Deck 8: Metal Casting Processes

Question 1

Which one of the following casting processes is the most widely used:

A)centrifugal casting
B)die casting
C)investment casting
D)sand casting
E)shell casting

Answer 1

sand casting

Question 2

In sand casting, the volumetric size of the pattern is

A)bigger than
B)same size as
C)smaller than the cast part

Answer 2

bigger than

Question 3

Silica sand has which one of the following compositions:

A)Al₂O₃
B)SiO
C)SiO₂
D)SiSO₄

Answer 3

SiO₂

Question 4

For which one of the following reasons is a green mold named:

A)green is the color of the mold
B)moisture is contained in the mold
C)the mold is cured
D)the mold is dry

Question 5

Given that W_m = weight of the molten metal displaced by a core and W_c = weight of the core, the buoyancy force is which one of the following:

A)downward force = W_m + W_c
B)downward force = W_m - W_c
C)upward force = W_m + W_c
D)upward force = W_m - W_c

Question 6

Which of the following casting processes are expendable mold operations (four correct answers):

A)centrifugal casting
B)die casting
C)investment casting
D)low pressure casting
E)sand casting
F)shell molding
G)slush casting
H)vacuum molding

Question 7

Shell molding is best described by which one of the following:

A)casting operation in which the molten metal has been poured out after a thin shell has been solidified in the mold
B)casting process in which the mold is a thin shell of sand bonded by a thermosetting resin
C)sand-casting operation in which the pattern is a shell rather than a solid form
D)casting operation used to make artificial sea shells

Question 8

The expanded polystyrene casting process uses a mold of sand packed around a polystyrene foam pattern that vaporizes when the molten metal is poured into the mold:

Question 9

Investment casting is also known by which one of the following names:

A)fast payback molding
B)full mold process
C)lost-foam process
D)lost-pattern process
E)lost-wax process

Question 10

In plaster mold casting, the mold is made of which one of the following materials:

A)Al₂O₃
B)CaSO₄-H₂O
C)SiC
D)SiO₂

Question 11

The Antioch process is similar to plaster-mold casting but uses a mixture of sand and plaster to make the mold:

Question 12

Which of the following qualifies as a precision-casting process (two correct answers):

A)ingot casting
B)investment casting
C)plaster-mold casting
D)sand casting
E)shell molding

Question 13

Which of the following are metals commonly cast in permanent mold casting (three best answers):

A)aluminum
B)brass
C)gold
D)magnesium
E)nickel
F)steel
G)Tungsten

Question 14

Which of the following casting processes are permanent mold operations (two correct answers):

A)centrifugal casting
B)expanded polystyrene process
C)sand casting
D)shell molding
E)slush casting
F)vacuum molding.

Question 15

In hot-chamber die-casting machines, molten metal is poured into an unheated chamber from an external melting container, and a piston is used to inject the metal under high pressure into the die cavity:

Question 16

Which of the following metals would typically be used in die casting (three best answers):

A)aluminum
B)cast iron
C)steel
D)tin
E)tungsten
F)Zinc

Question 17

Which of the following are advantages of die casting over sand casting (four best answers):

A)better surface finish
B)closer tolerances
C)higher melting temperature metals can be cast
D)higher production rates
E)larger parts can be cast
F)mold can be reused

Question 18

Which of the following names are applied to a process in which a molten metal is poured into a heated lower die, and the upper die is closed to create the mold cavity only after solidification begins (two correct answers):

A)liquid-metal casting
B)liquid-metal forging
C)rheocasting
D)squeeze casting
E)thixocasting

Question 19

Which one of the following is the name of the casting process in which molten metal is poured into a rotating mold to produce a tubular part:

A)centrifuge casting
B)semicentrifugal casting
C)true centrifugal casting

Question 20

Cupolas are furnaces used to melt which of the following metals (one best answer):

A)aluminum
B)cast iron
C)steel
D)zinc

Question 21

A misrun is which one of the following defects in casting:

A)globules of metal becoming entrapped in the casting
B)metal is not properly poured into the downsprue
C)metal solidifies before filling the cavity
D)microporosity
E)"pipe" formation

Question 22

An irregularity in the surface of the casting caused by erosion of the sand during pouring is called which one of the following sand casting defects:

A)penetration
B)sand blow
C)sand wash
D)scabs

Question 23

Which one of the following casting metals is most important commercially:

A)aluminum and its alloys
B)bronze
C)cast iron
D)cast steel
E)zinc alloys