Fabrication process

Mid 01 answers

Set-01
Short answers
1
a) How will you examine internal defects in casted components?
Ans: Using non destructive testing like ultrasonic inspection , radiographic
examination..
b) Define shrinkage allowance.
Ans: Shrinkage is defined as the reduction during the cooling or solidification
process. This is a common property of all materials The magnitude of shrinkage
varies from material to material, but each and every material has to shrinks.  For
avoiding this, the pattern is made larger than the required size of the casting
product with the help of the shrink rule.Then the difference between actual pattern
size and required casting size is known as shrinkage allowance. 
C ) What is the function of riser.
Ans: A riser is a reservoir built into casting mold to prevent cavities due to
shrinkage.
d) Choose a pattern material for investment casting.
Ans: we can use WAX PATTERN to shape a disposable ceramic mold
e) Define fusion welding.
Ans: FUSION WELDING - the metal at the joint is heated to molten state & it is
allowed to solidify.
f) Name various flux used in gas welding.
Ans: In gas welding, the borax, sodium chloride are commonly used as flux
material.
g) What is voltage range in submerged arc welding?
Ans: Voltage Range is 20-50 VOLTS.
h) What are the compounds used in exothermic reaction?
Ans: IRON OXIDE is commonly used in exothermic welding
i)Write two disadvantages of TIG welding?
Ans:1. Requires a high level of skill and experience to operate effectively
2. Slower process compared to other welding methods, resulting in
lowerproductivity
3. Requires a high-purity shielding gas, which can be expensive
j) How is the wire feed in MIG welding.
Ans: The purpose of wire feeder is to feed welding wire needed in welding from
spool coil to welding gun. wire feeder also allows for starting and stopping power
Source.
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Long answers
2.a) List out different types of patterns and sketch any two of them?
Ans: A pattern is a replica of final product and is used for preparing mould cavity made of
wood or metal.
Types of patterns:
 single piece pattern
 Sweep pattern.
 Two piece pattern
 Loose piece pattern
 Gated pattern
 Multipiece pattern
 Match plate pattern
 Cope & Drag pattern
 Follow Board pattern
 shell pattern
 Segmental pattern
SINGLE PIECE PATTERN

• Job is very simple and does not create any withdrawal problems.

Small-scale production or in prototype development.

• This type of pattern is expected to be entirely in the drag and one of the surface is expected
to be flat which is used as the parting plane.

A gating system is made in the mold by cutting sand with the help of sand tools.

• Most inexpensive of all types of patterns.

It is often used for the generation of large castings such as stuffing box of steam engine and for creating simple shapes, flat
surfaces like simple rectangular blocks

TWO PIECE PATTERN

It is split along the parting surface, One half of the pattern is molded in drag and the other half in cope.

The two halves of the pattern must be aligned properly by making use of the dowel pins, which are fitted,
to the cope half of the pattern.

These dowel pins match with the precisely made holes in the drag half of the pattern.

Widely used type of pattern for intricate castings. It is used in applications where it is very difficult to
withdraw casting from the mold.
Applications: It is used in AK-47. It is widely used in steam valves.
2.b) Enumerate different elements of Gating system.
Ans: The term 'gating' or 'gating system' refers to all the passageways through which metal
enters a mould cavity. It thus mainly includes parts such as a
 pouring basin,
 sprue,
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 sprue base,
 runner,
 runner extension
 ingate and
 gates.

1.Pouring basin:It is the conical hollow element or tapered hollow vertical portion of the
gating system which helps to feed the molten metal initially through the path of gating system
to mould cavity. It may be made out of core sand or it may be cut in cope portion of the sand
mould. It makes easier for the ladle operator to direct the flow of molten metal from crucible
to pouring basin and sprue.
It helps in maintaining the required rate of liquid metal flow.
It reduces turbulence and vertexing at the sprue entrance.
It also helps in separating dross, slag and foreign element etc.
from molten metal before it enters the sprue.

2. Sprue: Sprue is the channel through which the molten metal is brought to the parting plane
where it enters the runners and gates to ultimately reach the mold cavity.If the sprue is straight
and cylindrical, then metal flow would not be full at bottom, but some low pressure area would
be created around the metal in the sprue.Atmospheric air would be breathed into this low
pressure area which would be then carried to the mold cavity.To eliminate this problem tapered
sprue is used

3. Sprue base: This is reservoir of the metal at the bottom

Of the sprue to reduce the momentum of the molten metal.
The molten metal gains velocity while moving down the sprue, some of which is lost in the
sprue base well by which the mold erosion is reduced.

4. Runner: It is located in parting plane and connects the sprue to the in-gates.
• The runners are normally made trapezoidal in
cross-section.
• The slag trapping takes place in the runner,
when runner flows full.
If the amount of molten metal coming from sprue base
is more than the amount flowing through the in-
gates.
A partially filled runner causes slag to enter the mold cavity
5.Runner Extension: The runner is extended little further after it encounters the in-
gate.
This extension is provided to trap the slag in the molten metal
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6.Ingate:
• These are openings through which molten

metal enters the mold cavity.

Top Gate:

• In this type of gate metal

enters the cavity from top.

• Cavity is filled very quickly. Therefore, top gates are not advisable for those
materials which are likely to form dross (turbulence, waste, slag, etc.).

Bottom Gate:

• This type of gate is used when the molten metal enters the mold cavity from bottom
of the cavity.

• It takes more time to fill the mold.

Parting Gate:

• The metal enters the mold at the parting plane when a part of the casting is in the
cope and a part of the casting is in drag.

Step Gate:

• They are used for heavy and large castings.

• The molten metal enters mold cavity through a number of in- gates, which are
arranged in vertical steps.

• The size of in-gates is normally

increased from top to bottom.

• This ensures the gradual filling of the mold without mold erosion and produces
sound casting.
7. Riser: : A riser is a reservoir built into casting mold to prevent cavities due to
shrinkage.
Types of Risers

1. Top Risers: They are open to atmosphere. They Tare most conventional and
convenient to make.

2. Blind Riser: are completely concealed inside the mold cavity. It loses heat slowly
since it is surrounded by the molding sand and thus would be more effective.
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3.Internal Risers: They are enclosed on all sides by the casting. They are normally used
for the castings which are cylindrical in shape or have hollow portions

3. a) Justify the importance of flux.

3.b) Describe the principle of oxy-acetylene gas welding with neat

sketch.
Ans: OFW is the term to describe the group of fusion operations that burn
various fuels mixed with oxygen to perform welding.

 The OFW processes employ several type of gases, which is the

primary distinction among the members of this group.

 The most important OFW process is oxyacetylene welding.

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 Oxy-acetylene welding uses a high-heat, high-temperature flame that is
produced by burning a fuel gas (most commonly acetylene) mixed with pure
oxygen. The base material is melted with the filler rod using a flame from the
combination of oxy-fuel gas through the tip of the welding torch.
 The fuel gas and oxygen gas are stored in pressurized steel cylinders.
Regulators in the cylinder reduce gas pressure.
 Gas flows through flexible hoses, with the welder controlling the flow via the
torch. The filler rod is then melted with the base material. However, melting
two pieces of metals is also possible without the need for a filler rod.
 ADVANTAGES

 The equipment is low cost, portable

 It can weld most common material
 The gas flame temperature is lower & easily controllable.
 Sheet metal operations (Automobile & Aircraft industry)
DISADVANTAGES
 Oxygen & Acetylene gases are expensive
 Safety problems involved in their handling & Storing
 Not suitable for thick sections, This flame takes long time to heat up the metal
4.a) Differentiate between pressurized gating and non pressurized
gating. What is gating ratio.

Gating ratio:
• The gating ration refers to proportion of the cross sectional areas between the
sprue, runner and in-gates and generally denoted as:

Sprue area : runner area : in-gate area

5 b) List out various advantages and disadvantages of MIG welding.

Ans: MIG welding is extremely versatile, fast, and simple for beginner welders, although is
does have a high setup cost, isn’t suitable in windy environments, and is susceptible to burn-
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throughs. MIG welding is a process that uses a continuous wire feed to join metals. It’s one
of the most popular welding methods because it’s relatively easy to learn and produces
high-quality welds.

The advantages of MIG welding are:

1. Versatility
2. Weld Speed
3. Beginner-Friendly
4. Weld Quality
5. Long-Pass Welding
6. Fewer Stops and Starts
7. Higher productivity
8. Deep penetration on various materials
9. Clean process
10.No Stub end losses

The disadvantages of MIG welding are:

1. Set-Up Cost Is Higher
2. Burn-Throughs And Undercutting
3. Hot Spots And Distortion
4. Not Best For A Windy Environment
5. Frequent Gas Changes Are Required
6. Limited Positions
7. More Maintenance Required
8. Fast Cooling Of Weld Pool
9. Not Appropriate For Thick Metalls

Set-02
Short answers
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1.
a)Propose a casting method for ornaments making?

Ans: we can use DIE CASTING

b)Define gating ratio?

Ans: The gating ration refers to proportion of the cross sectional areas between the sprue, runner and
in - gates and generally denoted as: Sprue area : runner area : in-gate area

C)How do you manage to prevent the damage of mould walls while removing pattern?

Ans : Design your mould with thinner components walls to allow faster cooling near
Surface.

d)Select a suitable oxy-acetylene flame for welding of Brass materials?

Ans: Oxidizing Flame….

e) Define off time.

Ans: off time is amount of time that elapses between when welding current is turned off and
when its turned back on again.

f) Propose a welding technique for deeper penetrations.

Ans: BACK HAND OR RIGHT HAND WELDING TECHNIQUE.

g) How does spot welding differ from seam and projection welding?

Ans: spot welding is used for thin sheet welding, projection welding is used for multi points
welding acceptable,seam welding is used for air tight welding………

h) Name the two different types of sprue used ?

Ans: 1 . STRAIGHT SPRUE,
2.TAPERED SPRUE.
i) Name the welding which is has non consumable electrode?
Ans: Tungsten INERT gas welding (TIG).
j) what is the function of shielding gases in TIG welding?
Ans: Shielding gas used to protect weld pool from influence of atmosphere i.e.from oxidation and
nitrogen absorption and to stabilize Electric Arc.
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LONG ANSWERS

2a)With a neat sketch demonstrate the operation of cupola furnace.

Ans: Cupola is a melting device.
• Used in foundries for production of cast iron.
• Used for making bronzes.
• Its charge is Coke , Metal , Flux.
• Scrap of blast furnace is re melted in cupola.
• Large cupolas may produce up to 100 tons/hour of hot iron.
Operation of Cupola:
• Preparation of cupola.
• Firing the cupola.
• Soaking of iron.
• Opening of air blast.
• Pouring the molten metal.
• Closing the cupola
Preparation of cupola:
• Slag and metal adhere to the cupola lining from the previous run is removed and lining of
cupola is re made.
• The bottom plates are swung to closing position supported by prob.
• The sand bed is then prepared with molding sand such that its slopes to towards the tap hole.
Firing the cupola:
• The cupola is fired by kindling wood at the bottom.
• This should be done 2.5 to 3 hours before the molten metal is required.
• On the top of the kindling wood a bed of coke is built.
• The height of the coke bed is may be vary from 50cm to 125cm according to the size of cupola.
Soaking of iron:
• When the furnace is charged fully it is maintain for about 45 minutes.
• The charge is slowly heated.
During the stage the air blast is shut off and iron is soaked
Opening of air blast:
At the end of the soaking period the air blast is opened. The taping hole is closed by a plug when
the melting proceeds and molten metal is collect at the bottom
Pouring the molten metal:
• When the sufficient amount of metal has collected in the hearth the slag hole is opened and the
slag is removed.
• Then taping hole is opened and molten metal is flows out in the table.The same procedure is
repeated until the charge is melted and the operation is over.
Closing the cupola:
• When the operation is over the air blast is shut off .The bottom of furnace is opened by
removing the prop.

2b) Analyze and propose suitable strategies to prevent blowholes and

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porosity in casted products.
Ans:
1.BLOW HOLES:
 Balloon shaped gas cavities caused by release of mould gases during pouring are known as blow
holes.
CAUSES:
• Ramming is too hard.
• Cores are not sufficiently baked.
• Excess moisture content.
• Low sand permeability.
• Excessive fineness of sand grains.
• Rusted chills, chaplets & inserts.
• Presence of gas producing ingredients.
REMEDIES:
• Baking of cores properly.
• Control of moisture content in moulding sand.
• Use of rust free chills, chaplets & inserts.
• Provide adequate venting in mould and cores.
• Ramming the mould less harder.
2.POROSITY:
Porosity is in the form of cavities caused due to gas entrapment during solidification.
CAUSES:
• High pouring temperature.
• Gas dissolved in metal charge.
• Less flux used.
• Molten metal not properly degassed.
• Slow solidification of casting.
• High moisture and low permeability of mould.
REMEDIES:
• Regulate pouring temperature
• Control metal composition.
• Increase flux proportions.
• Ensure effective degassing.
• Modify gating and risering.
• Reduce moisture and increase permeability of mould.

3 a) With neat sketches, illustrate various types of welded joints.

Ans: A weld joint must be designed to withstand the forces to which it is expected to be
subjected to during its service life. This means that the design of the joint is determined by
the type and magnitude of the load that is expected to act on the weld. Certain types of
welding joints are designed to withstand extreme shear loads, while others are designed to
withstand extreme torsional loads. Types of joints used for welding are:
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 Butt Joint

 Corner Joint

 T – Joint

 Lap Joint

 Edge Joint

1.Butt joint –

a joint between two members aligned approximately in the same plane.

2.Corner joint-A joint between two members located at right angles to each other

3. T- joint – a joint between two members located approximately at right angles to each other in
the form of a T

4. Lap Joint- a joint between two overlapping members

5. Edge joint- a joint between the edges of two or more parallel or nearly parallel members
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3b) Categorize welding processes based on source of heat energy.

4a) Explain about various properties of sand?

4b) Compare TIG welding with MIG welding?

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SET-03
SHORT ANSWERS
1
a) Choose a suitable pattern for small castings in mass production.
Ans: GATED PATTERN.
b) Example of non pressurized gating ratio.
ANS: 1:2:2 OR 1:3:3,1:1:3
For Steel-1:3:3
c)What is the function of sprue base.
Ans: It connects pouring basin to runner.
Sprue base is a reservoir of metal at bottom of sprue to reduce momentum of
molten metal.

d)Suggest suitable oxy-acetylene flame for gas cutting.

Ans: NEUTRAL FAME .
e) Name any three pressurized welding processes.
Ans: 1.gas pressure welding
2. friction welding.
3. Resistance welding.
f) Define weld time.
Ans: The time during which current flows and this is when weld formation and growth
occurs.
g) Name different types of binder.
Ans : Organic binder
Inorganic binder
h) Write the composition of green sand.
Ans: consists of high quality silica SAND,about 10% BENTONITE CLAY,2 to 5%
WATER and 5% SEA COAL.
i)Name the gases used in TIG welding.
Ans: ARGON (Ar),HELIUM(He).
j) Write two applications of MIG welding.
Ans:sheet metal welding.
Welding of pipe lines.
Heavy constructions such as building materials and bridges.
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LONG ANSWERS
2 a) Explain about shrinkage cavity ,blow holes ,porosity with neat
sketch
and also suggest remedies.
Ans: 1.Shrinkage cavity is a void on
the surface of the casting caused
mainly due to uncontrolled and
haphazard solidification of the
metal.
 Shrinkage defects can be
split into two different types:
1) External shrinkage
2) Closed shrinkage defects.

 Causes :
• Inadequate and improper gating & risering system.
• Too much high pouring temperature.
• Improper chilling.
 Remedies :
• Ensure proper directional solidification by modifying gating,
risering & chilling system.

2.BLOW HOLES:
 Balloon shaped gas cavities caused by release of mould gases during pouring
are known as blow holes.
CAUSES:
• Ramming is too hard.
• Cores are not sufficiently baked.
• Excess moisture content.
• Low sand permeability.
• Excessive fineness of sand grains.
• Rusted chills, chaplets & inserts.
• Presence of gas producing ingredients.
REMEDIES:
• Baking of cores properly.
• Control of moisture content in moulding sand.
• Use of rust free chills, chaplets & inserts.
• Provide adequate venting in mould and cores.
• Ramming the mould less harder.
3.POROSITY:
Porosity is in the form of cavities caused due to gas entrapment during solidification.
CAUSES:
• High pouring temperature.
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• Gas dissolved in metal charge.
• Less flux used.
• Molten metal not properly degassed.
• Slow solidification of casting.
• High moisture and low permeability of mould.
REMEDIES:
• Regulate pouring temperature
• Control metal composition.
• Increase flux proportions.
• Ensure effective degassing.
• Modify gating and risering.
Reduce moisture and increase permeability of mould

2b) Using neat sketches, describe various types of gates.

Ans: There are 4 types of gates :
i) TOP GATE
ii) BOTTOM GATE
iii) PARTING LINE GATE
iv) STEP GATE
Top Gate:
• In this type of gate metal
enters the cavity from top.
• Cavity is filled very quickly. Therefore, top gates are not advisable for
those materials which are likely to form dross (turbulence, waste,
slag, etc.).
Bottom Gate:
• This type of gate is used when the molten metal enters the mold
cavity from bottom of the cavity.
• It takes more time to fill the mold.
Parting Gate:
• The metal enters the mold at the parting plane when a part of the
casting is in the cope and a part of the casting is in drag.
Step Gate:
• They are used for heavy and large castings.
• The molten metal enters mold
cavity through a number of in-
gates, which are arranged in
vertical steps.
• The size of in-gates is normally
increased from top to bottom.
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• This ensures the gradual filling of the mold without mold erosion
and produces sound casting.

3a) GTAW process is also called as? Illustrate various elements of the
process.
Ans: GTAW process is also called as TIG(TUNGSTEN INERT GAS WELDING)
 Gas tungsten arc welding is an arc welding process that uses a non-
consumable tungsten electrode and an inert gas for arc shielding.
 It is also known as GTAW.
WORKING PRINCIPLE:
 An arc is established
between the end of a
tungsten electrode and the
parent metal at the joint
line..
 A constant-current welding
power supply is used to
produces energy which is
conducted across the arc
through a column of highly
ionized gas and metal vapors known as a plasma.
 Argon and helium are the most commonly used shielding gases.
Characteristics of the TIG welding process:
 Uses a non-consumable tungsten electrode during the welding
process,
 Uses a number of shielding gases including helium (He) and
argon (Ar),
 Is easily applied to thin materials,
 Produces very high-quality, superior welds,
 Welds can be made with or without filler metal,
 Provides precise control of welding variables (i.e. heat),
 Welding yields low distortion,
 Leaves no slag or splatter.
Applications:
 TIG is most commonly used to weld thin sections of stainless steel and
non- ferrous metals such as aluminum, magnesium, and copper
alloys.
 The aerospace industry is one of the primary users of gas tungsten arc
welding,
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 It is also frequently employed to weld small-diameter, thin-wall tubing
such as those used in the bicycle industry.
 TIG is often used in piping of various sizes.
ADVANTAGES:
 No flux is used.
 Welding is smooth and sound with fewer scatters.
 Very suitable for high quality
welding in thin materials.
 Very good process for welding non- ferrous metals and stainless
steels.
 The surface finish is good.
The equipments are portable
LIMITATIONS:
 Tungsten inclusion is hard and brittle.
 Equipment costs are high
 In steel welding operations, TIG is slower and the most costly one
 Filler rod end, if by chance comes out, then inert gas shield can
cause weld metal contamination

3b) Demonstrate the process of submerged Arc Welding (SAW) with neat
sketch.
ANS: Submerged arc welding (SAW) is a method in which the heat required
to fuse the metal is generated by an arc formed by an electric current
passing between the electrode and the work piece
 There is no visible arc and
no sparks, spatter or fume.
The electrode may be a solid or
cored wire or a strip.
 SAW is normally a
mechanized process.
Process of SAW:
 The molten weld and the arc
zone are protected from
atmospheric contamination
by being "submerged" under a
blanket of granular fusible flux.
 flux consists of lime, silica, manganese oxide, calcium fluoride, and
other compounds.
 When molten, the flux becomes conductive, and provides a current
path between the electrode and the work.
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 This thick layer of flux completely covers the molten metal thus
preventing spatter and sparks as well as suppressing the intense
ultraviolet radiation and fumes that are a part of the shielded metal
arc welding (SMAW) process.
Advantages of SAW:
 High quality
 Little risk of undercut and porosity
 No spatter
 Very little risk of lack of fusion due to deep and safe penetration
 High deposition rate
Disadvantages of SAW:
 Precise joint preparation required
 No observation of arc and process during welding is possible
 High operational effort
 It cannot be used for plates less than 5mm thickness
Applications of SAW:
Fabrication of Boiler Pressure Vessel.
 Railroad tank cars.
 Structural shapes and cylinders.
 Circular welds.
 Beam Production.

4a) Explain the importance of various flames in gas welding?

Ans: A) A neutral flame: is obtained when the ratio of is oxygen
and acetylene is 1.
Most gas welding operations are carried out by this flame.

B) An oxidizing flame is obtained when this ratio is more than 1. This

type of flame is not suitable for welding of steels since excess oxygen
present reacts with carbon in steel and is generally used for welding
of copper and its alloys.

C) When the ratio in mixture is less than 1 a carburizing flame is

obtained. In this type of flame acetylene decomposes into carbon and
hydrogen and the flame temperature gets reduced. Joining operations
such as brazing and soldering which require lower temperature
generally use this flame.
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4b) Distinguish between centrifugal casting and die casting.

Ans:
Die casting refers to a casting method in which a molten metal is injected
into a metal mold at a high speed and crystallized under pressure, which is
referred to as die casting. The common injection pressure is 30-70 MPa, the
filling speed is about 0.5-50 m/s, and the filling time is 0.01-0.2 s.

Centrifugal casting is a casting molding method in which molten metal is

poured into a high-speed rotating metal mold under the action of a
centrifugal casting machine, the mold is rotated at a high speed, and driven
by centrifugal force to cool the crystal.

Difference:

1.The filling force is different, resulting in different gas porosity distribution:

centrifugal casting is inside, and high pressure casting is irregular,

2.Centrifugal casting metal utilization rate can reach 80%-90%,die casting is not
efficient due to the presence of gates, runners, and slag packs.

3.More efficient die casting than centrifugal casting.

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Set-04

Short answers
1
a)Define pattern.
Ans: A pattern is a replica of the final product and is used for preparing mould
cavity made of wood or metal
b)What is draft allowance.
Ans: DRAFT/TAPER ALLOWANCE
It is hard to remove casted object from pattern if it has vertical faces .
Vertical faces causes a continuous contact or friction when object is removing
from the pattern. The leading edge may break off during removal of cast, To
avoid this, vertical faces of the pattern are tapered in small known as draft
angle. Outer surface-1 to 3 degree, Inner surface - 5 to 8 degree
c) Write an a example of pressurized gating ratio.
Ans:1:2:1 or 1:0.75:0.5
Aluminium-1:2:1
d) The formation of air pockets in the casting causes what type of defect?
Ans: BLOW HOLE(open holes) at pieces surface.
e) Sate the functions of electrodes.
Ans: An Electrode is used to conduct current through a workpiece to fuse two
pieces together.
->Used to measure conductivity…
f)Define non fusion welding.
Ans:The metals parts are heated to plastic state and they are pressed together
to make joint.
g)Define squeeze time.
Ans: The time interval between the application of electrode pressure to the work and
switching on the welding current is called the squeeze time..
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h) Coated electrodes are not used in Submerged Arc Welding. Defend.
Ans: A consumable electrode is used in SAW.
-> Instead of electrode coating, external flux is provided to avoid the oxidation
of welding material.
->Only used for horizontal postions .
i)What is the function of shielding gas.
Ans: Shielding gas is to prevent exposure of molten weld pool to
oxygen ,nitrogen and hydrogen contained in air atmosphere.
j) What is the material used as electrode in MIG.
Ans: COPPER COATED COILED WIRE.

LONG ANSWERS

2a) Demonstrate the steps involved in making green

sand mould using split pattern?
Ans:
Steps involved in Green sand moulding
 First one half of the pattern is placed on the moulding board.
 The drag is placed with the dowel pins down.
 Moulding sand is filled in the moulding box to cover the pattern.
 The drag is completely filled with sand up to the top and rammed by the
peen end of the hand rammer.
 Excess sand is levelled by a strike-off bar.
 The drag is tilled upside down.
 Parting sand is applied on the surface.
 The other half of the pattern is how placed correctly on the already placed
half
 The cope is placed in position on the drag and aligned using dowel pins.
 The sprue pin is placed vertically for the purpose of pouring the molten
metal.
 The risers are placed over the highest point of the pattern for the purpose
of escaping the gases and identify the level of molten metal.
 Again the moulding sand filled in the cope box, and rammed.
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The riser and the sprue pin are removed.
 The funnel shaped opening called a pouring basin is cut at the top of the
sprue pinhole.
 The cope is lifted, turned over and placed on the floor.
 The pattern pieces are carefully removed.
 The gate is cut that is connecting the sprue basin and the mould cluity.
 The cope is placed carefully over the drag.
 Pouring the molten metal.

Advantages of green sand Moulding : 

 Green sand moulds are softer than dry sand moulds. This allows greater
freedom in construction when the castings solidify and cool.
 Green sand moulds are quite strong for small depths, as the gases escape
from them.
 Green sand moulds do not require any backing operations or equipment,
but dry sand cores are to be used.

Disadvantages of green sand moulding : 

 The green sand moulds cannot be stored for long time.
 The green sand moulds are not so strong as other moulds are liable to be
damaged during handling or pouring.
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 The surface finish of the casting obtained from green sand mould is not
very smooth.
 The green sand mould lacks permeability and strength, which causes
certain defects like blow holes etc.

2b) Compare investment casting and shell moulding.

Ans:
Shell Molding
Shell moulding is a process that involves pouring molten metal into a pre-formed sand core
or cavity. The sand core is formed by spraying liquid plastic or resin onto the surface of a
die or pattern, which then hardens and forms the shape of the product being made. This
method creates an incredibly strong bond between the metal and the sand core, making it
ideal for creating products with intricate details or complex geometries. It also has a
shorter setup time than other manufacturing methods, allowing you to produce parts faster
and more efficiently.

Investment Casting
Investment casting is another popular manufacturing method that involves creating a wax
model of the product being produced, dipping it in ceramic slurry and then heating it until
all of the wax melts away. This leaves behind an empty ceramic mould that can then be
filled with molten metal to form the desired product. Investment casting allows for greater
detail than other techniques because it captures small details in the wax model before it’s
dipped in slurry. It also has fewer material type restrictions than other methods, making it
easier to work with certain metals such as aluminium alloys or bronze.

Difference Between Shell Molding and Investment

Casting
Advantages of Shell Molding

One advantage of shell molding over investment casting is that it can be used to create
more intricate shapes. Additionally, shell moulding can produce stronger castings than
investment casting, as the resin-coated sand provides more support for the molten metal.
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Advantages of Investment Casting

One advantage of investment casting over shell molding is that it produces smoother
surfaces on the casting as the wax pattern provides a smooth surface for the molten metal
to flow over. Additionally, investment casting can be used to create thinner walls on  the
casting, as there is no need for support from the sand.

Disadvantages of Shell Molding

One disadvantage of shell molding is that it is a more expensive process than investment
casting, as the resin-coated sand is more costly than the wax used in investment casting.
Additionally, shell moulding can produce weaker castings than investment casting, as the
sand can break down under high temperatures and lose its support for the molten metal.

Disadvantages of Investment Casting

One disadvantage of investment casting is that it is a more time-consuming process than

shell molding, as the wax pattern must be created before the mold can be made.
Additionally, investment casting can produce castings with poorer dimensional accuracy
than shell moulding, as shrinkage occurs when the wax melts during the pouring.

3a) Describe any two resistance welding processes

with simple sketches.
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3b) List out various equipment used in TIG welding

and write a small note about each element.
Ans: Equipment s used in TIG:
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 Gas supply (cylinder)
 Electrical power source (AC/DC)
 Electrode holder, torch or gun
 Connection cables
 Hose (for gas supply)
 Tungsten electrode
 Coolant
 Filler rods
Power Source:

The first unit of equipment’s is power source. A high current power source
needed for TIG welding. It uses both AC and DC power source. Mostly DC
current is used for stainless steel, Mild Steel, Copper, Titanium, Nickel alloy,
etc. and AC current is used for aluminum, aluminum alloy and magnesium.
Power source consist a transformer, a rectifier and electronic controls. Mostly
10 – 35 V is required at 5-300 A current for proper arc generation.

TIG Torch:

It is a most important part of TIG welding. This torch has three main parts,
tungsten electrode, collets and nozzle. This torch is either water cooled or air
cooled. In this torch, collet is used to hold the tungsten electrode. These are
available in varying diameter according to diameter of tungsten electrode. The
nozzle allows the arc and shielded gases to flow into welding zone. The nozzle
cross section is small which gives high intense arc. There are passes of shielded
gases at nozzle. The nozzle of TIG needs to replace in regular interval because it
wear out due to presence of intense spark.
Shielding Gas Supply System:

Normally argon or other inert gases are used as shielded gas. The main purpose
of shielded gas to protects the weld from oxidization. Shielded gas does not
allow coming oxygen or other air into welded zone. The selection of inert gas is
depends upon metal to be welded. There is a system which regulates the flow of
shielded gas into welded zone.
Filler Material:

Mostly for welding thin sheets no filler material is used. But for thick weld, filler
material is used. Filler material is used in form of rods which are directly feed into weld
zone manually.
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4a) Explain the mechanism of solidification.
Ans: Mechanism of Solidification:
 Pure metals solidifies at a constant temp. equal to
its freezing point, which same as its melting point.
 The change form liquid to solid does not occur all at
once. The process of solidification starts with
nucleation, the formation of stable solid particles
within the liquid metal.
 Nuclei of solid phase, generally a few hundred atom
in size, start appearing at a temperature below the
freezing temperature.
 A nuclei, more than a certain critical size grows, and
causes solidification.
 By adding, certain foreign materials (nucleating
agents) the undercooling temp. is reduced which
causes enhanced nucleation.
 In case of pure metals fine equi-axed grains are
formed near the wall of the mold and columnar
grain growth takes place upto the centre of the
ingot.
 In typical alloy, the columnar grains do not extend
upto the center of casting but are interrupted by an
inner zone of equiaxed graines.
 By adding typical nucleating agents like sodium,
magnesium or bismuth the inner zone of equiaxed
grained can be extended in whole casting.
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4b) Differentiate between seam welding and

projection welding.
Ans:
PROJECTION WELDING

1. Projection welding is a variation of spot welding.

Projections are designed in one part.
These act as current concentrators for the welding
process.
When the two parts are mated together, these projections
are the high points that first make contact.
As the power is cycled, the projections simultaneously
carry the current and are welded.

2.Due to the efficiency of power transfer, thicker

materials can be successfully welded. Materials as thick
as 3 mm (0.125 in) canbe successfully welded.
3. Low carbon steels, low alloy steels, stainless steels, as
well as aluminum can be welded using this process.

4.Projections are usually semi-spherical or blunt conical

type.
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5. Projection welding requires that the height of
projections be controlled to within a range of 0.075 mm
(0.003 in).

Resistance seam welding is a variation of resistance spot welding

with the main difference being that the welding electrodes are
motor driven wheels rather than stationary rods.

Ideal for sheet metal fabrication, this welding method passes an

electric current through the sheets of metals to be joined while
they are held together by a mechanical force in a lap
configuration between shaped copper electrodes.

As with other types of resistance welding, fusion is produced

where the sheet surfaces come into contact due to this being the
point of highest electrical resistance and thereby the place where
heat generation is at its greatest.

The heat from the disc-shaped electrode wheels creates a

continuous weld as the work pieces are fed between them,
resulting in a rolling resistance weld or a non-hermetic seam
weld.

Resistance seam welding can either use an intermittent motion,

where the speed of the roller is not predetermined, or continuous
motion seam welding where the speed of the electrode roller is
predetermined before the current is supplied.