EAL Level 3 Diploma in Engineering Technology

QETA/064: Consumable Mould Casting Processes

Unit 064.3 Chemically Bonded Sand-Multiple Choice Question Paper
Candidate Name Candidate No.
Date Attempt No.
10 Marks

1. Which of the following is not a chemically bonded system? (Tick)

a. No bake
b. Greensand
c. Gas cured cold box
d. Hot box heat activated curing
2. What is the normal method of mixing furan bonded sand? (Tick)

a. Bucket and spade

b. Cement mixer
c. Screw blade continuous mixer
d. It is supplied ‘ready mixed’
3. What is a catalyst? (Tick)

a. Material that initiates the setting reaction

b. Acid used to bind the sand
c. A gas applied to the sand to improve permeability
d. Material that generates heat in the sand
4. Sodium Silicate is sometimes referred to as? (Tick)

a. Furan
b. The CO2 process
c. Glass bonded process
d. Petrobond
5. Which of the following is an inorganic binding system? (Tick)

a. Alkaline Phenolic
b. Sodium Silicate
c. Furfuryl Alcohol
d. Phenol Formaldehyde
6. Which of the following is an organic binding material? (Tick)

a. Alumina Phosphate
b. Sodium Silicate
c. Cement
d. Phenol Formaldehyde
7. What materials can be cast into chemically bonded moulds? (Tick)

a. All non-ferrous metals such as copper, brass & tin

b. Limited to grey iron, sg/ductile Iron, alloyed steel, carbon steel and stainless steel
c. Most metals - when good foundry processes are applied, or mould coatings are used
d. All ferrous and most non-ferrous metals - excluding titanium

Unit 064.3 Chemically Bonded Sand-Multiple Choice Question Paper

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EAL Level 3 Diploma in Engineering Technology
QETA/064: Consumable Mould Casting Processes
8. Which of the following is a gas cured binder system? (Tick)

a. Alkaline Phenolic + Ester

b. Phenolic Urethane + MDI + Amine
c. Furfuryl alcohol + Sulphonic acid
d. Acrylic Epoxy
9. Which of the following sand types has the greatest linear expansion? (Tick)

a. Olivine
b. Silica
c. Zircon
d. Chromite
10. What is the first requirement in calibrating a continuous mixer? (Tick)

a. Calculate how much sand is needed

b. Set the binder pump flow rate
c. Determine sand flow
d. Set catalyst flow rate
Candidates and/or Assessors Comments

Assessor Signature
Unit 64.3 Multiple Choice Questions Total /10
Pass Mark 60%. Date of re-assessment (if applicable)

Unit 064.3 Chemically Bonded Sand-Short Answer Question Paper

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EAL Level 3 Diploma in Engineering Technology
QETA/064: Consumable Mould Casting Processes
Candidate Name Candidate No.
Date Attempt No.
90 Marks
1. Explain the advantages and limitations of using chemically bonded sand
compared with using greensand? (Consider cost comparisons, rigidity of moulds,
30
pattern construction, thin section capability, COSHH requirements, and surface
finish)

Unit 064.3 Chemically Bonded Sand-Short Answer Question Paper

1. continued… See

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EAL Level 3 Diploma in Engineering Technology
QETA/064: Consumable Mould Casting Processes
above

2. No Bake Sand Systems

a) Explain the term ‘Nobake’?
b) Give two examples of gas activated Nobake systems and two examples of liquid
10
activated Nobake systems

Unit 064.3 Chemically Bonded Sand-Short Answer Question Paper

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EAL Level 3 Diploma in Engineering Technology
QETA/064: Consumable Mould Casting Processes
3. Answer the following relating to chemically bonded sand
a) What are the normal constituents of organic chemically bonded sand?
b) Give two examples of organic resins
20
c) Give three examples of organic resin binder catalysts
d) Give three examples of Non-binding additives
e) Foundry practice often refers to organic binding systems as what?

4. Relating to ‘heat activated curing’, explain the difference between ‘hot box’ and
‘warm box’ binding processes? (With reference to typical constituents and curing 10
temperatures)

Unit 064.3 Chemically Bonded Sand-Short Answer Question Paper

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EAL Level 3 Diploma in Engineering Technology
QETA/064: Consumable Mould Casting Processes
5. Relating to coldbox process answer the following:
a) Explain the methods of core production using the ‘coldbox’ process
b) Identify the tooling materials 20
c) Identify the binder and catalyst in a vapour cured cold box system.
d) Identify the binder and catalyst in two gas cured cold box systems.

Candidates and/or Assessors Comments

Assessor Signature
Multiple Choice Answer Marks /10
Short Answer Marks /90
Unit 64.3 Total Marks /100
Pass Mark 60%. Date of re-assessment (if applicable)

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