Minor-1 Exam of MCL131

Date: 14th February 2022

Time: 08:30 Hrs. to 09:30 Hrs.
Buffer Time for uploading the answer scripts on Moodle: 15 Mins (i.e., till 09:45 Hrs.)
Total Marks: 50
It is mandatory to answer all questions.
Marks Distribution: [Q1: 16 marks; Q2: 14 marks; Q3: 20 marks]

Note: The question paper contains 3 pages (excluding this page)

The answers must be written on a notebook. Take the snapshot of all the answers and
upload it on Moodle in PDF format

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 Question Paper
Q1.
(a) What are the criteria to be used for designing the pouring basin? Describe the types of
risers and their uses with suitable sketches. What are the essential conditions that are to
be kept in mind while designing risers? [Marks: 4]

(b) Refer to the following casting defect, as shown in the figure. Write down the type and
cause of the defect. Suggest a feasible remedy to rectify the same. [Marks: 4]

(c) It is intended to heat pure copper for casting a large plate in an open mould. The plate
dimensions are: (a) length 20 in, (b) width 10 in, and (c) depth 3 inch. Compute the
amount of heat that is required to heat the metal to a pouring temperature of 2150 F.
Assume that the amount of metal heated will be 10% more than needed to fill the mould
cavity. Properties of the metal are density = 0.324 lbm/in3, melting point = 1981 F,
specific heat of the metal = 0.093 Btu/lbm-F in the solid state and 0.090 Btu/lbm-F in
the liquid state, and the heat of fusion = 80 Btu/lbm. Assume the ambient temperature
to be 24 0C. Calculate the values up to two significant digits after decimal. [Marks: 6]

(d) Answer the following: [Marks: 2]

i. If a true centrifugal casting operation were to be performed in a space station circling
the Earth, how would weightlessness affect the process?
ii. Describe the drawbacks to having a riser that is (a) too large, and (b) too small.

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Q2.
(a) True centrifugal casting is performed horizontally to make large diameter copper tube
sections. The tubes have a length = 1.0 m, diameter = 0.25 m, and wall thickness = 15
mm. (a) If the rotational speed of the pipe = 700 rev/min, determine the G-factor on the
molten metal. (b) Is the rotational speed sufficient to avoid ‘‘rain?’’ (c) What volume
of molten metal must be poured into the mould to make the casting if solidification
shrinkage and contraction after solidification are considered? Solidification shrinkage
for copper = 4.5%, and solid thermal contraction = 7.5%. [Marks: 7]

(b) A 65 wt% Ni–35 wt% Cu alloy is heated to a temperature within the α + liquid-phase
region. If the composition of the α phase is 70 wt% Ni, determine: [Marks: 7]
a) The temperature of the alloy
b) The composition of the liquid phase
c) The mass fractions of both phases

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Q3.
(a) What are the advantages and disadvantages of welding compared to other types of
assembly operations? Please explain the fundamental differences between a fusion weld
and a solid-state weld? Why is it desirable to use energy sources having high power
densities for fusion welding? [Marks: 6]

(b) What are the reasons why most fusion welding operations are inherently dangerous?
Please explain with potential hazards in gas welding, resistance welding and arc welding
processes. What three types of flames can be produced by varying the oxygen-acetylene
ratio? Please explain with gas volume ratio. [Marks: 6]

(c) A fillet weld on low carbon steel has a cross-sectional area of 20 mm2 and is 225 mm
long. Determine the (a) amount of heat required to perform the weld, and (b) amount of
heat that must be generated by the heat source, if the heat transfer factor = 0.9 and
melting factor 0.6, assuming the melting temperature of the low carbon steel 1487 °C.
[Marks: 4]

(d) A resistance-welding operation is performed on two pieces of 1.5-mm-thick sheet steel

using 9,000 amps for a 0.20 s duration. The electrodes are 6 mm in diameter at the
contacting surfaces. Resistance is assumed to be 0.0001 Ω, and the resulting weld nugget
= 6 mm in diameter and averages 3 mm in thickness. The unit melting energy for the
metal Um = 12.0 J/mm3. How much of the heat generated was used to form the weld
nugget, and how much was dissipated into the work metal, electrodes, and surrounding
air? [Marks: 4]