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Shell Moulding

Special Casting
By S K Mondal

The sand is mixed with a thermosetting resin is


allowed to come in contact with a heated metal pattern
(2000C).
A skin (shell) of about 3.5 mm of sand and plastic
mixture adhere to the pattern.
Then the shell is removed from the pattern.
The cope and drag shells are kept in a f lask with
necessary backup material and the molten metal is
poured into the mold.

Can produce complex parts.


A good surface finish and good size tolerance

reduce the need for machining.


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

Shell moulding process

Molding Sand in Shell Molding

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

The molding sand is a mixture of fine grained quartz sand

soluble phenol formaldehyde resin is added. The mixer is

and powdered bakelite.


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.

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

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

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Advantages

Limitations

Dimensional accuracy.

Expensive pattern

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

Small size casting only.

Very thin sections can be cast.

Highly complicated shapes cannot be obtained.

Very small amount of sand is needed.

More sophisticated equipment is needed for handling

the shell moldings.

Applications
Cylinders and cylinder heads for air- cooled IC

engines
Automobile transmission parts.
Piston rings

IES 2010
Consider the following advantages of shell
mould casting:
1. Close dimensional tolerance.
2. Good surface finish.
3. Low cost.
4. Easier.
Which of these are correct?
(a) 1, 2 and 3 only
(b) 2, 3 and 4 only
(c) 1, 2 and 4 only
(d) 1, 2, 3 and 4

IES-1996

IES-2005

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

In shell moulding, how can the shell thickness


be accurately maintained?
(a) By controlling the time during which the pattern
is in contact with mould
(b) By controlling the time during which the pattern
is heated
(c) By maintaining the temperature of the pattern in
the range of 175oC 380oC
(d) By the type of binder used

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IES-2006
Shell moulding can be used for:
(a) Producing milling cutters
(b) Making gold ornaments
(c) Producing heavy and thick walled casting
(d) Producing thin casting

IAS-2007
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

IES 2007
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

IAS-1999
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

Investment Casting
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. 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. Investment flask-casting procedure

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Ceramic Shell Investment Casting


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).
After each dipping and stuccoing is completed, the

assembly is allowed to thoroughly dry before the next


coating is applied.

IES 2009
2 marks

Advantages

Limitations

Tight dimensional tolerances


Costly patterns and moulds

Excellent surface finish (1.2 to 3.0 m )


Machining

can

be

reduced

or

completely

eliminated

Labour costs can be high


Limited size

High melting point alloy can be cast, almost any

metal can be cast


Almost unlimited intricacy

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

GATE-2006
An expendable pattern is used in
(a) Slush casting
(b) Squeeze casting
(c) Centrifugal casting
(d) Investment casting

IES 2011
The proper sequence of investment casting steps is :
(a) Slurry coating pattern melt out-Shakeout 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

GATE-2011 (PI)
Which of the following casting processes uses
expendable pattern and expendable mould?
(a) Shell mould casting
(b) Investment casting
(c) Pressure die casting
(d) Centrifugal casting

ISRO-2010
Investment casting is used for
(a) Shapes which are made by difficulty using complex
patterns in sand casting
(b) Mass production

IES-1992
The most preferred process for casting gas turbine
blades is:
(a) Die moulding
(b) Shell moulding
(c) Investment moulding
(d) Sand casting

(c) Shapes which are very complex and intricate and


can't be cast by any other method
(d) There is nothing like investment casting

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JWM 2010
Consider the following materials :
1. Wax
2. Wood
3. Plastic
Which of these materials can be used as pattern in
investment casting process ?
(a) 1, 2 and 3
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only

IES 2007
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

IAS-1996
Light and intricate parts with close dimensional
tolerances of the order of 0.005 mm are
produced by
(a) Investment casting
(b) Die casting
(c) Centrifugal casting
(d) Shell mould casting

IES 2010
Assertion (A): The 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

IES-2006
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

Permanent Mould Casting


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.
Some time in die-casting we inject the molten metal
with a high pressure. When we apply pressure in
injecting the metal it is called pressure die casting
process.
Grey cast iron is used for mould material.

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Advantages

Disadvantages

Good surface finish and dimensional accuracy


Metal mold gives rapid cooling and fine-grain
structure

High initial mold cost


Shape, size, and complexity are limited
Mold life is very limited with high-melting-point

Multiple-use molds.

metals such as steel.


Low melting point metals can be cast

Applications
Pistons/cylinders/rods

Aluminum
Zinc
Magnesium alloys
Brass
Cast iron

Die Casting
Molten metal is injected into closed metal dies under

pressures ranging from 100 to 150 MPa.

Gears

Pressure is maintained during solidification

Kitchenware

After which the dies separate and the casting is ejected

along with its attached sprues and runners.


Cores must be simple and retractable and take the

form of moving metal segments

Die casting machines can be


Video

Hot chamber
Cold chamber

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Hot chamber machines are


Good for low temperature (approx. 400C)
Faster than cold chamber machines
Cycle times must be short to minimize metal
contamination
Metal starts in a heated cylinder
A piston forces metal into the die
The piston retracts, and draws metal in
Metal: Lead, Tin, Zinc

Hot Chamber

Cold chamber machines


Casts high melting point metals ( > 600C)
High pressures used
Metal is heated in a separate crucible
Metal is ladled into a cold chamber
The metal is rapidly forced into the mold before it

cools
Copper, Brass and Aluminium can cast.

Advantages
Extremely smooth surfaces (1 m)
Excellent dimensional accuracy
Rapid production rate
Better mechanical properties compared to sand

casting
Intricate parts possible
Minimum finishing operations
Thin sections possible

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Limitations
High initial die cost
Limited to high-fluidity nonferrous metals

Applications
Carburettors
Automotive parts
Bathroom fixtures
Toys

Part size is limited


Porosity may be a problem
Some scrap in sprues, runners, and flash, but this can

be directly recycled

IES 2011
Consider the following advantages of die casting over
sand casting :
1. Rapidity of the process
2. Smooth surface
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

JWM 2010
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) 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

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

IES-2009
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

IES-2005
Which one of the following processes produces a
casting when pressure forces the molten metal
into the mould cavity?
(a) Shell moulding
(b) Investment casting
(c) Die casting
(d) Continuous casting

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IES-2006
In which of the following are metal moulds used?
(a) Greensand mould
(b) Dry sand mould
(c) Die casting process
(d) Loam moulding

IES-1995
Match List I with List II and select the correct answer taking the help
of codes given below the lists:
List I
List II
(Products)
(Process of manufacture)
A.
Automobile piston in aluminium alloy
1. Pressure die-casting
B.
Engine crankshaft in spheroidal
graphite iron
2. Gravity die-casting
C.
Carburettor housing in aluminium alloy 3. Sand casting
D.
Cast titanium blades
4. Precision investment
casting
5. Shell moulding
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

IAS-1996
Assertion (A): Die casting yields a product of good
accuracy and finish.
Reason (R): Low melting alloys used in die
casting.
(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

IES-1995
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 its fluidity 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

IAS-2007
Consider the following statements:
1. Zinc die castings have low strength.
2. In the die casting process, very thin sections or
complex shapes can be obtained easily.
Which of the statements given above is/are correct?
(a) 1 only
(b) 2 only
(c) Both 1 and 2
(d) Neither 1 nor 2

IES 2011
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

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IES-1995

GATE-2007
Which of the following engineering materials is
the most suitable candidate for hot chamber die
casting?
(a) Low carbon steel
(b) Titanium
(c) Copper
(d) Tin

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

GATE -2009 (PI)


Hot chamber die casting process is NOT suited for
(a) Lead and its alloy
(b) Zinc and its alloy
(c) Tin and its alloy
(d) Aluminum and its alloy

Centrifugal Casting
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
A mold is set up and rotated along a vertical (rpm is

reasonable), or horizontal (200-1000 rpm is reasonable)


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

towards the center of rotation.

Fig. True centrifugal casting

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Properties

Advantages

The mechanical properties of centrifugally cast jobs are

Fine grained structure at the outer surface of the


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

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 on the metal throughout the solidification
causes the porosity to be eliminated giving rise to dense
metal.
No cores are required for making concentric holes in the
case of true centrifugal casting.

Limitations
More segregation of alloy component during pouring under

the forces of rotation


Contamination of internal surface of castings with non-

Common metals

Iron
steel
stainless steel
alloys of aluminium, copper, and nickel

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

GATE-2002
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

GATE-1993
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

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IES-2008

GATE -2008 (PI)


In hollow cylindrical parts, made by centrifugal casting,
the density of the part is
(a) maximum at the outer region
(b) maximum at the inner region
(c) maximum at the mid-point between outer and inner
surfaces

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
Select the correct answer using the code given below:
(a) 1 and 2
(b) 2 only
(c) 2 and 3
(d) 3 only

(d) uniform throughout

IES-2009

IES 2007

Which one of the following casting processes is


best

suited

to

make

bigger

size

hollow

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

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

IES-1998
Poor machinability of centrifugally cast iron pipe
is due to
(a) Chilling
(b) Segregation
(c) Dense structure
(d) High mould rotation speed

IES-2009
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

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IES 2007

IES-2000

Match List I with List II and select the correct answer using the code given
below the Lists:
List I
List II
(Casting Process)
(Principle)
A.
Die casting
1.The metal solidifies in a rotating mould
B.
Investment casting
2.The pattern cluster is repeatedly dipped
into a ceramic slurry and dusted with
refractory
C.
Shell moulding
3. Molten metal is forced by pressure into
a metallic mould
D.
Centrifugal casting
4. After cooling, the invest is removed
from the Casting by pressure jetting or
vibratory cleaning
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

Match List I (Process) with List II (Products/materials)


and select the correct answer using the codes given
below the Lists:
List I
List II
A. Die casting
1. Phenol formaldehyde
B. Shell molding
2. C.I. pipes
C. CO2 molding
3. Non-ferrous alloys
D. Centrifugal casting
4. Sodium silicate
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

IAS-2004

Semi-centrifugal Casting
Centrifugal force assists the flow of metal from a

Match List-I (Name of the Process) with List-II (Advantage) and select the correct
answer using the codes given below the lists:
List-I
List-II
(Name of the Process)
(Advantage)
A.
Sand Casting
1. Large cylindrical parts with good quality
B.
Ceramic mold casting
2.Excellent dimensional accuracy and surface
finish
C.
Die casting
3. Intricate shapes and close tolerance parts
D.
Centrifugal casting
4. Almost any metal is cast and there if no limit to
size, shape and weight
5. Good dimensional accuracy, finish and low
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 mold, which may be either expendable or
multiple-use
Rotational speeds are lower than for true centrifugal

casting
Cores can be used to increase the complexity of the

product.

IAS-2003
Assertion (A): Semi-centrifugal casting process is
similar to true centrifugal casting except that the
central core is used in it to form inner surface.
Reason (R): In semi-centrifugal casting process the
axis of spin is always 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. Semi-centrifugal casting

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Centrifuging
Uses centrifuging action to force the metal from a central

pouring reservoir into separate mold cavities that are


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

trees.

Fig. Method of casting by the centrifuging process

IES-2000
Match List I (Type of casting) with List II (Working principles)
and select the correct answer using the codes given below the
Lists:
List I
List II
A. Die casting
1. Molten metal is forced into the die
under pressure
B. Centrifugal casting
2. Axis of rotation does not coincide with
axis of mould
C. Centrifuging
3. Metal solidifies when mould is rotating
D. Continuous casting 4. Continuously pouring molten metal
into mould
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

Slush Casting
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.
The mold is then inverted and the remaining liquid is
poured out.
When the mold halves are separated, the resulting casting
is a hollow shape with good surface detail but variable wall
thickness.
Frequently used to cast low-melting-temperature metals
into ornamental objects such as candlesticks, lamp bases,
and statuary.

Dry Sand Molding


To reduce gas forming materials air dried mould used.

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

IAS-2004
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

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IES 2011
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

IES - 2012
The process of making hollow castings of non-circular
shape and desired thickness by permanent mould
without the use of cores is known as
(a) Die casting
(b) Slush casting
(c) Pressed casting
(d) Centrifugal casting

Squeeze Casting

IAS-2002

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
and die while the part solidifies.
4.The punch is retracted, and the part is knocked out
with an ejector pin.
Overcomes problems with feeding the die, and
produces near net, highly detailed parts.

Match List I (Casting Process) with List II


(Applications) and select the correct answer using the
codes given below the Lists:
List I
List II
(Casting Process)
(Applications)
A. Centrifugal casting
1.
Carburetor
B. Squeeze casting
2.
Pipes
C. Die Casting
3.
Wheels for
automobiles
4.
Gear housings
Codes: A
B
C
A
B
C
(a) 2
3
1
(b) 4
1
3
(c) 2
1
3
(d) 4
3
1

Single Crystal Casting


The process is effectively:
1. Prepare a mold so that one end is a heated oven, and
the other end chilled. The part should be oriented so
that the cooling happens over the longest distance.
2. Cast metal into the mold
3. Solidification will begin at the chill plate. These
dendrites will grow towards the heated end of the
part as long dendritic crystals. The part is slowly
pulled out of the oven, past the chill plate.
4. Remove the solidified part.

Creep and thermal shock resistance properties.

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IES 2009

Plaster Casting
Process: A slurry of plaster, water, and various additives is

2 marks

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 is removed.
Advantage: High dimensional accuracy and smooth
surface finish, thin sections and intricate detail can
produce.
Limitations: Lower-temperature nonferrous metals only:
Common metals: Primarily aluminium and copper

Pit Moulding

IES-1996

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

Which of the following pairs are correctly matched?


1. Pit moulding ..................For large jobs.
2. Investment moulding ... Lost wax process.
3. Plaster moulding Mould prepared in
gypsum.
(a) 1, 2 and 3 (b) 1 and 2
(c) 1 and 3
(d) 2 and 3

the foundry floor.

Loam Moulding
Moulding loam is generally artificially composed of

common brick-clay, and sharp sand.


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

IES-1997
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

cast conveniently in any other process.


It is costly.

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GATE-1998
List I
(A) Sand casting
circular shapes only
(B) Plaster mould casting
skins and soft interior
(C) Shell mould casting
casting processing
(D) Investment casting

List II
(1)
Symmetrical and
(2)

Parts have hardened

(3)

Minimum post-

(4)

Parts have a tendency


to warp
Parts have soft skin
and hard interior
Suitable only for nonferrous metals

(5)
(6)

GATE-1996
List I
(A) Rivets for aircraft body
(B) Carburettor body
(C) Crankshafts
(D) Nails

List II
1.
Forging
2.
Cold heading
3.
Aluminium-based
alloy
4.
Pressure die casting
5.
Investment casting

IES-1993
Match the items of List I (Equipment) with the items
of List II (Process) and select the correct answer using
the given codes.
List I (Equipment)
List II (Process)
P - Hot Chamber Machine
1.
Cleaning
Q - Muller
2.
Core making
R - Dielectric Baker
3.
Die casting
S - Sand Blaster
4.
Annealing
5.
Sand mixing
(a) P-2, Q-1, R-4, S-5
(b) P-4, Q-2, R-3, S-5
(c) P-4, Q-5, R-1, S-2
(d) P-3, Q-5, R-2, S-1

GATE-1992
Match the following moulding/casting processes with
the product:
Moulding/Casting processes
Product
(A) Slush casting
(P) Turbine blade
(B) Shell moulding
(Q) Machine tool bed
(C) Dry sand moulding
(R) Cylinder block
(D) Centrifugal casting
(S) Hollow castings
like lamp shades
(T) Rain water pipe
(U) Cast iron shoe
brake

IES-2003
Match List I (Products) with List II (Casting Process) and select
the correct answer using the codes given below the Lists:
List I
List II
(Products)
(Casting Process)
A. Hollow statues
1.
Centrifugal Casting
B. Dentures
2.
Investment Casting
C. Aluminium alloy pistons
3.
Slush Casting
D. Rocker arms
4.
Shell Moulding
5.
Gravity Die Casting
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

IAS-2004
Match List-I (Name of the Casting Process) with List-II (Process Definition) and select
the correct answer using the codes given below the lists:
List-I
List-II
(Name of the Casting Process)
(Process Definition)
A.
Die casting
1.This process involves use of a mould made of
Dried silica sand and phenolicresin mixture
B.
Electroslagcasting
2. In this process, molten metal is forced by
Pressure into a metal mould
C.
Centrifugal casting
3. This process employs a consumable electrode
D.
Precision casting
4. This process involves rotating a mould while the
metal solidifies
5. This process produces very smooth, highly
Accurate castings from both ferrous and non
ferrous alloys
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

18

1/5/2014

GATE 2007 (PI)


Match the lists

Group-1
P. Sand Casting
Q. Centrifugal Casting
R. Investment Casting
S. Die Casting

Group-2
1. Turbine blades
2. IC Engine Pistons
3. Large bells
4. Pulleys

(a) P 4, Q 1, R 3, S 2
(c) P 3, Q 4, R 1, S 2

(b) P 2, Q 4, R 3, S - 1
(d) P 3, Q 2, R 1, S - 4

Conventional Casting Process Ch-21

Special Casting Process Ch-22

Q. No

Option

Q. No

Option

13

Q. No

Option

14

15

16

Q. No

Option

11

12

13

17

18

14

19

15

20

16

17

21

10

11

10

12

19