Types of Casting Processes
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Questions and Answers

Which casting process is the most widely used?

  • Permanent mold casting
  • Die casting
  • Investment casting
  • Sand casting (correct)

    • For which type of metals is sand casting particularly suitable?

  • Metals with high melting temperatures like steels, nickels, and titaniums (correct)
  • Precious metals like gold and silver
  • Aluminum and copper alloys only
  • Low melting point metals only

    • What is required after the casting is removed from the sand mold?

  • PVD coating
  • Ultrasonic cleaning
  • Painting
  • Heat treatment (correct)

    • What is included in the sand mold to create the cavity for casting?

    <p>Pattern</p> Signup and view all the answers

    Why must a new sand mold be made for each part produced in sand casting?

    <p>The mold is sacrificed to remove the casting</p> Signup and view all the answers

    Besides the casting operation itself, what other components are involved in sand casting?

    <p>Fabrication of the pattern and making of the mold</p> Signup and view all the answers

    Which of the following is NOT a disadvantage of casting processes?

    <p>High dimensional accuracy and surface finish</p> Signup and view all the answers

    What is the primary function of a foundry?

    <p>All of the above</p> Signup and view all the answers

    Why is the mold cavity slightly oversized compared to the desired final part?

    <p>To allow for shrinkage during solidification and cooling</p> Signup and view all the answers

    What type of mold is used in an open mold casting process?

    <p>Open mold</p> Signup and view all the answers

    Which of the following is NOT a potential safety hazard when processing hot molten metals in casting?

    <p>Improved dimensional accuracy</p> Signup and view all the answers

    What is the primary role of the workers who perform the casting operations in a foundry?

    <p>To be called foundrymen</p> Signup and view all the answers

    What is the primary purpose of the gating system in a closed mold?

    <p>To allow the molten metal to flow into the mold cavity</p> Signup and view all the answers

    Which type of mold is considered more important for production casting operations?

    <p>Permanent mold</p> Signup and view all the answers

    What is the primary characteristic of an expendable mold?

    <p>It must be destroyed to remove the casting</p> Signup and view all the answers

    What is the primary advantage of the expendable mold casting processes?

    <p>They can produce castings with more complicated geometries</p> Signup and view all the answers

    What is the primary limitation of the permanent mold casting processes?

    <p>They can only produce simple part shapes</p> Signup and view all the answers

    Which permanent mold casting process is mentioned as the most familiar?

    <p>Die casting</p> Signup and view all the answers

    What is the main purpose of baking a dry-sand mold in an oven?

    <p>To strengthen the mold and harden the cavity surface</p> Signup and view all the answers

    What is the main disadvantage of dry-sand molding compared to green-sand molding?

    <p>Dry-sand molding has a lower production rate</p> Signup and view all the answers

    What is the purpose of the gating and riser system in a mold?

    <p>To deliver liquid metal into the cavity and provide a reservoir of molten metal during solidification shrinkage</p> Signup and view all the answers

    What is the main advantage of a skin-dried mold compared to a green-sand mold?

    <p>Improved dimensional control of the cast product</p> Signup and view all the answers

    What is the purpose of adding special bonding materials to the sand mixture in a skin-dried mold?

    <p>To strengthen the cavity surface of the mold</p> Signup and view all the answers

    What is the primary reason that moisture in the sand can cause defects in some castings?

    <p>It depends on the metal and geometry of the part</p> Signup and view all the answers

    What is the primary function of chaplets in a mold cavity?

    <p>To hold the core in place within the mold cavity</p> Signup and view all the answers

    What is the typical composition (by volume) of a foundry sand mixture?

    <p>90% sand, 3% water, 7% clay</p> Signup and view all the answers

    Which of the following factors can influence the permeability of a mold?

    <p>All of the above</p> Signup and view all the answers

    What is the purpose of using a flask in the mold making process?

    <p>All of the above</p> Signup and view all the answers

    Which property of the foundry sand is most important for achieving a better surface finish on the cast part?

    <p>Small grain size</p> Signup and view all the answers

    What is the primary function of the bonding agent in the foundry sand mixture?

    <p>To hold the sand grains together</p> Signup and view all the answers

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