Code No: R05321804 Set No.

1
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY TECHNOLOGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. (a) Explain why allowances for the following are made in pattern making: the
shrinkage allowance, draft allowance, machining allowance, and distortion al-
lowance.
(b) What is the function of pattern coatings?
(c) What are the advantages of expanded polystyrene patterns? [8+4+4]

2. (a) What properties make the use of shell cores popular over oil sand cores?
(b) If the cores are to be made more permeable, what are the methods to do so?
(c) How do you measure the scratch hardness of a baked core?
(d) Why are releasing agents used in core making. [5+4+4+3]

3. (a) Explain an operating cycle of manually operated permanent mold casting ma-
chine.
(b) How do turntables in automated permanent mold casting machines facilitate
operations pouring, mold coating, core setting, solidification, and ejection done
in a sequential and reproducible fashion? [7+9]

4. (a) If the requirement is to feed a number of casting cavities from a common

runner, which gating system is advantageous? Why.
(b) What is the role of choke in a gating system?. How do you determine the
choke area?
(c) List and explain the methods by which directional solidification is ensured in
molds filled with liquid metal? [5+5+6]

5. (a) Why is solidification retarded at internal angles of a casting? What practical

problems do you think this effect might cause?
(b) Why is the rate of solidification of a sand casting important? [10+6]

6. Explain the reasons for the following in cupola operation:

(a) Bridging
(b) Low metal temperature and
(c) Low melting rate. [16]

7. Distinguish between the stages of production of sand cores and the cores using
furan no bake sand. [16]

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Code No: R05321804 Set No. 1
8. What are the castings defects attributed for mishandling and bad preparation of
cores? How could these defects be eliminated? [16]

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Code No: R05321804 Set No. 2
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY TECHNOLOGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Explain how properly mulled aggregate of sand particles, bentonite and water
system attains the mix of properties suitable for molding.
(b) Explain how the mulling action is different from that of mixing in a mixer.
[10+6]
2. (a) Explain how shell cores are made. Explain how you judge that the shell cores
are properly baked.
(b) Explain properties required of core sands? What additives are made to core
sands and how do they condition the properties? [8+8]
3. What are limitations of gravity die casting process on product shape, size, and
melting point, physical properties like thermal diffusivity? [16]
4. Write short notes on:
(a) Antipiping compounds
(b) Whirl gate
(c) Formation of dendrites. [6+5+5]
5. (a) What types of alloys are most likely to exhibit pipe and center line shrinkage?
List four commercially used alloys of this type.
(b) In sand cast bronze valves, chills are frequently used in the region where the
valve seat is to be machined. Discuss briefly. [10+6]
6. (a) What is carbon equivalent and how does it affect the various properties of cast
iron?
(b) What are the elements added to obtain white iron castings of higher section
thickness? [8+8]
7. Discuss the low head type of continuous casting machine and discuss its applica-
tions. [16]
8. (a) How the hot-tears are formed in the castings? State the reasons for their
occurrence and suggest the remedies for their control.
(b) Why the cores do not float in Aluminium castings? Explain how do you
calculate the chaplet area for supporting the cores. [8+8]

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Code No: R05321804 Set No. 3
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY TECHNOLOGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) A cast iron jobbing foundry need to make 50 pieces of axisymmetric shell
castings (dimensions 2000mm internal diameter and height 601 mm). The
average shell thickness is 35 mm. What should be the pattern material?
Justify your choice. If the external profile of this casting require usage of a
concentric outer core, what should be the core material?
(b) What general factors decide the parting line (plane) in the production of the
pattern of a cored casting?
(c) Usage of a vertical core is necessary to produce the internal detail in a hollow
surface of a steel casting. What measures do you take against flotation of core
under high metallostatic pressure. [6+5+5]

2. Explain the basic steps of conventional plaster molding process. Explain its advan-
tages over sand molding processes. [16]

3. Explain how metal is injected into the die in die casting? Explain the construction
of gating system feeding the liquid metal to mold cavity in a

(a) cold chamber process

(b) hot chamber process. [8+8]

4. (a) Which gating system is likely to deliver metal like fountain to mold cavity?
What are possible effects of this type of metal delivery on casting quality?
(b) Under what conditions grain growth in cast products is likely?
(c) State Bernoullis principle and explain how it is useful in gating design?
(d) With suitable sketches explain the design rules for riser neck of
i. general side riser,
ii. Side riser for a plate casting,
iii. for a top round riser. [5+3+4+4]

5. (a) How do you control the rate of flow of metals in moulds? Explain.
(b) What is centerline feeding resistance of the castings? Discuss its importance.
[8+8]

6. (a) What are the functions of flux in melting metals and alloys?
(b) Describe the constructional features of cupola furnace. [6+10]

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Code No: R05321804 Set No. 3
7. (a) What is a ‘dummy plug bar’ and what is its function in continuous casting
process?
(b) Suggest what steps to be taken in reducing the expenses using furan sands.
[8+8]

8. What are the castings defects attributed for mishandling and bad preparation of
cores? How could these defects be eliminated? [16]

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Code No: R05321804 Set No. 4
III B.Tech Supplimentary Examinations, Aug/Sep 2008
FOUNDRY TECHNOLOGY
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Explain a general classification of the patterns into different kinds

(b) What is loam molding? How it is done?
(c) Discuss the suitability of following as candidate materials for making patterns
: wood, polystyrene, aluminum, steel, graphite, lead. [5+4+7]
2. (a) Explain the basic steps of Vacuum molding process? What advantages are
claimed for it.
(b) Match plate patterns are cast by plaster molding. What advantages of plaster
molding prompt this selection? [8+8]
3. (a) Explain an operating cycle of manually operated permanent mold casting ma-
chine.
(b) How do turntables in automated permanent mold casting machines facilitate
operations pouring, mold coating, core setting, solidification, and ejection done
in a sequential and reproducible fashion? [7+9]
4. (a) What is the function of sprue well? How do you eliminate the possibility of
sand abrasion at the bottom of sprue well?
(b) Sketch a drag runner and cope ingates in a gating system. What are its merits
and demerits?
(c) What are the disadvantages of bottom gating. [6+5+5]
5. (a) Distinguish between equiaxed and columnar grains in a solidified metal struc-
ture.
(b) With the help of a phase diagram explain the solidification of hypo and hy-
pereutectic cast iron. [8+8]
6. Explain the reasons for the following in cupola operation:
(a) Bridging
(b) Low metal temperature and
(c) Low melting rate. [16]
7. Classify the various cold setting processes and explain the principle and operation
of any one of the process. [16]
8. (a) List six defects more commonly found in castings and discuss how they could
be avoided.

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Code No: R05321804 Set No. 4
(b) What are the causes for sand inclusion? How can they be prevented? [8+8]

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