Question 1

Heating a metal from room temperature to pouring temperature in a casting operation depends on all of the following properties except which one:

Accepted Answer

A) density 
B) heat of fusion 
C) melting temperature 
D) specific heat 
E) thermal expansion 
A) density 
B) heat of fusion 
C) melting temperature 
D) specific heat 
E) thermal expansion E

Question 2

Metal inserts in the walls of a sand mold cavity designed to remove heat from the molten metal more rapidly than the surrounding sand are called which one of the following:

Accepted Answer

A) external chills 
B) internal chills 
C) pipes 
D) sprues 
A) external chills 
B) internal chills 
C) pipes 
D) sprues A

Question 3

Casting is a process in which molten metal flows into a mold where it solidifies in the shape of the mold cavity; the term casting also applies to the part that is made by this process:

Accepted Answer

A) True 
 B)False  True

Question 4

In casting, a flask is which one of the following:

Accepted Answer

A) beverage bottle for workers who perform casting 
B) box which holds the cope and drag 
C) container for holding liquid metal 
D) metal which extrudes between the mold halves 
A) beverage bottle for workers who perform casting 
B) box which holds the cope and drag 
C) container for holding liquid metal 
D) metal which extrudes between the mold halves

Question 5

According to the empirical relationship in the previous question, total solidification time is proportional to which one of the following quantities:

Accepted Answer

A) (A/V)n 
B) Hf 
C) Tm 
D) V 
E) V/A
F)(V/
A) 2; where A = surface area of casting Hf = heat of fusion Tm = melting temperature and V = volume of casting 
A) (A/V)n 
B) Hf 
C) Tm 
D) V 
E) V/A
F)(V/
A) 2; where A = surface area of casting Hf = heat of fusion Tm = melting temperature and V = volume of casting

Question 6

Turbulence during pouring of the molten metal is undesirable for which of the following reasons (two best answers):

Accepted Answer

A) it causes discoloration of the mold surfaces 
B) it dissolves the binder used to hold together the sand mold 
C) it increases erosion of the mold surfaces 
D) it increases the formation of metallic oxides that can become entrapped during solidification 
E) it increases the mold filling time
F)it increases total solidification time 
A) it causes discoloration of the mold surfaces 
B) it dissolves the binder used to hold together the sand mold 
C) it increases erosion of the mold surfaces 
D) it increases the formation of metallic oxides that can become entrapped during solidification 
E) it increases the mold filling time
F)it increases total solidification time

Question 7

The pattern that determines the geometry of the casting in expendable mold processes is usually made

Accepted Answer

A) oversized 
B) the same size 
C) undersized relative to the dimensions of the casting 
A) oversized 
B) the same size 
C) undersized relative to the dimensions of the casting

Question 8

During solidification of an alloy when a mixture of solid and liquid metals is present, the solid-liquid mixture is referred to as which one of the following:

Accepted Answer

A) eutectic composition 
B) ingot segregation 
C) liquidus 
D) mushy zone 
E) solidus 
A) eutectic composition 
B) ingot segregation 
C) liquidus 
D) mushy zone 
E) solidus

Question 9

Solidification shrinkage in casting is defined as which one of the following:

Accepted Answer

A) liquid contraction during cooling prior to solidification 
B) liquid contraction during cooling and solidification 
C) contraction during the phase change from liquid to solid 
D) thermal contraction of the solidified casting during cooling to room temperature. 
A) liquid contraction during cooling prior to solidification 
B) liquid contraction during cooling and solidification 
C) contraction during the phase change from liquid to solid 
D) thermal contraction of the solidified casting during cooling to room temperature.

Question 10

In a sand-casting mold, the V/A ratio of the riser should be

Accepted Answer

A) equal to 
B) greater than 
C) smaller than the V/A ratio of the casting itself 
A) equal to 
B) greater than 
C) smaller than the V/A ratio of the casting itself

Question 11

A riser in casting is described by which of the following (three correct answers):

Accepted Answer

A) an insert in the casting that inhibits buoyancy of the core 
B) gating system in which the sprue feeds directly into the cavity 
C) metal that is not part of the casting 
D) source of molten metal to feed the casting and compensate for shrinkage during solidification 
E) waste metal that is usually recycled 
A) an insert in the casting that inhibits buoyancy of the core 
B) gating system in which the sprue feeds directly into the cavity 
C) metal that is not part of the casting 
D) source of molten metal to feed the casting and compensate for shrinkage during solidification 
E) waste metal that is usually recycled

Question 12

Sand casting is which of the following types of casting process:

Accepted Answer

A) expendable mold 
B) permanent mold 
A) expendable mold 
B) permanent mold

Question 13

The empirical relationship that determines total solidification time in casting is known as which one of the following:

Accepted Answer

A) Bernoulli's theorem 
B) Chvorinov's rule 
C) continuity law 
D) flow curve 
E) Hooke's law
F)Ohm's law 
A) Bernoulli's theorem 
B) Chvorinov's rule 
C) continuity law 
D) flow curve 
E) Hooke's law
F)Ohm's law

Question 14

A factory that performs casting processes is called which of the following (one best answer):

Accepted Answer

A) casting plant 
B) foundry 
C) ingot-making plant 
D) metal working plant 
E) molding plant 
A) casting plant 
B) foundry 
C) ingot-making plant 
D) metal working plant 
E) molding plant

Question 15

Two important relationships that determine the flow of molten metal in casting are which of the following (two correct answers):

Accepted Answer

A) Bernoulli's theorem 
B) Chvorinov's rule 
C) continuity law 
D) flow curve 
E) Hooke's law
F)Ohm's law 
A) Bernoulli's theorem 
B) Chvorinov's rule 
C) continuity law 
D) flow curve 
E) Hooke's law
F)Ohm's law

Question 16

Which of the following riser types are completely enclosed within the sand mold and connected to the main cavity by a channel to feed the molten metal (two correct answers):

Accepted Answer

A) blind riser 
B) open riser 
C) side riser 
D) top riser 
A) blind riser 
B) open riser 
C) side riser 
D) top riser

Question 17

In casting processes, a runner is which one of the following:

Accepted Answer

A) channel in the mold leading from the downsprue to the main mold cavity 
B) worker who moves the molten metal to the mold 
C) vertical channel into which molten metal is poured into the mold 
A) channel in the mold leading from the downsprue to the main mold cavity 
B) worker who moves the molten metal to the mold 
C) vertical channel into which molten metal is poured into the mold

Question 18

The internal surfaces of a casting are determined during the casting process by means of which one of the following:

Accepted Answer

A) core 
B) gating system 
C) parting line 
D) pattern 
E) sprue 
A) core 
B) gating system 
C) parting line 
D) pattern 
E) sprue

Question 19

Total solidification time is defined as which one of the following:

Accepted Answer

A) time between pouring and complete solidification 
B) time between pouring and cooling to room temperature 
C) time between solidification and cooling to room temperature 
D) time to give up the heat of fusion 
A) time between pouring and complete solidification 
B) time between pouring and cooling to room temperature 
C) time between solidification and cooling to room temperature 
D) time to give up the heat of fusion

Question 20

The upper half of a sand-casting mold is called which one of the following:

Accepted Answer

A) cope 
B) drag 
C) flask 
D) pattern 
A) cope 
B) drag 
C) flask 
D) pattern

Exam 7: Fundamentals of Metal Casting

Heating a metal from room temperature to pouring temperature in a casting operation depends on all of the following properties except which one:

Metal inserts in the walls of a sand mold cavity designed to remove heat from the molten metal more rapidly than the surrounding sand are called which one of the following:

Casting is a process in which molten metal flows into a mold where it solidifies in the shape of the mold cavity; the term casting also applies to the part that is made by this process:

In casting, a flask is which one of the following:

According to the empirical relationship in the previous question, total solidification time is proportional to which one of the following quantities:

Turbulence during pouring of the molten metal is undesirable for which of the following reasons (two best answers):

The pattern that determines the geometry of the casting in expendable mold processes is usually made

During solidification of an alloy when a mixture of solid and liquid metals is present, the solid-liquid mixture is referred to as which one of the following:

Solidification shrinkage in casting is defined as which one of the following:

In a sand-casting mold, the V/A ratio of the riser should be

A riser in casting is described by which of the following (three correct answers):

Sand casting is which of the following types of casting process:

The empirical relationship that determines total solidification time in casting is known as which one of the following:

A factory that performs casting processes is called which of the following (one best answer):

Two important relationships that determine the flow of molten metal in casting are which of the following (two correct answers):

Which of the following riser types are completely enclosed within the sand mold and connected to the main cavity by a channel to feed the molten metal (two correct answers):

In casting processes, a runner is which one of the following:

The internal surfaces of a casting are determined during the casting process by means of which one of the following:

Total solidification time is defined as which one of the following:

The upper half of a sand-casting mold is called which one of the following:

Introduction and Overview of Manufacturing

The Nature of Materials

Mechanical Properties of Materials

Physical Properties of Materials

Engineering Materials

Dimensions, Surfaces, and Their Measurement

Metal Casting Processes

Glassworking

Shaping Processes for Plastics

Processing of Polymer Matrix Composites and Rubber

Powder Metallurgy

Processing of Ceramics and Cermets

Fundamentals of Metal Forming

Bulk Deformation Processes in Metal Workiing

Sheet Metalworking

Theory of Metal Machining

Machining Operations and Machine Tools

Cutting Tool Technology

Economic and Product Design Considerations

Grinding and Other Abrasive Processes

Nontraditional Machining and Thermal Cutting

Heat Treatment of Metals

Surface Processing Operations

Fundamentals of Welding

Welding Processes

Brazing, Soldering, and Adhesive Bonding

Mechanical Assembly

Rapid Prototyping and Additive Manufacturing

Processing of Integrated Circuits

Electronics Assembly and Packaging

Microfabrication Technologies

Nanofabrication Technologies

Automation Technologies for Manufacturing Systems

Integrated Manufacturing Systems

Process Planning and Production Control

Quality Control and Inspection

Filters