10/9/2011

ShellMoulding
y The sand is mixed with a thermosetting resin is

SpecialCasting
BySKMondal

allowed to come in contact with a heated metal pattern

(2000C).
y A skin
3.5 mm off sand
ki (shell)
( h ll) off about
b
d and
d plastic
l i
mixture adhere to the pattern.
y Then the shell is removed from the pattern.
y The cope and drag shells are kept in a flask with
necessary backup material and the molten metal is
poured into the mold.

y Can produce complex parts.

y A good surface finish and good size tolerance

reduce the need for machining.

g
y Materials can be cast: CI, Al and Cu alloys.

Shellmouldingprocess

MoldingSandinShellMolding
y The molding sand is a mixture of fine grained quartz sand

to loading the sand. In the course of sand mixing, the

soluble phenol formaldehyde resin is added. The mixer is

and powdered bakelite.

y Cold coating and Hot coating methods are used for

allowed to cool up to 80 90o C. Hot coting gives better

properties to the mixtures than cold method.

coating the sand grains with bakelite.

y

y Hot coating: the mixture is heated to 150oC 180oC prior

Cold coating: quartz sand is poured into the mixer and

then the solution of powdered bakelite in acetone and
ethyl aldehyde are added. (mixture is 92% quartz sand,
5% bakelite, 3% ethylaldehyde )

Contd

10/9/2011

Advantages

Limitations

y Dimensional accuracy.

y Expensive pattern

y Smoother surface finish. (Due to finer size grain used)

y Small size casting only.

y thin sections can be cast.

y Very

y Highly complicated shapes cannot be obtained.

y Very small amount of sand is needed.

y More sophisticated equipment is needed for handling

the shell moldings.

Applications
y Cylinders and cylinder heads for air cooled IC

engines
y Automobile transmission parts.
y Piston rings

IES2010
Considerthefollowingadvantagesofshell
mouldcasting:
1.Closedimensionaltolerance.
2.Goodsurfacefinish.
3.Lowcost.
4.Easier.
Whichofthesearecorrect?
(a)1,2and3only (b)2,3and4only
(c)1,2and4only (d)1,2,3and4

IES1996

IES2005

Consider the following ingredients used in

moulding:
1. Dry silica sand
2.Clay
3.Phenol formaldehyde
4.Sodium silicate
Those used for shell mould casting include
(a) 1, 2 and 4
(b) 2, 3 and 4
(c) 1and 3
(d) 1, 2, 3 and 4

Inshellmoulding,howcantheshellthickness
beaccuratelymaintained?
(a)Bycontrollingthetimeduringwhichthepattern
isincontactwithmould
(b)Bycontrollingthetimeduringwhichthepattern
isheated
(c)Bymaintainingthetemperatureofthepatternin
therangeof175oC 380oC
(d)Bythetypeofbinderused

10/9/2011

IES2006
Shellmouldingcanbeusedfor:
(a) Producingmillingcutters
(b) Makinggoldornaments
(c) Producingheavyandthickwalledcasting
(d) Producingthincasting

IAS2007
The mould in shell moulding process is made up
of which of the following?
(a) Gypsum + setting agents
(b) Green sand + clay
(c) Sodium silicate + dried sand
(d) Dried silica + phenolic resin

IES2007
Which of the following are employed in shell
moulding?
1. Resin binder 2. Metal pattern 3. Heating coils
Select the correct answer using the code given
below:
(a) 1 and 2 only
(b) 1 and 3 only
(c) 2 and 3 only
(d) 1, 2 and 3

IAS1999
Match List I (Moulding Process) with List II (Binding
Agent) and select the correct answer using the codes
given below the lists:
List I
List II
A. Green sand
1. Silicate
B. Core sand
2. Organic
C. Shell moulding
3. Clay
D. CO2 process
4. Plaster of Paris
5. Plastic
Codes:A
B
C
D
A
B
C
D
(a) 3
2
5
1
(b) 3
2
4
1
(c) 2
3
5
4
(d) 2
3
4
5

InvestmentCasting
Investment casting process or lost wax process
Basic steps:
1. Produce expendable wax, plastic, or polystyrene patterns.
2. Assemble these patterns onto a gating system
3.
3 Investing or covering the pattern assembly with refractory
slurry
4. Melting the pattern assembly to remove the pattern material
5. Firing the mould to remove the last traces of the pattern
material
6. Pouring molten metal
7. Knockout, cutoff and finishing.
Fig.Investmentflaskcastingprocedure

10/9/2011

CeramicShellInvestmentCasting
y In ceramic shell investment casting a ceramic shell is

built around a tree assembly by repeatedly dipping a

pattern into a slurry (refractory material such as
zircon with binder).
y After each dipping and stuccoing is completed, the

assembly is allowed to thoroughly dry before the next

coating is applied.

IES2009
y 2marks

Advantages

Limitations

y Tight dimensional tolerances

y Costly patterns and moulds

y Excellent surface finish (1.2 to 3.0 m )

y Machining
g

can

be

reduced

or

completely
p
y

eliminated

y Labour costs can be high

y Limited size

y High melting point alloy can be cast, almost any

metal can be cast

y Almost unlimited intricacy

10/9/2011

Applications
y Aerospace and rocket components.
y Vanes and blades for gas turbines.
y Surgical instruments

GATE2006
An expendable pattern is used in
(a) Slush casting
(b) Squeeze casting
(c) Centrifugal casting
(d) Investment casting

JWM2010
Considerthefollowingmaterials:
1.Wax
2.Wood
3.Plastic
Whichofthesematerialscanbeusedaspatternin
investmentcastingprocess?
(a)1,2and3
(b)1and2only
(c)2and3only
(d)1and3only

IES2011
The proper sequence of investment casting steps is :
(a) Slurry coating pattern melt outShakeout Stucco
coating
(b) Stucco coating Slurry coating Shakeout Pattern
melt out
(c) Slurry coating Stucco coating Pattern melt out
Shakeout
(d) Stucco coating Shakeout Slurry coating Pattern
melt out

IES1992
Themostpreferredprocessforcastinggasturbine
bladesis:
(a) Diemoulding
(b) Shellmoulding
(c) Investmentmoulding
(d) Sandcasting

IES2010
Assertion (A): These investment casting is used for
precision parts such as turbine plates, sewing
machines etc.
Reason (R): The investment castings have a good
surface finish and are exact reproductions of the
master pattern.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is NOT the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true

10/9/2011

IES2007
Consider the following statements in respect of
investment castings:
1. The pattern or patterns is/are not joined to a stalk or
sprue also of wax to form a tree of patterns.
2.The prepared moulds are placed in an oven and heated
gently to dry off the invest and melt out the bulk of wax.
3.The moulds are usually poured by placing the moulds in
a vacuum chamber. Which of the statements given above
are correct?
(a) 1 and 2 only
(b) 1 and 3 only
(c)2 and 3 only
(d) 1, 2 and 3

IES2006
Which of the following materials are used for
making patterns in investment casting method?
1. Wax
2. Rubber 3. Wood
4. Plastic
Select the correct answer using the codes given below:
(a) Only 1 and 3
(b) Only 2 and 3
(c) Only 1, 2 and 4
(d) Only 2, 3 and 4

IAS1996
Light and intricate parts with close dimensional
tolerances of the order of 0.005 mm are
produced by
(a) Investment casting
g
(b) Die casting
(c) Centrifugal casting
(d) Shell mould casting

PermanentMouldCasting
y The process in which we use a die to make the

castings is called permanent mold casting or gravity

die casting, since the metal enters the mold under
gravity.
gravity
y Some time in diecasting we inject the molten metal
with a high pressure. When we apply pressure in
injecting the metal it is called pressure die casting
process.
y Grey cast iron is used for mould material.

Advantages
y Good surface finish and dimensional accuracy
y Metal mold gives rapid cooling and finegrain

structure
y Multipleuse molds.

Disadvantages
y High initial mold cost
y Shape, size, and complexity are limited
y Mold life is very limited with highmeltingpoint

metals such an steel.

steel
y Low melting point metals can be cast

Aluminum
Zinc
Magnesium alloys
Brass
Cast iron

10/9/2011

Applications
y Pistons/cylinders/rods

DieCasting
y Molten metal is injected into closed metal dies under

pressures ranging from 100 to 150 MPa.

y Gears

y Pressure is maintained during solidification

y Kitchenware

y After which the dies separate and the casting is ejected

along with its attached sprues and runners.

y Cores must be simple and retractable and take the

form of moving metal segments

Diecastingmachinescanbe
Video

y Hotchamber
y Coldchamber

Hotchambermachinesare
y Good for low temperature (approx. 400C)
y Faster than cold chamber machines
y Cycle times must be short to minimize metal

contamination
y Metal starts in a heated cylinder
y A piston forces metal into the die
y The piston retracts, and draws metal in
y Metal: Lead, Tin, Zinc

HotChamber

10/9/2011

Coldchambermachines
y Castshighmeltingpointmetals(>600C)
y Highpressuresused
y Metalisheatedinaseparatecrucible
l h
d
bl
y Metalisladledintoacoldchamber
y Themetalisrapidlyforcedintothemoldbeforeit

cools
y Copper,BrassandAluminiumcancast.

Advantages
y Extremelysmoothsurfaces(1m)
y Excellentdimensionalaccuracy
y Rapidproductionrate
y Bettermechanicalpropertiescomparedtosand

casting
y Intricatepartspossible
y Minimumfinishingoperations
y Thinsectionspossible

Limitations
y Highinitialdiecost
y Limitedtohighfluiditynonferrousmetals
y Partsizeislimited
y Porositymaybeaproblem
y Somescrapinsprues,runners,andflash,butthiscan

bedirectlyrecycled

Applications
y Carburettors
y Automotive parts
y Bathroom fixtures
y Toys

Common metals
y Alloys of aluminum, zinc, magnesium, and lead
y Also possible with alloys of copper and tin

10/9/2011

IES2011

Consider the following advantages of die casting over

sand casting :
1. Rapidity of the process
2. Smooth surface
3.
3 Strong dense metal structure
Which of these advantages are correct ?
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only

JWM2010
Assertion (A) : In die casting method, small
thickness can be filled with liquid metal.
Reason (R) : The air in die cavity trapped inside the
casting causes problems.
(a) BothAandRareindividuallytrueandRisthe
correctexplanationofA
(b) BothAandRareindividuallytruebutRisnot the
correctexplanationofA
(c) AistruebutRisfalse
(d) AisfalsebutRistrue

IES2006
In which of the following are metal moulds used?
(a) Greensand mould
(b) Dry sand mould
(c) Die casting process
(d) Loam moulding

IES2009
Which of the following are the most suitable
materials for die casting?
(a) Zinc and its alloys
(b) Copper and its alloys
(c) Aluminium and its alloys
(d) Lead and its alloys

IES2005
Which one of the following processes produces a
casting when pressure forces the molten metal
into the mould cavity?
(a) Shell moulding
g
(b) Investment casting
g
(c) Die casting
(d) Continuous casting

IES1995
Assertion (A): An aluminium alloy with 11 % silicon is
used for making engine pistons by die casting
technique.
Reason (R): Aluminium has low density and addition
of silicon improves
p
its fluidity
y and therefore its
castability.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true

10/9/2011

IES1995
MatchListIwithListIIandselectthecorrectanswertakingthehelp
ofcodesgivenbelowthelists:
ListI
ListII
(Products)
(Processofmanufacture)
A.
Automobilepistoninaluminium alloy
1.Pressurediecasting
B.
Enginecrankshaftinspheroidal
graphiteiron
hi i
2.Gravitydiecasting
G i di
i
C.
Carburettor housinginaluminium alloy 3.Sandcasting
D.
Casttitaniumblades
4.Precisioninvestment
casting
5.Shellmoulding
Code: A
B
C
D
A
B
C
D
(a) 2
3
1
5
(b)
3
2
1
5
(c) 2
1
3
4
(d)
4
1
2
3

IAS1996
Assertion (A): Die casting yields a product of good
accuracy and finish.
Reason (R): Low melting alloys used in die
casting.
(a)
( ) Both
B h A and
d R are individually
i di id ll true and
d R is
i the
h
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true

GATE2007
Which of the following engineering materials is
the most suitable candidate for hot chamber die
casting?
(a)
( ) Low carbon
b steell
(b) Titanium
(c) Copper
(d) Tin

IAS2007
Considerthefollowingstatements:
1. Zincdiecastingshavelowstrength.
2. Inthediecastingprocess,verythinsectionsor
complexshapescanbeobtainedeasily.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1only
(b) 2only
(c) Both1and2
(d) Neither1nor2

IES2011
Consider the following statements :
1. Hot chamber machine is used for casting zinc, tin and
other low melting alloys.
2. Cold chamber machine is used for die casting of
ferrous alloys
3. Rapid cooling rate in die casting produces high
strength and quality in many alloys.
Which of these statements are correct?
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only

IES1995
Assertion (A): Aluminium alloys are cast in hot
chamber die casting machine.
Reason (R): Aluminium alloys require high melting
when compared to zinc alloys.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true

10

10/9/2011

CentrifugalCasting
y Process: Molten metal is introduced into a rotating sand,

metal, or graphite mould, and held against the mould

wall by centrifugal force until it is solidified
y A mold is set up and rotated along a vertical (rpm is

reasonable), or horizontal (2001000 rpm is reasonable)

axis.
y The mold is coated with a refractory coating.
y During cooling lower density impurities will tend to rise

Fig.Truecentrifugalcasting

towards the center of rotation.

Properties
y The mechanical properties of centrifugally cast jobs are

better compared to other processes, because the inclusions

such as slag and oxides get segregated towards the centre
and can be easily removed by machining. Also, the
pressure acting
p
g on the metal throughout
g
the solidification
causes the porosity to be eliminated giving rise to dense
metal.
y No cores are required for making concentric holes in the
case of true centrifugal casting.

Limitations

Advantages
y Fine grained structure at the outer surface of the

casting free of gas and shrinkage cavities and

porosity
y Formation of hollow interiors in cylinders without
cores
y Can produce a wide range of cylindrical parts,
including ones of large size.
y Good dimensional accuracy, soundness, and
cleanliness
y There is no need for gates and runners, which
increases the casting yield, reaching almost 100 %.

y More segregation of alloy component during pouring under

the forces of rotation

y Contamination of internal surface of castings with non

metallic
lli inclusions
i l i
y Inaccurate internal diameter
y Shape is limited.
y Spinning equipment can be expensive
y Poor machinability

11

10/9/2011

Commonmetals
y
y
y
y

GATE2002

Iron
steel
stainlesssteel
alloysofaluminium,copper,andnickel

In centrifugal casting, the impurities are

(a) Uniformly distributed
(b) Forced towards the outer surface
(c) Trapped near the mean radius of the casting
(d) Collected at the centre of the casting

GATE1993

IES2008

Centrifugally cast products have

(a) Large grain structure with high porosity
(b) Fine grain structure with high density
(c) Fine grain structure with low density
(d) Segregation of slug towards the outer skin of the
casting

IES2009

IES2007

Which one of the following casting processes is

best

suited

to

make

symmetrical
y
p
pipes?
p
(a) Die casting
(b) Investment casting

bigger

Which of the following casting processes does not

/do not require central core for producing pipe?
1. Sand casting process
2. Die casting process
3 Centrifugal casting process
3.
Select the correct answer using the code given below:
(a) 1 and 2
(b) 2 only
(c) 2 and 3
(d) 3 only

size

hollow

Which one of the following is the correct

statement?
In a centrifugal casting method
(a) No core is used
(b) Core may be made of any metal
(c) Core is made of sand
(d) Core is made of ferrous metal

(c) Shell moulding

(d) Centrifugal casting

12

10/9/2011

IES1998

IES2009

Poormachinability ofcentrifugallycastironpipe
isdueto
(a) Chilling
(b) Segregation
(c) Densestructure
(d) Highmouldrotationspeed

Which of the following are the most likely

characteristics in centrifugal casting?
(a) Fine grain size and high porosity
(b) Coarse grain size and high porosity
(c) Fine grain size and high density
(d) Coarse grain size and high density

IES2007

IES2000

MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(CastingProcess)
(Principle)
A.
Diecasting
1.Themetalsolidifiesinarotatingmould
B.
Investmentcasting
2.Thepatternclusterisrepeatedlydipped
intoaceramicslurryanddustedwith
refractory
f
C.
Shellmoulding
3.Moltenmetalisforcedbypressureinto
ametallicmould
D.
Centrifugalcasting
4.Aftercooling,theinvestisremoved
fromthe Castingbypressurejettingor
vibratorycleaning
Code: A
B
C
D
A
B
C
D
(a) 2
1
3
4
(b)
3
4
2
1
(c) 2
4
3
1
(c)
3
1
2
4

MatchListI(Process)withListII(Products/materials)
andselectthecorrectanswerusingthecodesgiven
belowtheLists:
ListI
ListII
A. Diecasting
1.Phenolformaldehyde
B. Shellmolding
2.C.I.pipes
C. CO2 molding
3.Nonferrousalloys
D. Centrifugalcasting
4.Sodiumsilicate
Codes:A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b) 3
1
4
2
(c) 3
1
2
4
(d) 1
3
2
4

IAS2004

SemicentrifugalCasting
y Centrifugal force assists the flow of metal from a

MatchListI(NameoftheProcess)withListII(Advantage)andselectthecorrect
answerusingthecodesgivenbelowthelists:
ListI
ListII
(NameoftheProcess)
(Advantage)
A.
SandCasting
1.Largecylindricalpartswithgoodquality
B.
B
Ceramicmoldcasting
C
i ld
i
2.Excellentdimensionalaccuracyandsurface
E ll di
i
l
d f
finish
C.
Diecasting
3.Intricateshapesandclosetoleranceparts
D.
Centrifugalcasting
4.Almostanymetaliscastandthereifnolimitto
size,shapeandweight
5.Gooddimensionalaccuracy,finishandlow
porosity
Codes:A
B
C
D
A
B
C
(a)
2
3
5
1
(b)
4
1
2

D
3

(c)

(d)

central reservoir to the extremities of a rotating

symmetrical
y
mold,, which mayy be either expendable
p
or
multipleuse
y Rotational speeds are lower than for true centrifugal

casting
y Cores can be used to increase the complexity of the

product.

13

10/9/2011

IAS2003
Assertion (A): Semicentrifugal casting process is
similar to true centrifugal casting except that the
central core is used in it to form inner surface.
Reason (R): In semicentrifugal casting process the
axis of spin
p is always
y vertical
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Fig. Semicentrifugalcasting

Centrifuging
y Uses centrifuging action to force the metal from a central

pouring reservoir into separate mold cavities that are

offset from the axis of rotation.
y Low speed
y May used to assist in the pouring of investment casting

trees.

Fig.Methodofcastingbythecentrifugingprocess

IES2000
MatchListI(Typeofcasting)withListII(Workingprinciples)
andselectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListI
ListII
A. Diecasting
1.Moltenmetalisforcedintothedie
underpressure
B. Centrifugalcasting
2.Axisofrotationdoesnotcoincidewith
axisofmould
C. Centrifuging
3.Metalsolidifieswhenmouldisrotating
D. Continuouscasting 4.Continuouslypouringmoltenmetal
intomould
Codes: A
B
C
D
A
B
C
D
(a) 1
3
2
4
(b)
4
3
2
1
(c) 1
2
3
4
(d)
4
2
3
1

DrySandMolding
y To reduce gas forming materials air dried mould used.

Types:
1 Skin drying and
1.Skin
2.Complete mold drying

14

10/9/2011

SlushCasting
y Slush casting is a variation of the permanent mold process

in which the metal is permitted to remain in the mold only

until a shell of the desired thickness has formed.
y The mold is then inverted and the remaining liquid is
poured out.
y When the mold halves are separated, the resulting casting
is a hollow shape with good surface detail but variable wall
thickness.
y Frequently used to cast lowmeltingtemperature metals
into ornamental objects such as candlesticks, lamp bases,
and statuary.

IES2011
The method of casting for producing ornamental pieces
are:
(a) Slush and gravity casting
(b) Pressed and slush casting
(c) Gravity and semi permanent mould casting
(d) Semi permanent mould and pressed casting

IAS2004
Which of the following are produced by slush
casting?
(a) Hollow castings with thick walls
(b) Hollow castings with thin walls
(c) Thin castings
(d) Thick castings

SqueezeCasting
Process:
1. Molten metal is poured into an open face die.
2. A punch is advanced into the die, and to the metal.
3 Pressure (less than forging) is applied to the punch
3.Pressure
and die while the part solidifies.
4.The punch is retracted, and the part is knocked out
with an ejector pin.
y Overcomes problems with feeding the die, and
produces near net, highly detailed parts.

IAS2002

SingleCrystalCasting

MatchListI(CastingProcess)withListII
(Applications)andselectthecorrectanswerusingthe
codesgivenbelowtheLists:
ListI
ListII
(CastingProcess)
(Applications)
A. Centrifugalcasting
1.
Carburetor
B. Squeezecasting
2.
Pipes
C. DieCasting
3.
Wheelsfor
automobiles
4.
Gearhousings
Codes:A
B
C
A
B
C
(a) 2
3
1
(b) 4
1
3
(c) 2
1
3
(d) 4
3
1

Theprocessiseffectively:
1. Prepareamoldsothatoneendisaheatedoven,and
theotherendchilled.Thepartshouldbeorientedso
thatthecoolinghappensoverthelongestdistance.
2. Castmetalintothemold
C t t li t th ld
3. Solidificationwillbeginatthechillplate.These
dendriteswillgrowtowardstheheatedendofthe
partaslongdendritic crystals.Thepartisslowly
pulledoutoftheoven,pastthechillplate.
4. Removethesolidifiedpart.

15

10/9/2011

IES2009

y Creepandthermalshockresistanceproperties.

2marks

PlasterCasting
y Process: A slurry of plaster, water, and various additives is

additives is pouted over a pattern and allowed to set. The

pattern is removed and the mould is baked to remove
excess water. After pouring and solidification, the mould is
broken and the casting
g is removed.
y Advantage: High dimensional accuracy and smooth
surface finish, thin sections and intricate detail can
produce.
y Limitations: Lowertemperature nonferrous metals only:
y Common metals: Primarily aluminium and copper

PitMoulding
y This method is used for very large castings and is done on

the foundry floor.

IES1996
Whichofthefollowingpairsarecorrectlymatched?
1. Pitmoulding ..................Forlargejobs.
2. Investmentmoulding ...Lostwaxprocess.
3.
3 Plastermoulding Mouldpreparedin
Mouldpreparedin
gypsum.
(a) 1,2and3 (b) 1and2
(c) 1and3
(d) 2and3

LoamMoulding
y Moulding loam is generally artificially composed of

common brickclay, and sharp sand.

y Loam means mud.
y Loam Moulding is restricted to forms which cannot be

cast conveniently in any other process.

y It is costly.

16

10/9/2011

IES1997
Which one of the following pairs is not correctly
matched?
(a) Aluminium alloy piston Pressure die casting
(b) Jewellery.. Lost wax process
(c) Large pipes ..Centrifugal casting
(d) Large bells Loam moulding

GATE1998
ListI
(A) Sandcasting
circularshapesonly
(B) Plastermouldcasting
skinsandsoftinterior
(C) Shellmouldcasting
castingprocessing
(D) Investmentcasting

ListII
(1)
Symmetricaland
(2)

Partshavehardened

(3)

Minimumpost

(4)

Partshaveatendency
towarp
Partshavesoftskin
andhardinterior
Suitableonlyfornon
ferrousmetals

(5)
(6)

GATE1992
Matchthefollowingmoulding/castingprocesseswith
theproduct:
Moulding/Castingprocesses
Product
(A) Slushcasting
(P)Turbineblade
(B) Shellmoulding
(Q)Machinetoolbed
(C) Drysandmoulding
(R)Cylinderblock
(D) Centrifugalcasting
(S)Hollowcastings
likelampshades
(T)Rainwaterpipe
(U)Castironshoe
brake

IES2003
MatchListI(Products)withListII(CastingProcess)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
(Products)
(CastingProcess)
A. Hollowstatues
1.
CentrifugalCasting
B.
B
Dentures
2.
2
InvestmentCasting
C. Aluminium alloypistons
3.
SlushCasting
D. Rockerarms
4.
ShellMoulding
5.
GravityDieCasting
Codes: A
B
C
D
A
B
C
D
(a) 3
2
4
5
(b)
1
3
4
5
(c) 1
2
3
4
(d)
3
2
5
4

GATE1996
ListI
ListII
(A) Rivetsforaircraftbody 1.
Forging
(B) Carburettor body
2.
Coldheading
(C) Crankshafts
3
3.
Aluminiumbased
alloy
(D) Nails
4.
Pressurediecasting
5.
Investmentcasting

IES1993
MatchtheitemsofListI(Equipment)withtheitems
ofListII(Process)andselectthecorrectanswerusing
thegivencodes.
ListI(Equipment)
ListII(Process)
P HotChamberMachine 1.
1
Cleaning
Q Muller
2.
Coremaking
R DielectricBaker
3.
Diecasting
S SandBlaster
4.
Annealing
5.
Sandmixing
(a) P2,Q1,R4,S5
(b) P4,Q2,R3,S5
(c) P4,Q5,R1,S2
(d) P3,Q5,R2,S1

17

10/9/2011

IAS2004
MatchListI(NameoftheCastingProcess)withListII(ProcessDefinition)andselect
thecorrectanswerusingthecodesgivenbelowthelists:
ListI
ListII
(NameoftheCastingProcess)
(ProcessDefinition)
A.
Diecasting
1.Thisprocessinvolvesuseofamouldmadeof
Driedsilicasandandphenolic resinmixture
B.
B
Electroslag
El
l casting
i
2.Inthisprocess,moltenmetalisforcedby
I hi
l
li f
db
Pressureintoametalmould
C.
Centrifugalcasting
3.Thisprocessemploysaconsumableelectrode
D.
Precisioncasting
4.Thisprocessinvolvesrotatingamouldwhilethe
metalsolidifies
5.Thisprocessproducesverysmooth,highly
Accuratecastingsfrombothferrousandnon
ferrousalloys
Codes:A
B
C
D
A
B
C
D
(a)
5
4
1
2
(b)
2
3
4
5
(c)
5
3
4
2
(d)
2
4
1
5

ConventionalCastingProcessCh21
Q.No

Option

Q.No

Option

13

14

15

16

17

18

19

20

21

10

11

12

SpecialCastingProcessCh22
Q.No

Option

10

Q.No

Option

11

12

13

14

15

16

17

18