Casting Revision

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Lecture [1]: Intro
 Casting is a manufacturing process whereby the desired
material is heated to the molten (liquid) state, then
introduced into a previously prepared mold cavity of proper
design and allowed to solidify in the mold before being
extracted, trimmed and cleaned.
 Mold: Negative replica of an object ( a cavity)
 Pattern: Positive replica of an object
 Types of Foundries :

I. According to metal type:

1. Ferrous Foundries 2. Non - Ferrous Foundries

II. According to work nature:

1. Jobbing Foundries 2. Semi - Production Foundries

3. Production Foundries

 Types of casting :

I. Wrought Alloy Casting:

1. Ingot Casting – Continuous Casting

2. Semi-finished products

II. Shaped Casting:

1. Sand Casting – Special Casting Techniques

2. Finished product

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Lecture [2]: Continuous Casting
 Advantages:
1. > 60% of total liquid steel in the world. ( ‫من اكثر العمليات‬
‫)استخداما‬
2. Higher yield. ( )
3. Lower energy consumption. (‫)اقل استهالكا للطاقة‬
4. Elimination of primary mills. ((hot rolling) ‫)تقليل عمليات ال‬
 Material Shape Classification:

 Continuous Casting:

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 Continuous Casting Machines:

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 The Production Stages:
1. The bottom of the copper mold is sealed with a so called
dummy bar. The shape of the mold defines the shape of the
steel. 2. Liquid steel passes from the pouring ladle, with the
exclusion of air, via a tundish with an adjustable discharge
device into the short, water - cooled copper mold.
2. As soon as the bath reaches its intended steel level, the
mold starts to oscillate vertically in order to prevent the
strand adhering to its walls. The red - hot strand, solidified at
the surface zones, is drawn from the mold, first with the aid
of a dummy bar, and later by driving rolls.
 Note that:
 Because of its liquid core, the strand must be carefully
sprayed and cooled down with water.
 Rolls on all sides must also support it until it has completely
solidified. This prevents the still thin rim zone from
disintegrating.
 Walls covered with coating ceramics to save the mold from
the high temperature.

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 The primary features:
1. Dissimilar grades of steel could be cast directly after each
other by means of two ladles, turrets and swiveling devices
for the wear-exposed tundish.
2. Improving the products cleanness (preventing reoxidation)
by the aid of inert gases to protect the pouring stream
between the ladle and tundish, as well as between the
tundish and the mold.
3. Oscillating molds and fully automated addition of casting
fluxes for improving the strand surface, as well as adjustable
molds for changing strand dimensions during casting.
4. Mold level control.
5. Constant casting temperature.
6. Precise strand guidance and consistent strand crosssection
by means of matching roll design of high precision and/or
split rolls. 7. Intensive secondary cooling of the strand with
the aid of uniform and metered spraying.
7. Electromagnetic stirring in the mold to improve surface
quality (no surface shrinkage cavities or inclusions close to
the surface).
8. Electromagnetic stirring of the partly solidified strand to
obtain a globular - non-directional – solidification
microstructure with no segregation zones in the center of
the strand.

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Lecture [2]: Sand Casting Process:
 Expendable versus permanent mold:
Expendable Mold Permanent Mold

Material Sand - Ceramics Meta

No. of times to Only one Large No

use

Suitable Cast large Small

Size
Suitable Cast Complex Simple
Complexity
Suitable Cast Low High
Surface Finish
Suitable No. of Small Large
Castings
Mold Cost Less High
Product Cost Much Less
 Sand Mold Properties and Characteristics:
Sand Mold Properties and Characteristics

1 Strength : to maintain shape and resist erosion

2 Permeability : to allow hot air and gases to pass through voids in

sand

3 Thermal stability : to resist cracking on contact with molten metal

4 Collapsibility : ability to give way and allow casting to shrink without

cracking the casting

5 Reusability : sand from broken mold be reused to make other molds

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  Sand Mold Contents (Physically Bonded Sand) :

1. Silica Sand SiO2

2. Binding Material (Clay, Bentonite…)

3. Activator (Water)

 Sand Casting Mold Terms:

 Mold consists of two halves:

– Cope = Upper half of mold – Drag = Bottom half

 Mold halves are contained in a box, called a flask .

 The two halves separated at the parting line.

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 Types of Molding Sand :
1. Facing sand: The small amount of carbonaceous material
sprinkled on the inner surface of the molding cavity to give
better surface finish to the castings.
2. Moulding sand: It is the freshly prepared refractory material
used for making the mold cavity. It is a mixture of silica, clay
and moisture in appropriate proportions to get the desired
results and it surrounds the pattern while making the mold.
3. Backing sand: It is what constitutes most of the refractory
material found in the mold. This is made up of used and
burnt sand.
 Pattern:
 Pattern Material:
1. Pattern can be made from any material specially wood,
various plastics, metal like aluminum, or foam.
2. Pattern is usually coated with parting agent to ease their
removal from the mold.
 Disposable Vs Permanent Pattern:
Permanent Pattern Disposable Pattern
Pattern Material wood, plastics or Foam
metal
No. of times to use Large No. One time
Suitable Cast Size Small Large
Suitable Cast Simple Complex
Complexity
Suitable No. of Small No. Large No.
Castings

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 Pattern Design Considerations (DFM):
1. Shrinkage allowance:

2. Machining allowance:

3. Distortion allowance
4. Parting line
5. Draft angle

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No Description Photograph
.
Equipment’s
1 Hand Riddles :
They are types of foundry
tools generally used for
cleaning sand. They are used
for separating sand and
another object that serve as
obstacles when molding.

2 Shovel:
They are used for moving or
transferring the molding sand
into the container, molding
box, or flask.

3 Rammer:
They are used for repairing or
arranging the molding sand
that loses from the mold.
These types of sand casting
tools are used to pack or
compact the uniformly
around the pattern.
Types of rammer:
Hand rammer-Peen rammer
Floor rammer-Pneumatic
rammer

4 Sprue pin:
It is used to produce a vertical
hole in a sand casting. It is
made of wood, metal, or

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 tapered rod. It is pushed in
cope to join the mold cavity
and produces a cylindrical or
conical shape in the molding
sand.

5 Strike of bar:
Strike bars are sand casting
tools that are made of iron
and wood. they are used to
remove or strike off excess
sand from the top of a
molding box. It is made of a
flat bar having a straight edge.

6 Draw spike:
Draw spike is a tapered steel
rod having a screw head on
the end and a loop or ring at
the end. It is used for driving
into a pattern that is
embedded in the molding
sand and reps the pattern. To
get separate from the pattern
and finally draws it out from
the mold cavity.

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7 Vent rod:
Vent rods are types of casting
tools made of a round-headed
wooden handle and a pointed
edge. At the end made of wire
of a thin spiked steel rod. It is
used after utilizing ramming
and striking of excess sand to
produce a series of small
holes in the molding sand in
the cope portion. The holes
pierce allows the steam and
gases produced during the
pouring process and
solidifying stage to escape.

8 Lifter:
A lifter is also known as a
cleaner or finishing tool. It’s
used for cleaning, repairing,
and finishing the bottom and
sides of the deep and narrow
opening in the mold. The lifter
is made of thin sections of
steel of various lengths and
widths one end bent.

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9 Slicslick:
Slicslicks are types of foundry
tools that are generally used
for repairing and finishing
mold surfaces and their
edges. It’s done after the
withdrawal of the pattern.
The common types of slicks
are heart and leaf, square and
heart, spoon and bead, and
heart spoon. Their
nomenclature is largely due to
their shapes.

10 Swabs:
Swabs are small hemp fiber
brush used for moistening the
edges of sand mold surface
and pattern. It is also used for
coating the liquid blacking on
the mold faces in dry sand
molds.

11 Disk:
Use the disk to press all sand.

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12 Flask:
It is a type of tooling used to
contain a mold in metal
casting.
A flask has only sides, and no
top or bottom, and forms a
frame around the mold, which
is typically made of molding
sand. The shape of a flask may
be square, rectangular, round
or any convenient shape.

13 Casting Sand:
Green sand casting
Sand 80%
Clay 5%
Water 5%

14 Flame Source:
To melt the Metal

15 The used metal:

Tin
16 Cooling source(Water)

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No Description Photograph
.
Procedures
1 Prepare the desired
pattern.

2 Put the lower have of the

flask on the table and put
the flat have of the pattern
in it.

3 Fill the Lower flask with

the green casting sand.

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4 Use the rammer to press
the sand into the flask in
the tied corners.

5 Use the disk to press all

sand.

6 Use the Strike of bar to

remove or strike off excess
sand from the top of lower
flask.

7 Turn on the lower flask on

the other face and add the
second have of the
pattern.

8 Fix the Sprue pins in the

sand to make the Pouring
sprue and the riser.

9 Spray the powder of

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 graphite or the Red brick
between the two halves of
the flask.

10 Put the upper have of the

flask and fill it with the
green casting sand.

11 Use the disk to press all

sand and Use the Strike of
bar to remove or strike off
excess sand from the top
of upper flask.

12 Separate the two halves of

the flask and wet the area
around the two parts of
the pattern with water
using the Swab.

13 Smoothly dislocate the

part of the pattern little
then remove it using the
draw spike.

14 Make paths for the metal

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 in the sand using slicslick.

15 Prepare the core:

a. Using the die fill it with
the same sand.
b. Press it good.
c. Reinforce it with steel
bolts.
d. Open the die and
remove it.

16 Put the core in its place in

the cavity.

17 Prepare the metal to pour

using the flame source to
melt it.

18 Face the inside two surface

to the flame to get rid of
water moisture.

19 Also, face the permanent

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 die to the flame.
20 Close the two halves of the
flaks and the permanent
die.
21 Start the pouring process:
a. Sand casting: Pour with
steady rate through the
pouring sprue until the
riser fills with the metal.
b. The permanent die:
Pour with steady rate
through the die hole until
it fills with the metal.

22 Waiting a little until the

metal solidified then
remove it from the flask
and from the die.

23 Cooling with water and

clean it from sand.

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Lecture [3]: Metal Casting: Design,
Materials, & Economics:
 Design for Expandable-Mold Casting:
1. Flask
2. Parting line
3. Flat areas
4. Corners, angles, and section thickness
5. Shrinkage
6. Machining allowance
7. Draft
8. Dimensional tolerances
9. Residual stresses

 Flask = Cope or Drag:

 Flask Dimensions: L X W X H
 100 mm Allowance from all sides (50 may be used for H)
 Then Approximate to the nearest 50 mm

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  Casting Design Modifications:

Suggested design modifications to avoid defects in castings. Note

that sharp corners are avoided to reduce stress concentrations.

 Example:

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Lecture [5]: Special Casting
Technique:
 Expendable Mold Casting Processes:
1. Shell Molding
2. Vacuum Molding
3. Expanded Polystyrene Process
4. Investment Casting
5. Plaster Mold Casting
6. Ceramic Mold Casting
 Permanent Mold Casting Processes:
1. Basic permanent mold casting (Gravity casting)
2. Die casting :
a) Hot - Chamber Machine
b) Cold - Chamber Machine
3. Centrifugal casting:
a) True centrifugal casting
b) Semi-centrifugal casting
c) Centrifuge casting

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 Shell Molding Vacuum Molding
View

Description - Developed in Germany - Developed in Japan around 1970

during early 1940s - Uses sand mold held together by vacuum
- A Casting process in which pressure rather than by a chemical binder
the mold is a thin shell of
sand held together by
thermosetting resin binder
Advantages – Smoother cavity surface – Easy recovery of the sand, since binders not
permits easier flow of used
molten metal and better – Sand does not require mechanical
surface finish on casting reconditioning normally done when binders are
– Good dimensional used
accuracy – Since no water is mixed with sand, moisture -
– Machining often not related defects are absent
required
– Mold collapsibility usually
avoids cracks in casting
– Can be mechanized for
mass production
Disadvantages – More expensive metal – Slow process
pattern – Not readily adaptable to mechanization
– Difficult to justify for small
quantities

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 Expanded Polystyrene Investment Casting (Lost Wax
Process(lost foam process) Process)
View

Description -Uses a mold of sand packed -A pattern made of wax is coated with a
around a polystyrene foam pattern refractory material to make mold, after
which vaporizes when molten which wax is melted away prior to pouring
metal is poured into mold molten metal
-Polystyrene foam pattern includes -It is a precision casting process - capable of
sprue, risers, gating system, and castings of high accuracy and intricate
internal cores (if needed) detail.
-Mold does not have to be opened
into cope and drag sections
Applications:
-Mass production of castings for
automobile engines
Advantages - Pattern need not be removed -Parts of great complexity and intricacy can
from the mold be cast
-Simplifies and expedites mold - -Close dimensional control and good
making, since two mold halves surface finish
(cope and drag) are not required -Wax can usually be recovered for reuse
as in a conventional green-sand -Additional machining is not normally
mold required - this is a net shape process
Disadvantages -A new pattern is needed for every -Many processing steps are required
casting -Relatively expensive process
-Economic justification of the
process is highly dependent on
cost of producing patterns

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 Plaster Mold Casting Ceramic Mold Casting
View

Description -Similar to sand casting except mold -Similar to plaster mold casting except that
is made of plaster of Paris (gypsum - mold is made of refractory ceramic materials
CaSO4 -2H2O) that can withstand higher temperatures than
-In mold-making, plaster and water plaster
mixture is poured over plastic or -Ceramic molding can be used to cast steels,
metal pattern and allowed to set cast irons, and other high - temperature alloys
-Plaster mixture readily flows -Applications similar to those of plaster mold
around pattern, capturing its fine casting except for the metals cast
details and good surface finish
Advantages -Good dimensional accuracy and -Good dimensional accuracy and surface finish
surface finish -Can be used for mass production
-Capability to make thin cross- -High temperature pours possible therefore
sections in casting suitable for steels and other alloys
Disadvantages -Moisture in plaster mold causes -it is only cost effective for small- to medium-
problems: sized production runs and the ceramic is not
• Mold must be baked to remove reusable.
moisture
• Mold strength is lost when is
over-baked, yet moisture content
can cause defects in product
-Plaster molds cannot stand high
temperatures, so limited to lower
melting point alloys

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 Basic permanent Die casting Centrifugal casting
mold casting (Gravity
casting)
View

Description -Uses a metal mold -A permanent mold casting -A group of casting

constructed of two process in which molten processes in which the
sections designed for metal is injected into mold mold is rotated at high
easy, precise opening cavity under high pressure speed so centrifugal force
and closing -Pressure is maintained distributes molten metal
-Molds used for casting during solidification, then to outer regions of die
lower melting point mold is opened and part is cavity
alloys are commonly removed -The Centrifugal Casting
made of steel or cast -Molds in this casting group includes: 1.True
iron operation are called dies centrifugal casting
-Molds used for casting -Use of high pressure to 2.Semi-centrifugal casting
steel must be made of force metal into the die 3.Centrifuge casting
refractory material, due cavity is what distinguishes
to the very high pouring this from other permanent
temperatures mold processes
-Ejector pins required to
remove part from die when
it opens
-Lubricants must be
sprayed into cavities to
prevent sticking

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Advantages -Good dimensional -Economical for large -Castings acquire high
control and surface production quantities density, high mechanical
finish -Good dimensional strength and fine grained
-More rapid accuracy and surface finish structure
solidification caused by -Thin sections are possible -Inclusions and impurities
the cold metal mold -Rapid cooling provides are lighter
results in a finer grain small grain size and good -Gates and risers are not
structure, so stronger strength to casting needed
castings are produced -High output
Applications: -Formation of hollow
automotive pistons, interiors without cores
pump bodies, and Applications:
certain castings for Casting pipe, bushings,
aircraft and missiles gears, flywheel... etc.
Metals commonly cast:
aluminum, magnesium,
copper - base alloys, and
cast iron
Disadvantages -Generally limited to -Generally limited to metals -An inaccurate
metals of lower melting with low metal points Diameter of the inner
point -Part geometry must allow surface of the casting.
-Simple part geometries removal from die cavity -Not all alloys can be cast
compared to sand in this way.
casting because of the
need to open the mold
-High cost of mold

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 Hot - Chamber Machine Cold - Chamber Machine
View

Description -Metal is melted in a container, and a -Molten metal is poured into

piston injects liquid metal under high unheated chamber from external
pressure into the die melting container, and a piston
-High production rates - 500 parts per injects metal under high pressure
hour not uncommon into die cavity
- limited to low melting point metals -High production but not usually
that do not chemically attack plunger as fast as hot - chamber machines
and other mechanical components because of pouring step
Casting zinc, tin, lead, and magnesium aluminum, brass, and magnesium
metals alloys

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 True Centrifugal Casting Semi-Centrifugal Centrifuge Casting
Casting
View

Description - Molten metal is poured into - Centrifugal force is - Mold is designed with part
rotating mold to produce a used to produce solid cavities located away from
tubular part castings rather than axis of rotation, so that
- Outside shape of casting can be tubular parts molten metal poured into
round, octagonal, hexagonal, - Molds are designed mold is distributed to these
…etc , but inside shape is with risers at center to cavities by centrifugal force
(theoretically) perfectly round, supply feed metal - Used for smaller parts
due to radially symmetric forces. - Density of metal in - Radial symmetry of part is
final casting is greater not required as in other
in outer sections than centrifugal casting methods
at center of rotation
Parts pipes, tubes, bushings, and rings wheels and pulleys wheels

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 Typical Pouring Properties
Temperatures(˚C)
Cast Iron 1400 -Most important of all casting alloys
-Tonnage of cast iron castings is several times that of all other
metals combined
Steel 1650 Steel readily oxidizes, so molten metal must be isolated from air.
Aluminum 660 -Light weight
-Range of strength properties by heat treatment
-Ease of machining
Copper --- -Corrosion resistance
Alloys -Attractive appearance
-Good bearing qualities
Zinc 419 Low creep strength, so castings cannot be subjected to prolonged
Alloys high stresses

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Sections:

[7] Casting Defects

Videos:

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0G643

Slides:https://drive.google.com/drive/folders/1BdW3McSXbfYJSszWz1YsIZh
m7uWZWvTe?usp=sharing

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Sec [6]: Sand Control Test
1. What properties are desirable of molding sand from the stand point of
sound castings?
► Properties:
1. High refractoriness
2. Suitable-high collapsibility
3. Suitable permeability
4. High strength ‘green & dry’
5. High moldability
6. High flowability
7. Long benchlife
8. High durability
9. Very low chemical reactivity ‘inert’

2. Explain the importance of permeability of molding sands.

►Needed for gases ‘e.g. those absorbed by the metal during melting’, air
and steam to escape from the mold to avoid their entrapment and causing
casting defects.
The permeability should be average, otherwise if high, the metal would
flow between the sand grains and early cooling would take place. If, on the
other hand, it has low permeability, heat transfer will be affected and the
metal will remain hot for longer time.

3. State the essential ingredients of molding sand.

► 1. Sand grains ‘Silica (most used), Zircon, Olivine, or Chromite’
2. Binder ‘Fireclay, Bentonite (Na/Ca+Clay), Limonite (Iron oxide
(hydroxide)), or Kaolite’
3. Water ‘1.5-8% or 2-7%’
4. Additives ‘Iron oxide, Molasses, Coal Dust’

4. Explain the method of determining the moisture content in molding sand.

1. Make the simple of the sand casting.
2. Weight the simple(W1).
3. Heat it in the oven to get rid of water.
4. Weight the simple after heating (W2).
5. Calculate the moisture:

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5. What is the role played by clay in molding sand? What is the method
adopted for determining the clay content in a molding sand?

► The Role: Clay acts as binders, holding the sand grains together.
►Testt Method:
1. Weight the heated simple (W2).
2. Crush it into a cup of water.
3. Stir the mixture ,then get rid of the water.
4. Repet step 3 until the water be pure.
5. Weight the rest of the sand in the cup(W3).
6. Calculate the clay percentage:

6. What is meant by grain fineness number? Explain the procedure for

determining this number for molding sand.
► Grain Fineness Number: is a number assigned by the American Foundry
Society to expresses the average grain size of a given sand. It gives the
approximate number of meshes per inch of the sieve that allows the sample
to pass through if all its grains were of uniform size.
► The Procedures:
1. Weigh all the empty riddles of Sieving
Machine and consider it as𝑾𝟏.
2. Weigh simple of dry sand and place the Sample
into the top sieve of vibrator.
3. Now adjust the Vibrator to suitable time.

4. After completion of Vibration remove the sieves and weigh the quantity
of sand remaining on each sieve and consider it as W₂.
5. Now, calculate the weight of sand on each individual mesh by
Subtracting W1-W2.
6. .Calculate the percentage of the Sample weight retained on each
Sieve, and arrange in a column multiply the percentage retained by
appropriate multiplier and add the product.
7. Divide by the total of the percentage retained to give the average
grain Size.

∑ ∑
∑ ∑

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7. How is a standard sand test specimen prepared for testing the
strength or permeability?
►We use standard specimen (50mm*50mm).
►The sand specimen is taken out of the specimen tube and immediately
put on the strength testing machine or the permeability machine.
►Determine the required force and the permeability.

8. Describe the method used for determining the permeability of any

molding sand.
► The quantity of air that will pass through a standard specimen of the
sand at a particular pressure condition is called the permeability test of
molding sand.
► The major parts of the permeability test equipment:
1. An inverted bell jar, floats in water.
2. Specimen tube, for the purpose of holding the equipment.
3. A manometer (measure the air pressure).

► The Procedures:
1. The air (2000 cc volume) held in the bell jar was forced to pass through
the sand specimen.
2. At this time, air entering the specimen equals the air that escaped through
the specimen.
3. Take the pressure reading in the manometer.
4. Note the time required for 2000cc of air to pass the sand
5. Calculate the permeability number
6. Permeability number (N) = ((V x H) / (A x P x T))
Where,
V-Volume of air (cc)
H-Height of the specimen (mm)
A-Area of the specimen (mm2)
P-Air pressure (gm / cm2)
T-Time was taken by the air to pass through the sand (seconds).
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9. State the detriment caused to the mould properties if the molding sand
contains

(a) Too much clay,

► Molding sand is used in the casting process in production. It is a mixture
of Silica sand, Clay, Water, and binding additives like Molasses linseed oil,
etc. by reducing the Clay content permeability of the casting will increase

(b) Too much moisture.

► High moisture content causes a decrease in permeability of the sand.

10. A sample of molding sand of 50 g is weighed after washing and drying

and found to weigh 41.6 g. What would be the clay percentage in this sand
sample?
►

11. Calculate the permeability number of a sand specimen if takes 1 min 15

s to pass 2000 cub cm of air at a pressure 6 g/sq cm, through the standard
sample.
► Permeability number (N) = ((V x H) / (A x P x T))

11. A certain yellow sand sample has given the following sieve distribution.
Sieve No 12 20 30 40 50 70 100 140 200 270 Pan
Retained, % 2.50 4.50 3.50 3.50 2.00 4.75 3.80 6.00 10.47 14.17 38.52
Calculate the grain fineness number and specify application for which this
sand is suitable if its sinter temperature range is 1050 - 1100 oC
∑
► ∑
►Used in sand molds for metals that have melting temperatures lower than
this range to avoid sintering as it causes the grains to grow ‘fuse’ and the
pores between them to decrease leading to interaction and decrease in
permeability.

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 12. A sand specimen with a permeability number of 140 takes 45 seconds
to pass 2000 cub cm of air at a pressure of 5 cm. Calculate the height of the
sand specimen.
► Permeability number (N) = ((V x H) / (A x P x T))

H=5.15cm
13. The hypothetical molding sand sample when sieved through the
standard sieves was found to retain the following amounts of sand on the
respective sieves.
Sieve No 12 20 30 40 50 70 100 140 200 270 Pan
Retained weight; g 0.73 1.26 1.03 1.44 2.2 3.57 5.77 14.15 11.13 3.98 4.67
Plot the cumulative grading curve and calculate the grain fineness number.

Sieve No. Retained Retained Multiplier Cumulative Multiplier*

Weight, g Weight % weight % Retained
Weight
%
12 0.73 1.46 5 1.46 7.3
20 1.26 2.52 10 3.98 25.2
30 1.03 2.06 20 6.04 41.2
40 1.44 2.88 30 8.92 86.4
50 2.2 4.4 40 13.32 176
70 3.57 7.14 50 20.46 357
100 5.77 11.54 70 32 807.8
140 14.15 28.3 100 60.3 2,830
200 11.13 22.26 140 82.56 3,116.4
270 3.98 7.96 200 90.52 1,592
Pan 4.67 9.34 300 99.86 2,802
Total 49.93 99.86 11,841.3

∑
∑

► Medium to fine grain

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►

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Sec [7]: Casting Defects:
 Why there are cast defects?

1. Choosing improper design

2. Improper design of the pattern cope & drag

3. Improper design of the feeding or gating system

4. Improper pouring ways

5. No good environment for casting

 A casting defect is an irregularity in the metal casting process that is

undesired.
 It can also be defined as conditions in a casting that must be
corrected or removed, or the casting must be rejected.
 It may sometimes be tolerated, sometimes eliminated with proper
moulding practice or repaired using methods such as welding,
metallization etc.
 There are many types of defects which result from many different
causes. Some of the remedies to certain defects may be the cause for
another type of defect.

43 | P a g e
  Defects Types:

[1] Incorrect shape and dimensions:

[Misrun- Mismatch – Flashing - Knob or Swelling - Wrapping - Damaged

Casting ]

[2] Surface Defects:

[Penetration – Cold Shut – Rattail or Scrabs – Sand wash – Veining –Sweat]

[3] Cracks:

[Hot tears – Cold cracks]

[4] Cavities:

[Gas holes – Surface Pinholes – Shrinkage Cavities]

[5] Non Metallic Inclusion:

[Particle Inclusions – Flat Inclusion – Metallic Inclusion – Cold Shut – Drop

Fine Surface]

[6] Segregates

[7] Inhomogeneity in chemical composition

[8] Inhomogeneity in mechanical composition:

[Hard Spots – Inhomogeneous Structure]

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Defects View Causes Remedies
MISMATCH •Worn out or bent • Increase strength of
clamping pins. mould & core.
• Misalignment of two • Provide adequate
halves of pattern. support to core.
• Improper location & • Proper alignment of two
support of core. halves of the pattern.
MISRUN • Low pouring • Smooth pouring with the
temperature. help of monorail.
• Faulty gating system • Providing appropriate
design. pouring temperature.
• Too thin casting sections. • Modifying the gating
system design.
COLD SHUTS • Low pouring • Smooth pouring with the
temperature. help of monorail.
• Faulty gating system • Providing appropriate
design. pouring temperature.
• Too thin casting sections. • Modifying the gating
system design.
SHRINKAGE • Inadequate and • Ensure proper directional
CAVITY improper gating & risering solidification by modifying
system. gating, risering & chilling
• Too much high pouring system.
temperature. • Improper
chilling.
BLOW HOLES • Ramming is too hard. • Baking of cores properly.
• Cores are not sufficiently • Control of moisture
baked. content in moulding sand.
• Presence of gas • Provide adequate
producing ingredients. venting in mould and
cores.

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POROSITY • High pouring • Regulate pouring
temperature. temperature
• Gas dissolved in metal • Control metal
charge. composition.
• Less flux used. • Increase flux
proportions.
HOT TEARS • Lack of collapsibility of • Providing softer
core & mould. ramming. • Improve
• Hard ramming of mould. casting design. • Improve
• Faulty casting design. collapsibility of core &
mould.
PENETRATION • Low strength of • Use of fine grain with low
moulding sand. permeability.
• Large size of moulding • Appropriate ramming
sand.
• High permeability of
sand.
PIN HOLES • Sand with high moisture • Reducing the moisture
content. content & increasing
• Absorption of permeability of moulding
hydrogen/carbon sand.
monoxide gas in the metal. • Employing good melting
• Alloy not being properly and fluxing practices.
degassed
SWELL • Insufficient or soft • Sand should be rammed
ramming. evenly and properly.
• Low strength mould & • Increase strength of
core. mould & core.

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DROP • Low green strength of • Moulding sand should
the moulding sand. • Low have sufficient green
mould hardness strength.
• Provide adequate
reinforcement to sand
projections and cope by
using nails and gaggers.
RAT TAILS • Excessive mould • Suitable addition of
hardness. combustible additives to
• Lack of combustible moulding sand.
additives in the moulding • Reduction in mould
sand. hardness.

47 | P a g e
MCQ:
1. Which of the following statement is true?
a) Casting is the replica of the object to be cast
b) Pattern is the replica of the casting object
c) Casting and the pattern are same things
d) Molten material is casted into the casting cavity

2. Which of the following carries the mould cavity where the metal is to be
poured?
a) Casting
b) Pattern
c) Sand
d) Core

3. Which of the following is ‘not’ an allowance given to the pattern for

casting?
a) Shrinkage
b) Draft
c) Hole
d) Machining

4. The following diagram shows the application of which of the allowances

given to a pattern?

a) Shrinkage allowance b) Draft allowance

c) Shake allowance d) Distortion allowance

48 | P a g e
5. What will be the machining allowance for a bore of a 405mm cast iron
object to be casted?
a) 1.0mm
b) 2.0mm
c) 3.0mm
d) 5.0mm

6. The quality of the final product is not dependent on _______________

a) Method of withdrawal of pattern
b) Allowance provided to the pattern
c) The complexity of the casting
d) The metal used in Casting

7. The life of a pattern is most likely to depend upon which of the following
term?
a) Number of castings produced
b) Type of cooling rate of the casting
c) Size of the casting
d) Size o

8. What is the function of cores in the casting process?

a) To support the pattern
b) To provide differential cooling rates at specific portions
c) To make holes and cavities
d) For ease of flow of the molten materialf the pattern

9. Which of the following is ‘not’ an advantage of the usage of pattern in a

casting of metals?
a) Using patterns to cast objects, less time is consumed for mass production
b) It is cost efficient and profitable for mass production
c) Production of the pattern requires extra effort to cast the object
d) Cores in the pattern could be used to decrease the amount of machining
done for making cavities

49 | P a g e
10. A draft allowance is provided to ___________
a) All linear faces
b) Only the interior dimensions
c) Only the exterior dimensions
d) Only the dimensions that are perpendicular to the parting plane

11. Which of the following is not measuring, marking or layout tools?

a) Caliper
b) Trisquare
c) T-bevel
d) Compass Saw

12. Which of the following tool is not used for clamping purpose?
a) C-clamp
b) Trammels
c) Bar clamp
d) Hand Vice

13. Which of the following is not a sawing tool?

a) Coping saw
b) Pinch dog
c) Panel saw
d) Bow saw

14. Gimlet is which of the following tool?

a) Clamping tools
b) Drilling tool
c) Sawing tool
d) Wood planing tool

15. Which of the following is not a drilling or boring tool?

a) Brace
b) Counter sink bit
c) Auger bit
d) Hand vice

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16. Which of the following is not a wood planing tool?
a) Block plane
b) Scrub plane
c) Spokeshave
d) Centre bit

17. A mallet comes under which type of tool?

a) Drilling tool
b) Clamping tool
c) Other pattern maker’s tool
d) Sawing tool

18. Which of the following pattern making machine works on two pulleys?
a) Circular saw
b) Band saw
c) Wood turning lathe
d) Jig saw

19. Which of the following pattern making machine makes wooden board?
a) Jointer
b) Drill press
c) Mortiser
d) Scroll saw

20. Disc Sander is an abrasive type of machine.

a) True
b) False

21. What is mixed with natural sand to make it semisynthetic sand?

a) Bentonite
b) Barelelne
c) Cubane
d) Prismane

51 | P a g e
22. The figure below shows which foundry sand grain shape?

a) Round
b) Sub angular
c) Angular
d) Compound

23. The figure below shows which foundry sand grain shape?

a) Round
b) Sub angular
c) Angular
d) Compound

24. Round grain has higher permeability than angular grains.

a) True
b) False

25. The figure below shows which foundry sand grain shape?

a) Round
b) Sub angular
c) Angular
d) Compound

26. Which of the following is not a characteristic property of any moulding

sand?
a) Flowability
b) Hardenability
c) Green strength
d) Dry strength

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27. What does a mould having adequate green strength, does not have?
a) Ability to retain its shape
b) Ability not to get distorted
c) Ability not to collapse
d) Ability to retain hardness

28. Dry sand does not have the strength for what functions?
a) To withstand corrosion forces
b) To withstand pressure of molten metal
c) To be able to retain its shape
d) To be able to retain the hardenability

29. Which of the following would not happen if hot strength is not enough?
a) The mould may get hardened
b) The mould may get enlarged
c) The mould may get eroded
d) The mould may crack

30. Why should the moulding sand be porous?

a) For gases to enter
b) For gases to escape
c) For water to enter
d) For water to escape

31. Which of the following is not a defect if permeability is not enough?

a) Brittleness
b) Gas holes
c) Mould blast
d) Surface blows

32. In green sand what is the amount of water used?

a) 5%
b) 10%
c) 15%
d) 20%

53 | P a g e
33. What is the amount of clay needed in green sand?
a) 5% – 10%
b) 5% – 15%
c) 15% – 30%
d) 25% – 40%

34. Parting sand is a type of moulding sand.

a) True
b) False

35. High moisture causes what in molding sands?

a) Increase in permeability
b) Decrease in permeability
c) Increase in hardness
d) Increase in strength

36. Permeability of molding sand does not depend on which of the

following factors?
a) Grain distribution
b) Degree of ramming
c) Binder contents
d) Amount of wax present

37. For the functioning of the gating system, which of the following factors
need not be controlled?
a) Type of sprue
b) Size of runner
c) Temperature of molten metal
d) Type of riser

38. Sprues up to what diameters are round in section?

a) 10mm
b) 20mm
c) 30mm
d) 40mm

54 | P a g e
39. What prevents the liquid metal from entering the gate?
a) Gate basin
b) Sprue
c) Runner
d) Riser

40. When would dross and slag tend to float on the metal surface?
a) When pouring basins are doubled
b) When pouring basins are made large
c) When pouring basins are made small
d) When pouring basins are removed

41. Which of the following helps connecting runner and the mold cavity?
a) Sprue
b) Riser
c) Gate
d) Pouring cup

42. Which of the following is not a type of a gate?

a) Top gate
b) Bottom gate
c) Parting gate
d) Middle gate

43. Which of the following gate is also called as ‘drop gate’?

a) Top gate
b) Bottom gate
c) Parting gate
d) Middle gate

44. Which of the following gates is used for making stove plate castings?
a) Edge gate
b) Wedge gate
c) Ring gate
d) Finger gate

55 | P a g e
45. Which of the following gates is not favourble for non ferrous castings?
a) Top gate
b) Bottom gate
c) Parting gate
d) Middle gate

46. Ring gates retain slag.

a) True
b) False

47. What is the general shape of an open riser?

a) Cubical
b) Trapezoidal
c) Cylindrical
d) Rounded

48. With an increase in the weight of riser, what would be the

corresponding change in the yield?
a) Increase
b) Decrease
c) Will not change
d) Not related

49. Which of the following factors is not considered in regards with

directional solidification?
a) Riser diameter
b) Riser height
c) Riser location
d) Metal to be casted

50. With an increase in the initial volume, how does it affect the efficiency
of the riser?
a) Increases b) Decreases
c) Will not change
d) No relation

56 | P a g e
51. In solidification of a riser, which of the following cannot be used for
insulation?
a) Insulation powder
b) Insulation sleeve
c) Insulation pad
d) Insulation clip

52. A blind riser is bigger than an open riser.

a) True
b) False

53. How can we eliminate the shrinkage cavity?

a) By increasing riser height
b) By reducing riser height
c) Reducing the number of risers
d) By using an open riser

54. Which of the following can be used for increasing feeding distance?
a) Uniform temperature gradient
b) Negative temperature gradient towards the riser
c) No temperature gradient
d) Positive temperature gradient towards the riser

55. How can we enhance the feeding distance during casting?

a) Reducing molten metal temperature
b) Increase fluidity
c) By using low thermal conductivity mold
d) Using sand mold

56. When do we need more number of risers during casting?

a) Feeding distance is low
b) Feeding distance is high
c) Thermal conductivity of mold is high
d) Fluidity of molten metal is high

57 | P a g e
57. How can we calculate the solidification time?
a) Shrinkage volume consideration method
b) Modulus method
c) Novel research method
d) Chvorinov’s rule

58. If feeding distance is more, the number of risers required will be more.
a) True
b) False

59. Which of the following relations is given by chvorinov for the

solidification time of a casting?
a) ts = k(V/SA)2
b) ts = k(V/SA)
c) ts = k(V*SA)2
d) ts = k(V/SA)3

60. Cylinder and cylinder heads for air cooled IC engines are casted using
which technique?
a) Precision investment casting
b) Shell moulding
c) Permanent mould casting
d) Die casting

61. Another name of Gravity Die Casting is?

a) Centrifugal casting
b) Permanent mould casting
c) Precision investment casting
d) Hot chamber process

58 | P a g e
62. Which of the following is a limitation of die casting, but is overcome in
vacuum die casting?
a) The air left in the cavity when the die is closed
b) The moisture left in the cavity when the die is closed
c) The air left in the cavity when the die is open
d) The moisture left in the cavity when the die is open

63. Pattern used in shell moulding is normally made up of?

a) Wax
b) Metal
c) Wood
d) Plastic

64. The tundish is a _______

a) Pouring vessel
b) Riser
c) Type of core
d) Machine name

65. Which of the type of centrifugal casting methods is used to produce

‘non-symmetrical’ shaped castings?
a) True centrifugal casting
b) Semi centrifugal casting
c) Centrifuging
d) Non centrifugal casting

66. True centrifugal casting method is usually used to make __________

a) Bent pipes
b) Hollow pipes
c) Bolts
d) Nuts

59 | P a g e
67. Pressure range for low pressure die casting is ___________
a) 0.3-1.5 bars
b) 0.5-2 bars
c) 2-6 bars
d) up to 8 bars

68. Which of the following synthetic resins are used for mixing with sand in
shell moulding?
a) Thermosetting resins
b) Epoxy resins
c) Fiber glass resins
d) Kevlar

69. Grain size of the sand particles has no affects on the surface finish of
the casting.
a) True
b) False

70. In shell moulding sand preparation, the resin is combined with a

catalyst (hexa) to develop the_____
a) thermoplastic characteristics
b) toughness of the resin
c) thermosetting characteristics
d) viscosity of the resin

71. Which of the following compositions of the shell sand is used for
avoiding of thermal crack during pouring?
a) Silica sand
b) Zircon sand
c) Resin
d) Additives

60 | P a g e
72. Which of the following devices is used for the mixing or complete
formation of the shell sand mixture?
a) Chucker
b) Mueller
c) Semicircular roller
d) Semi cylindrical roller

73. Which of the following types of clamping is mostly performed for the
joining of shells?
a) Mechanical
b) Electrical
c) Pneumatic
d) Hydraulic

74. It is easy to produce any complex shapes and narrow sections in the die
casting.
a) True
b) False

75. Due to the presence of ejector die, there is no need of lubricant for the
removal of casting from the dies.
a) True
b) False

76. A single piece or unitary part of the metallic die is used for making
castings in die casting.
a) True
b) False

77. Which of the following ways of cooling is used for the maintaining of die
temperature?
a) Natural air cooling
b) Forced air cooling
c) Water channels cooling
d) Liquid nitrogen cooling

61 | P a g e
78. In cold chamber die casting, rapid cooling of the castings is done as
compared to the hot chamber die casting.
a) True
b) False

79. In the hot chamber die casting process, which of the following parts is
used for the pumping of liquid metal into the cavity?
a) Accumulator
b) Slug
c) Guide pin
d) Gooseneck

80. In hot chamber die casting processes, downward motion of plunger in

the gooseneck leads to injection of molten metal into the cavity with high
pressure.
a) True
b) False

81. In hot chamber die casting, the plunger is also used for taking back of
unused molten metal to the gooseneck after the fulfilling of the cavity.
a) True
b) False

82. Which of the following materials is not suitable to be cast by a hot

chamber die casting process?
a) Lead
b) Tin
c) Aluminium
d) Zinc

83. The chances of defects in the castings by cold chamber die casting are
more than the castings produced by hot chamber die casting.
a) True
b) False

62 | P a g e
84. Which of the following forces provides continuous pressure on the
metal in centrifugal casting?
a) Spring force
b) Centrifugal force
c) Gravitational force
d) Frictional force

85. Which of the following methods of casting is best suited for casting of
hollow pipes and tubes?
a) Investment casting
b) Permanent mould casting
c) Die casting
d) Centrifugal casting

86. Special type of sand cores is mainly used for the making of hollow part
in the centrifugal casting.
a) True
b) False

87. The axis of rotation of the mould should be horizontal for the casting of
long pipes in centrifugal casting.
a) True
b) False

88. Dry sand cores may be required for the provision of spigot at the end
section of the casting.
a) True
b) False

89. Which of the following parts is provided in between the mould and
casing to reduce the vibrations?
a) Steel balls
b) Metallic roller
c) Viscous fluid
d) Grease

63 | P a g e
90. In centrifugal casting, the casting yield is approximately equaled to
100%.
a) True
b) False

91. Castings made by the centrifugal casting process have negligible

porosity.
a) True
b) False

92. Which of the following types of centrifugal casting process is used for
the casting, whose shape of casting is not axi-symmetric?
a) True centrifugal casting
b) Semi centrifugal casting
c) Centrifuging
d) Full centrifugal casting

93. Which of the following methods of casting is the fastest method for the
production of constant cross-section shapes of casting?
a) Permanent mould casting
b) Centrifugal casting
c) Continuous casting
d) Die casting

94. Which of the following methods of casting is best suitable for the
casting of long length slabs and billets?
a) Investment casting
b) Permanent mould casting
c) Die casting
d) Continuous casting

95. In continuous casting, different cooling rates provide different

properties to the castings.
a) True
b) False

64 | P a g e
96. Which of the following terms is used for the intermediate pouring
vessel in continuous casting?
a) Tundish
b) Biscuit
c) Platen
d) Runner

97. Before starting of casting process, a dummy starter bar is used in the
continuous casting method.
a) True
b) False

98. Which of the following parts is used for the support of steel shell in
continuous casting?
a) Steel balls
b) Conveyor belt
c) Steel rollers
d) Steel frame

99. Higher extent of automation can be possible in a continuous casting

method.
a) True
b) False

100. Continuously cast products in the continuous casting show very less
segregation.
a) True
b) False

101. Which of the following is used for the reduction of friction between
the mould’s surface and metal strand?
a) Water b) Casting powder
c) Oil d) Grease

For More: https://www.sanfoundry.com/casting-multiple-choice-questions-

answers/
65 | P a g e
Q A Q A Q A
1 b 35 b 69 b
2 b 36 d 70 c
3 c 37 d 71 d
4 b 38 b 72 b
5 d 39 a 73 a
6 d 40 b 74 a
7 a 41 c 75 b
8 c 42 d 76 b
9 c 43 a 77 c
10 d 44 b 78 b
11 d 45 a 79 d
12 b 46 a 80 a
13 b 47 c 81 a
14 b 48 b 82 c
15 d 49 d 83 a
16 d 50 b 84 b
17 c 51 d 85 d
18 b 52 b 86 b
19 a 53 a 87 a
20 a 54 d 88 a
21 a 55 b 89 b
22 c 56 a 90 a
23 a 57 d 91 a
24 a 58 b 92 c
25 d 59 a 93 c
26 b 60 b 94 d
27 d 61 b 95 a
28 d 62 a 96 a
29 a 63 b 97 a
30 b 64 a 98 c
31 a 65 c 99 a
32 a 66 b 100 a
33 c 67 a 101 b
34 a 68 a

66 | P a g e
Good Luck

67 | P a g e