Master Metal Casting Techniques: Online Quizzes for Advanced Diploma in Engineering

Question 1

Which of the following is a key limitation of sand casting compared to other casting methods?

Accepted Answer

Lower dimensional accuracy

Answer

Inability to produce complex shapes

Answer

High production cost

Answer

Limited to small batch production

Question 2

Investment casting is primarily used for producing components that:

Accepted Answer

Require intricate surface details

Answer

Are made of materials with high melting points

Answer

Demand high strength

Answer

Are produced in large quantities

Question 3

Centrifugal casting is most suitable for producing components that are:

Accepted Answer

Hollow and cylindrical

Answer

Flat and thin

Answer

Complex and intricate

Answer

Large and heavy

Question 4

Die casting molds are commonly made of:

Accepted Answer

Steel

Answer

Aluminum

Answer

Copper

Answer

Iron

Question 5

Which type of casting method is particularly suitable for producing pipes and tubes?

Accepted Answer

Centrifugal casting

Answer

Die casting

Answer

Investment casting

Answer

Sand casting

Question 6

Which casting process is most suitable for producing intricate shapes with precise dimensions?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Die casting

Answer

Centrifugal casting

Question 7

Which of the following is **not** a primary **type** of metal casting process?

Accepted Answer

Forging

Answer

Sand casting

Answer

Investment casting

Answer

Continuous casting

Question 8

What is the primary **function** of the sprue in a sand casting mold?

Accepted Answer

To provide a passage for molten metal to enter the mold

Answer

To form the casting cavity

Answer

To support the cope and drag

Answer

To create a vacuum to draw molten metal into the mold

Question 9

Which of the following materials is commonly used for investment casting?

Accepted Answer

Ceramic

Answer

Plaster

Answer

Sand

Answer

Metal

Question 10

What is the purpose of a riser in a casting?

Accepted Answer

To provide extra metal to compensate for shrinkage during solidification

Answer

To create a vacuum to draw molten metal into the mold

Answer

To support the mold during pouring

Answer

To enhance the cooling rate of the casting

Question 11

Which of the following is a common casting defect **caused by** the presence of gas?

Accepted Answer

Blowholes

Answer

Shrinkage cavities

Answer

Cold shuts

Answer

Hot tears

Question 12

What is the primary **role** of a binder in a sand casting mold?

Accepted Answer

To hold the sand particles together

Answer

To create a smooth surface for the casting

Answer

To increase the strength of the mold

Answer

To reduce the mold's porosity

Question 13

Which of the following is **not** a consideration when selecting a casting method?

Accepted Answer

Environmental regulations

Answer

Production volume

Answer

Material properties

Answer

Casting size

Question 14

What is the main **advantage** of continuous casting over other casting processes?

Accepted Answer

Continuous production

Answer

Lower cost

Answer

Better quality

Answer

Wider range of materials

Question 15

What is the primary purpose of a sprue in a casting system?

Accepted Answer

To provide a passage for molten metal to enter the mold cavity

Answer

To create a vacuum to draw molten metal into the mold

Answer

To cool the molten metal as it enters the mold

Answer

To filter out impurities from the molten metal

Question 16

Which of the following materials is used as the pattern material in investment casting?

Accepted Answer

Wax

Answer

Ceramic

Answer

Metal

Question 17

What is the purpose of a chill in a casting mold?

Accepted Answer

To accelerate solidification in a specific area

Answer

To prevent shrinkage porosity

Answer

To improve the surface finish

Answer

To create a decorative effect

Question 18

What is the primary role of flux in continuous casting?

Accepted Answer

To protect the molten metal from oxidation

Answer

To lubricate the mold

Answer

To control the solidification rate

Answer

To improve the surface finish

Question 19

Which casting process involves pouring molten metal into a mold made of sand and binders?

Accepted Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Answer

Continuous casting

Question 20

Which casting method is best suited for producing continuous shapes, such as bars and pipes?

Accepted Answer

Continuous casting

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 21

What is the primary function of a sprue in a casting mold?

Accepted Answer

To control the flow of molten metal into the mold cavity

Answer

To allow gases to escape from the mold

Answer

To provide support for the casting

Answer

To improve the surface finish of the casting

Question 22

Which factor has the greatest impact on the solidification rate of a casting?

Accepted Answer

Casting thickness

Answer

Mold material

Answer

Molten metal temperature

Answer

Mold temperature

Question 23

Which type of casting defect is characterized by a void or cavity in the casting?

Accepted Answer

Shrinkage cavity

Answer

Gas porosity

Answer

Cold shut

Answer

Hot tear

Question 24

Which casting process is known for its ability to produce castings with intricate shapes and high dimensional accuracy?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Die casting

Answer

Continuous casting

Question 25

Which of the following is NOT a crucial parameter in the design of a sand casting mold?

Accepted Answer

Die cavity design

Answer

Pattern design

Answer

Sand type and properties

Answer

Pouring temperature

Question 26

What is the primary advantage of investment casting over sand casting?

Accepted Answer

Enhanced dimensional accuracy

Answer

Increased production rate

Answer

Reduced cost

Answer

Expanded range of castable materials

Question 27

Which casting process is best suited for the production of large, hollow castings?

Accepted Answer

Centrifugal casting

Answer

Die casting

Answer

Investment casting

Answer

Sand casting

Question 28

What is the primary function of a riser in a casting process?

Accepted Answer

To provide additional material to compensate for shrinkage

Answer

To create a vacuum to draw molten metal into the mold

Answer

To reduce porosity in the casting

Answer

To enhance the surface finish of the casting

Question 29

Which of the following factors does NOT influence the solidification rate of molten metal in a casting mold?

Accepted Answer

Metal composition

Answer

Type of mold material

Answer

Casting dimensions

Answer

Mold temperature

Question 30

Which casting defect is characterized by the presence of small, spherical voids within the casting?

Accepted Answer

Porosity

Answer

Shrinkage cavity

Answer

Cold shut

Answer

Hot tear

Question 31

How does additive manufacturing contribute to the evolution of casting techniques?

Accepted Answer

Additive manufacturing allows for the rapid production of complex casting patterns.

Answer

Semi-solid casting involves injecting molten metal into a mold containing solidifying metal.

Answer

Vacuum casting employs a vacuum environment to minimize porosity in castings.

Question 32

Identify a property NOT desirable in a casting pattern material.

Accepted Answer

High thermal conductivity

Answer

Good dimensional stability

Answer

Low thermal expansion

Answer

High strength

Question 33

What is the primary purpose of a sprue in a sand casting mold?

Accepted Answer

To serve as a passage for molten metal to enter the mold cavity

Answer

To create a vacuum within the mold cavity

Answer

To support the cope and drag

Question 34

Which casting process is most suitable for creating intricate shapes with high dimensional accuracy?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Die casting

Answer

Centrifugal casting

Question 35

What is the main advantage of using a centrifugal casting process?

Accepted Answer

Produces castings with minimal porosity and high strength

Answer

Can be used to cast a wide range of metals

Answer

Is relatively inexpensive

Question 36

What is the intended purpose of a chill in a casting mold?

Accepted Answer

To facilitate rapid solidification in a specific area of the casting

Answer

To reduce shrinkage porosity

Answer

To improve the surface finish of the casting

Question 37

What is the fundamental distinction between open-die forging and closed-die forging?

Accepted Answer

Open-die forging employs flat dies, whereas closed-die forging uses shaped dies

Answer

Open-die forging produces less flash than closed-die forging

Answer

Open-die forging is employed for large workpieces, while closed-die forging is used for small workpieces

Question 38

Which of the following materials is not commonly used in investment casting?

Accepted Answer

Carbon steel

Answer

Cobalt-chrome alloys

Answer

Stainless steel

Answer

Aluminum

Question 39

What is the primary benefit of continuous casting compared to other casting processes?

Accepted Answer

High production rate and reduced waste

Answer

Requires less labor than other casting processes

Answer

Can be used to cast a wide variety of shapes and sizes

Answer

Produces castings with exceptional surface finish

Question 40

Which of the following is NOT a primary metal casting process?

Accepted Answer

Electroplating

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 41

Which key characteristic distinguishes investment casting from other casting methods?

Accepted Answer

Ability to produce intricate shapes with high precision

Answer

Uses a permanent mold

Answer

Relatively low production rate

Answer

Suitable for mass production

Question 42

What is the primary function of a sprue in a casting mold?

Accepted Answer

To provide a channel for molten metal to flow into the mold cavity

Answer

To create a vacuum within the mold

Answer

To facilitate the removal of gases from the mold

Question 43

Which of the following factors can significantly affect the quality of a casting?

Accepted Answer

All of the provided factors

Answer

Molten metal composition

Answer

Mold design and preparation

Question 44

What is the primary purpose of the annealing process in casting?

Accepted Answer

To enhance the metal's softness and ductility

Answer

To eliminate impurities from the metal

Answer

To increase the metal's hardness and strength

Answer

To prevent corrosion

Question 45

Which of the following is a notable advantage of centrifugal casting?

Accepted Answer

Production of castings with superior density and strength

Answer

Relatively low production rate

Answer

Limited shape complexity

Question 46

In sand casting, what is the primary material used to create the mold?

Accepted Answer

Sand

Answer

Plastic

Answer

Metal

Answer

Ceramic

Question 47

Which of the following is a limitation associated with continuous casting?

Accepted Answer

Restricted shape complexity

Answer

High production rate

Answer

Excellent surface finish

Question 48

What is the main purpose of a riser in a casting mold?

Accepted Answer

To supply additional molten metal to compensate for shrinkage during solidification

Answer

To facilitate the removal of gases from the mold

Answer

To create a vacuum within the mold