Unit I: Metal Casting Processes (Model Tutorial question)

1. Explain briefly the main constituents of molding sand. And how do the
grain size and shape affect the performance of molding sand?
2. How are binders classified? Name and describe the different properties of
good molding sand.
3. What is meant by green strength and dry strength as applied to a molding
sand?
4. What is grain fineness number? Explain how you will use a sieve shaker
for determining the grain fineness of foundry sand.
5. Define casting. And also briefly explain types of casting.
6. What are the controlling factors of solidification in casting? Name
different stages through which the metal contraction takes place during the
solidification of the casting?
7. What different metals and alloys are commonly used in casting?
8. What is investment casting? What are the main materials used for making
the investment pattern?
9. Describe the complete step by step procedure of plaster mold casting.
What are the main advantages and disadvantages of this casting?
10. Discuss briefly the causes and remedies of the following casting defects:
(i) Blow holes, (ii) Porosity, (iii) Hot tears (iv) Shrinkage cavities, (v)
Scabs, (vi) Gas porosity (vii) Sand inclusions, (viii) Cuts and washes, (ix)
Misrun and cold shuts, (x) Honey combing, (xi) Metal penetration, (xii)
Drops, (xiii) Warpage and (xiv) blow holes
11. What are the various non-destructive testing methods used for inspection
of castings? State their advantages and limitations.

Unit II: Joining Processes (Model Tutorial question)

1. What is welding? How is it classified? And also advantages, disadvantages
and applications of welding joints over other joints?
2. What effect does welding have on the grain-size of a metal? What effect
will pre-heating have on the microstructure of the weld-area in high carbon
steel? Show it with the help of neat diagram.
3. Sketch the three types of gas welding flames and give differences between
them. And give the advantages, limitations and applications of gas welding?
4. Write short notes on:
(i) Welding rods
(ii) Fluxes
(iii) Gas flames
(iv) Working of pressure regulators
5. How will you obtain neutral, oxidizing and reducing flames using welding
torch in gas welding?
6. Define electric arc welding. Discuss with the help of neat sketch, the
principle of arc welding. Give a list of equipments required in general for
electric arc welding.
7. Explain the principle of atomic hydrogen welding.
8. Write short notes on :
(a) Arc crater
(b) Arc blow
(c) Electrode
(d) Flux
9. Explain TIG welding and MIG welding with its merits, demerits and
application.
10. Explain submerged arc welding and electro-slag welding with neat
sketch. Compare it with electro-gas welding.
11. What do you understand by thermit welding? What are its main
advantages? How does thermit welding process differ from ordinary arc
welding?
12. Write short notes on:
(i) Forge or smithy welding.
(ii) Leftward welding.
(iii) Rightward welding.
(iv)Vertical welding

13. Discuss the method of resistance welding. What are its advantages and
disadvantages? What is the main source of heat in resistance welding?
Unit III: Metal Forming (Model Tutorial question)
1. Define metal forming process and differentiate between Cold and Hot
working.
2. Write all require parameters and relation between radius of roller and
thickness of work piece in rolling. Also explain types of rollers.
3. Explain all rolling defect with required neat sketch.
4. Defference between Smithy and Forging. Types of forging operation
and forging defect.
5. Sketch and describe the following forging tools
(i) Anvil. (ii) Swage Block, (iii) Set hammers (iv) Punches, (v) Drift,
and (vi) Hardie
6. Explain with neat sketches the following forging operations:
(i) Upsetting, (ii) Drawing down, (iii) Bending,
(iv) Drifting, (v) Punching, (vi) Welding
(vii) Fullering
7. Extrusion is one of the metal forming process, how? And also describe
with their types. Discuss their relative merits and demerits of different
kind of extrusion.
8. What is Drawing? And what is the drawing product? Explain any.
9. Describe type of Sheet metal forming processes and their categories.
10.
Write short notes on:
(a) Punching (b) Piercing (c) Blanking (d) Slitting (e) Bending (f)
Lancing
11.
Difference between High Energy Rate Forming Processes and
Explosive Forming process with the reference of processing, properties
and ecconomical.
12.
Write notes on Electro Hydraulic Forming and Electro Magnetic
Forming.
13.
Which type of metal forming process is more ecconomical and
why?

Unit IV: Processing of Powder Metals, Ceramics and Glass (Model

Tutorial question)
1.What do you under stand by powder metallurgy? What are the main stages
of powder metallurgy process?
2. What important considerations should be made in designing the powder
metallurgy products?
3. Explain the objectives of powder compaction and list important products
of powder metallurgy.
4. Describe briefly the methods by which powders suitable for powder
metallurgy can be produced. Also enumerate the main characteristics of metal
powder.
5. Describe the atomization process of making powder in detail.
6. What are the effects of sintering on the powder compact produced by
pressing?
7. Describe the process of blending, compacting and sintering in detail.
8. What are the effects of sintering on the powder compact produced by
pressing?
9. Name the products of powder metallurgy.
10. List the advantages, dis-advantages and applications of powder
metallurgy process.
11. It is necessary to use lubricants in the press compaction of powders?
Explain.
12. What are cermets? Give a few examples of useful applications
13. State briefly the process of making a powder metallurgy product having
improved properties.
14. What are cemented carbides? How are they processed?
Unit V: Processing of Plastics and Composite Materials (Model
Tutorial question)
1. Define plastics and what is the basic difference between plastics and
metals.
2. Describe Types of Plastics with apropiriate application.
3. What is the plastic manufacturing process?
4. What is molding and their typs?

5. What is the application of molding in plastic manufacturing.

6. Difference between Injection molding and Blow molding on the basis
of process flow and product.
7. Write short notes on:
(i) Compression molding
(ii) Transfer molding
(iii) Thermoforming
(iv) Reinforced plastics
8. What is composite. And what is the main difference between
metal/alloys and composite.
9. The main difference between Metal Matrix Composites and Ceramic
Matrix Composites.
10.
Write application of these:
(i) Reinforced plastics
(ii) Metal Matrix Composites
(iii) Ceramic Matrix Composites
Module VI: Rapid Prototyping and Tooling (Model Tutorial question)
1. What do you mean by Prototyping.
2. Write different prototype process with required application.
3. What is Rapid Tooling techniques? Describe with proper application.