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

Accepted Answer

Sand casting is the most widely used casting process because of its versatility and simplicity. It can be used for almost any metal alloy and requires relatively low-cost equipment and supplies.

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

Accepted Answer

In sand casting, the pattern is made slightly larger than the cast part to compensate for the shrinkage of the metal during cooling and solidification. This ensures that the final cast part achieves the desired dimensions.

Question 3

Silica sand has which one of the following compositions: A)Al₂O₃ B)SiO C)SiO₂ D)SiSO₄

Accepted Answer

Silica sand is composed of silicon dioxide (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

Accepted Answer

The answer of For which one of the following reasons...

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

Accepted Answer

The buoyancy force is equal to the weight of the molten metal displaced by the core, which is W_m, minus the weight of the core itself, W_c, and it acts in the upward direction.

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

Accepted Answer

Investment casting, sand casting, shell molding, and vacuum molding are expendable mold processes where the mold is destroyed to remove the casting.

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

Accepted Answer

Shell molding is a casting process where the mold is a thin shell of sand bonded by a thermosetting resin, which creates a high-quality surface finish and accurate dimensions in the cast parts.

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:

Accepted Answer

This describes the lost-foam casting process, where a polystyrene foam pattern is used to create a mold in sand, and then vaporizes when molten metal is poured in, creating a metal casting in the shape of the original foam pattern.

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

Accepted Answer

Investment casting is most commonly known as the lost-wax process. This method involves creating a wax model, which is then encased in a ceramic material. Once the ceramic material hardens, the wax is melted and drained away, leaving a cavity into which metal can be poured to create the final cast piece.

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

Accepted Answer

In plaster mold casting, the mold is made of plaster of Paris, which is chemically known as Calcium Sulfate Hemihydrate (CaSO4·1/2H2O).

Question 11

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

Accepted Answer

The Antioch process indeed uses a mixture of sand and plaster for mold making, combining the properties of both materials to create detailed and accurate molds for casting.

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

Accepted Answer

The answer of Which of the following qualifies as a...

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

Accepted Answer

The answer of Which of the following are metals commonly...

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.

Accepted Answer

The answer of Which of the following casting processes are...

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:

Accepted Answer

the description is that of a cold-chamber die-casting machine.

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

Accepted Answer

Aluminum, tin, and zinc are commonly used in die casting due to their low melting points and good fluidity, which make them suitable for the die casting process. Cast iron, steel, and tungsten have higher melting points and are not typically used in die casting.

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

Accepted Answer

Die casting offers a better surface finish and closer tolerances due to the precision of the metal molds. It allows for higher production rates because the molds can be reused multiple times, unlike sand casting. However, it is not suitable for higher melting temperature metals or larger parts.

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

Accepted Answer

Liquid-metal forging and squeeze casting both involve pouring molten metal into a die and applying pressure as it begins to solidify, creating a dense and detailed casting.

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

Accepted Answer

True centrifugal casting involves pouring molten metal into a rotating mold to produce a tubular part. The centrifugal force distributes the metal uniformly around the die cavity, creating parts with good dimensional accuracy and surface finish.

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

Accepted Answer

Cupolas are a type of furnace primarily used for melting cast iron. They are one of the oldest and most efficient methods of melting iron in foundry operations.

Quiz 8: Metal Casting Processes

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

In sand casting, the volumetric size of the pattern is

Silica sand has which one of the following compositions:

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

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:

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

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

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:

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

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

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

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

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

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

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:

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

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

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) :

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:

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

Quiz 8: Metal Casting Processes

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

In sand casting, the volumetric size of the pattern is

Silica sand has which one of the following compositions:

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

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

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

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

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:

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

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

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

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

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

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

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:

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

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

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) :

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:

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

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: