefly each. (Nov/Dec- 2013) (16)
Five types of allowances were taken into consideration for various reasons. They are
1.Shrinkage allowance
Any metal when heated to liquid stage and solidified will undergo change in dimension. Mostly the
dimension of the product will be reduced, then the actual size of the pattern. Hence the patterns are
made slightly in larger dimensions.(3%-5%)
2. Draft allowance
It will be difficult to remove the pattern from the mould cavity (without disturbing the mould) after
ramming of sand. Hence the pattern (wooden or metal pattern) is slightly given 2 o– 3 o TAPER in the
z - axis or vertical direction.
3. Finish allowance
It is otherwise called as machining allowance .The pattern is made slightly 5mm -10mm large in
dimension than the required final part dimension. After casting the extra material is removed from
the solidified material by machining.
4. Shake or Rapping allowance.
Before withdrawing the pattern it is rapped and thereby the size of the mould cavity increases.
Actually by rapping , the external sections move outwards increasing the size and internal sections
move inwards decreasing the size. This allowance is kept negative and hence the pattern is made
slightly smaller in dimensions 05.1.0 mm.
5. Distortion allowance.
Some material might tend to bend or distort from the actual size or dimensions. Hence the pattern is
give counter balance degree or angle of recess so that the material will be in the required dimension
when solidified in the mould cavity.
 2. Explain the CO2 process of core making state its advantages and applications. (16)

Working Principle
The highly flowable mixture of pure dry silica sand and sodium silicate binder is rammed or
blown into the mould or core box. Carbon –dioxide gas at a pressure of about 1.5 bar is diffused
through the mixture (of sand and sodium silicate) to initiate the hardening reaction which takes from
a few seconds to a few minutes depending upon the size of core or mould.Passage of carbon-
dioxide through the sand containing sodium silicate produces carbonic acid in the aqueous solution,
this causes a rise in the SiO2- Na2O ratio and the formation of a colloidal silica gel which hardens
and forms a bond between the sand grains. The reaction is represented by the following equation.

NaSiO3 + CO2----------------------------- NaCO3 + SiO2

(Sodium Silicate) (Silica Gel)

Carbon Dioxide Moulding Operation

This sand is mixed with 3 to 5 % sodium silicate
liquid base binder in Muller for 3 to 4 minutes.
Additives such as coal powder, wood flour sea coal,
and dextrin may be added to b improve its
properties. Aluminium oxide Kaolin clay may also
added to the sand. Patterns used in this method may
be coated with Zinc of 0.05 mm to 0.13 mm and
then spraying a layer of aluminium or brass of
about 0.25 mm thickness for good surface finish
and good results.
Advantages
• Operation is speedy since we can use the mould and cores immediately after processing.
• Heavy and rush orders
• Floor space requirement is less
• Semi skilled labor may be used.
Disadvantages
Difficult in reusing the moulding sand.
3. Write a short note on ‘Green sand mould’ and shell Moulding.

Sand Casting (Green sand mould) is simply melting the metal and pouring it into a
preformed cavity, called mold, allowing (the metal to solidify and then breaking up the
mold to remove casting. In sand casting expandable molds are used. So for each casting
operation you have to form a new mold.

– Sand with a mixture of water and bonding clay

– Typical mix: 90% sand, 3% water, and 7% clay
– to enhance strength and/or permeability
Sand – Refractory for high temperature.
TYPES OF SAND

a) Green-sand molds - mixture of sand, clay, and water; “Green" means mold contains
moisture at time of pouring.
b) Dry-sand mold - organic binders rather than clay and mold is baked to improve
strength
c) Skin-dried mold - drying mold cavity surface of a green-sand
– mold to a depth of 10 to 25 mm, using torches or
heating

Steps in Sand Casting

The cavity in the sand mold is formed by packing sand around a pattern, separating the mould into two
halves.The mold must also contain gating and riser system For internal cavity, a core must be included in
mold A new sand mold must be made for each part
1. Pour molten metal into sand mold
2. Allow metal to solidify
3. Break up the mold to remove casting
4. Clean and inspect casting
5. Heat treatment of casting is sometimes required to improve metallurgical properties
Steps in shell-molding
Shell-mold casting yields better surface quality and tolerances.
The process is described as follows:
The 2-piece pattern is made of metal (e.g. aluminum or steel), it is heated to between 175°C-
370°C, and coated with a lubricant, e.g. silicone spray. Each heated half-pattern is covered
with a mixture of sand and a thermoset resin/epoxy binder. The binder glues a layer of sand to
the pattern, forming a shell. The process may be repeated to get a thicker shell.The assembly is
baked to cure it.The patterns are removed, and the two half-shells joined together to form the
mold; metal is poured into the mold. When the metal solidifies, the shell is broken to get the
part.

Advantages of shell moulding

Smoother cavity surface permits easier flow of molten metal and better surface
finish on casting
Good dimensional accuracy
Machining often not required
Mold collapsibility usually avoids cracks in casting
Can be mechanized for mass production

Disadvantages of shell moulding.

More expensive metal pattern
Difficult to justify for small quantities
4. Briefly explain about Investment
casting. Investment Casting
Investment casting produces very high surface quality and dimensional accuracy.
Investment casting is commonly used for precision equipment such as surgical
equipment, for complex geometries and for precious metals.
This process is commonly used by artisans to produce highly detailed artwork.
The first step is to produce a pattern or replica of the finished mould. Wax is
most commonly used to form the pattern, although plastic is also
used.Patterns are typically into a permanent die.mass-produced by injecting
liquid or semi-liquid wax Prototypes, small production runs and specialty
projects can also be undertaken by carving wax models.
Cores are typically unnecessary but can be used for complex internal structures.
Rapid prototyping techniques have been developed to produce expendable patterns.
Several replicas are often attached to a gating system constructed of the same
material to form a tree assembly. In this way multiple castings can be produced in a
single pouring.

Casting with expendable mould: Investment Casting

advantages
– Parts of great complexity and intricacy can be cast
– Close dimensional control and good surface finish
– Wax can usually be recovered for reuse
– Additional machining is not normally required - this is a net shape process

Disadvantages
– Many processing steps are required
– Relatively expensive process
 UNIT – II

METAL JOINING PROCESS

1 List out any four arc welding equipment. (May 2006)
Ans: The most commonly used equipments for arc welding are as follows:
(a) A.C or D.C. machine
(b) Wire brush
(c) Cables and connectors
(d) Ear thing clamps
(e) Chipping hammer

2 What are the special features of friction welding? (May 2007)

Ans:
• Friction welding is a solid state welding process where coalescence is produced by the heat obtained
from mechanically induced sliding motion between rubbing surfaces.
• The work parts are held together under pressure.
• Its operating is simple.
• Power required for the operation is low.
• It is used for joining steels, super alloys, non-ferrous metals and combinations
of metals.
3. Define resistance welding process. (May 2006, May 2007)
Ans: Resistance welding is a process where coalescence is produced by the heat obtained from resistance
offered by the workpiece to the flow of electric current in a circuit of which the workpiece is a part and by
the application of pressure.
4. What is the purpose of flux? (May 2008)
Ans: 1) It acts as shield to weld.
2) To prevent atmospheric reaction of molten metal with atmosphere.

5. How can slag inclusions in welding be avoided? (May 2008)

Ans: Avoid multi layer welding
• Reduce arc length
• Increase electrode angle
• Avoid using large electrode
6 How does brazing differ from braze welding? (Dec.
2008) Ans:
Brazing Braze Welding
The filler alloy is fed to one or more The filler alloy is deposited
points in the assembly and it isdirectly at the point where it is
drawn into the rest of the joint by desired.
capillary action.
7 Why flux is coated on filler rods? (Dec. 2008)
Ans: The coating improves penetration and surface finish.
• Suitable coating will improve metal deposition rates.

8 What is the application of carburizing flame? (Dec. 2009) Ans:

• Carburizing flame is generally used for: o Welding
of low alloy steel rods
o Non-ferrous metals
o High carbon steel

9 What are the diameter and length of the electrodes available in the market? (Dec. 2009)
Ans: Standard length of electrodes are 250 mm, 300 mm and 450 mm.
• Standard diameters of electrodes are 1.6,2 ,2.5, 3.2, 4,5,6,7,8, and 9 mm.

10. Classify various ARC welding processes

(i) Arc welding

• Carbon arc
• Metal arc
• Metal inert gas
• Tungsten inert gas
• Plasma arc
• Submerged arc
• Electro-slag

11. Classify various GAS welding processes

(ii) Gas Welding

• Oxy-acetylene
• Air-acetylene
• Oxy-hydrogen

12. Name the various methods of Resistance Welding

B UTT
Spot
Seam
Projection & Percussion.
13. What is ‘Brazing’
It is defined as the t3echnique of joining two dissimilar or similar materials by addition of
special filler material. Brazing gives a much stronger joint than soldering but requires greater heat
which cannot be obtained from copper in soft soldering.
14.Mention the applications of friction welding.

Used in refrigeration.
Used in super alloys.
Making simple forging.
Production of taper and reamer drills
Production of axle shafts , valves and gears.

15.Name the chemicals used in flux Manufacure.

1.Chlorides
2.Borax and boric acid.
3.Borates
4.Fluorides.

Part-B (16Marks)

1. Define welding, mention its types, Explain Arc welding with a neat sketch and
Mention its advantages and limitations. (16) (NOV/DEC 2010)

Welding
Welding is a materials joining process which produces coalescence of
materials by heating them to suitable temperatures with or without the
pplication of pressure or by the application of pressure alone, and with or without
the use of filler material. Welding is used for making permanent joints. It is used in
the manufacture of automobile bodies, aircraft frames, railway wagons, machine
frames, structural works, tanks, furniture, boilers, general repair work and ship
building.
Types of welding
ARC Welding
Gas Welding

Arc welding
Uses an electric arc to coalesce metals
Arc welding is the most common method of
welding metals
Electricity travels from electrode to base metal
to ground

Arc welding Equipments

• A welding generator (D.C.)
or Transformer (A.C.)
• Two cables- one for work
and one for electrode
• Electrode holder
 • Electrode
• Protective shield
• Gloves
• Wire brush
• Chipping hammer
• Goggles

Electrode

Electrode is a thin rod made up of same as that of parent material. Flux is coated over the electrode to
avoid oxidation. It is mostly connected to the negative polarity.

Two Basic Types of AW Electrodes

 Consumable – consumed during welding process
 Source of filler metal in arc welding
 Nonconsumable – not consumed during welding process
 Filler metal must be added
separately

Consumable Electrodes
Forms of consumable electrodes
• Welding rods (a.k.a. sticks) are 9 to 18 inches and 3/8 inch or less in
diameter and must be changed frequently
• Weld wire can be continuously fed from spools with long lengths of
wire, avoiding frequent interruptions
In both rod and wire forms, electrode is consumed by arc and added to weld joint as filler metal.

Nonconsumable Electrodes
 Made of tungsten which resists melting
 Gradually depleted during welding (vaporization is principal mechanism)
 Any filler metal must be supplied by a separate wire fed into weld pool

Flux
A substance that prevents formation of oxides and other contaminants in welding, or
dissolves them and facilitates removal
 Provides protective atmosphere for welding
 Stabilizes arc
 Reduces spattering

Welding practice & equipment

STEPS :
• Prepare the edges to be joined and maintain the proper position

• Open the acetylene valve and ignite the gas at tip of the torch

• Hold the torch at about 45deg to the work piece plane

 • Inner flame near the work piece and filler rod at about 30 – 40 deg

• Touch filler rod at the joint and control the movement according to the flow

Advantages of the material

Most efficient way to join metals

Lowest-cost joining method
Affords lighter weight through better utilization of materials
Joins all commercial metals
Provides design flexibility

Disadvantages
• Manually applied, therefore high labor cost.
• Need high energy causing danger
• Not convenient for disassembly.
• Defects are hard to detect at joints.

2. Define welding, mention its types, Explain Gas welding with a neat sketch and
Mention the equipments used , types of flames produced and give its
advantages and limitations. (16) APR /MAY -2010

Welding
Welding is a materials joining process which produces coalescence of
materials by heating them to suitable temperatures with or without the
application of pressure or by the application of pressure alone, and with or
without the use of filler material. Welding is used for making permanent joints. It is
used in the manufacture of automobile bodies, aircraft frames, railway wagons,
machine frames, structural works, tanks, furniture, boilers, general repair work and
ship building.
Types of welding
ARC Welding
Gas Welding

GAS WELDING
 Sound weld is obtained by selecting proper
size of flame, filler material and method of
moving torch
 The temperature generated during the
process is 33000c.
 When the metal is fused, oxygen from the
atmosphere and the torch combines with
molten metal and forms oxides, results
defective weld
 Fluxes are added to the welded metal
to remove oxides
 Common fluxes used are made of sodium, potassium. Lithium and borax.
 Flux can be applied as paste, powder, liquid. solid coating or gas.
GAS WELDING EQUIPMENT

1.Gas Cylinders
Pressure
Oxygen – 125 kg/cm2
Acetylene – 16 kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the thickness of the work pieces welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve

Three basic types of oxyacetylene flames used in oxyfuel-gas welding and

cutting operations:
(a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.

Addition of more oxygen give a bright

whitish cone surrounded by the transparent
blue envelope is called Neutral flame (It has a balance of
fuel gas and oxygen) (32000c)
• Used for welding steels, aluminium, copper and cast iron
 oxygen give a bright whitish cone surrounded by the transparent
blue envelope is called Neutral flame (It has a balance of fuel gas and oxygen) (32000c)
• Used for welding steels, aluminium, copper and cast iron

Oxygen is turned on, flame immediately changes into a long white inner area (Feather)
surrounded by a transparent blue envelope is called Carburizing flame (30000c)

Advantages of Gas welding.

1.Simple Equipment
2.Portable
3.Inexpensive
4.Easy for maintenance and repair

Disadvantages Of Gas welding

1.Limited power Density

2.Very low welding speed.
3.High total heat input per unit length
4.Large Heat affected Zone
5.Severe Distortion
6.Not recommended for welding reactive metals such as titanium and Zirconium.

3. Give the Difference between Gas Welding and Arc Welding.

GAS WELDING ARC WELDING

Sr No
Heat is produced by the Gas Heat is produced by Electric Arc
1. Flame
2. The flame temperature is
about 3200oC The temperature of Arc is about 4000oC
 3. Separate Filler rod introduced Arc Producing as well as filler rod material is the
electrode.
4. Suggested for thin materials Suggested for medium and thick materials

5. Gas welded parts do not have Arc welded parts have very high strength
much strength
6. Filler metal may not be the Filler metal must be same or an alloy of the parent metal
same parent metal
7. Brazing and soldering are Brazing and soldering can’t be carried out by electric arc.
done using gas

4. Explain Submerged arc welding with a neat sketch. State its advantages
and disadvantages. (NOV/DEC-2011).
Submerged arc welding
• Weld arc is shielded by a granular flux , consisting of silica, lime,
manganese oxide, calcium fluoride and other compounds.
• Flux is fed into the weld zone by gravity
flow through nozzle Thick layer of flux
covers molten metal

• Flux acts as a thermal

insulator ,promoting deep
penetration of heat into the
work piece
• Consumable electrode is a
coil of bare round wire fed
automatically through a tube
• Power is supplied by
3-phase or 2-phase
power lines