Roll No. ..

Lingayas University
M.Tech 2 n d Year (Term VI ) PT
E n d Term Exam in ation May - Ju n e 2012
Fou n d ry Tech n ology (ME - 526)

[Time: 3 Hours] [Max. Marks: 100]

Before answering the question, candidate should ensure that they
have been supplied the correct and complete question paper. No
complaint in this regard, will be entertained after examination.

Note: Attempt five questions in all. All questions carry equal

marks. Question no. 1 (Section A) is compulsory. Select four
questions from Section B.

Section A

Q-1. Select the correct answer of the following multiple

choice questions: [102=20]
(i) Castings are designed with rounded edges and corners so as to
(a) Increase the overall strength of the casting
(b) Improve toughness
(c) Prevent mould erosion by the metal stream
(d) Improve ductility
(ii) Two cubical castings of the same metal and sizes of 2 cm side
and 4 cm side are moulded in green sand. If the smaller
casting solidifies in 2 minutes, the expected time of
solidification of the larger casting will be
(a) 16 min (b) 28 min
(c) 8 min (d) 4 min
1
(iii) Grade 20 castings have
(a) Brinell lardness of 20
(b) Tensile strength of 20 kgf/mm2
(c) Compression strength of 20 kgf/mm2
(d) Yield strength of 20 kgf/mm2
(iv) Which of the following materials will require the largest size of
riser for the same size of casting?
(a) Aluminum (b) C.I.
(c) Steel (d) Copper
(v) In green sand moulding process, uniform ramming leads to
(a) Less chances of gas porosity
(b) Uniform flow of molten metal into the mould
(c) Greater dimensional stability of casting
(d) Less sand expansion type of casting defects
(vi) In centrifugal casting, impurities are
(a) Uniformly distributed in casting
(b) Forced towards outer surfaces
(c) Collected close to the centre of casting
(d) Both (b) & (c)
(vii) Consider the following ingredients used for moulding
(1) Dry silica sand (2) Clay
(3) Phenol formaldehyde (4) Sodium silicate
Those used for shell moulding include
(a) 1, 2, 3 (b) 2 & 3
(c) 1 & 3 (d) 1, 2, 3, 4
(viii) Gates and riser removal method choice depends on
(a) Casting size (b) Casting shape
(c) Casting material (d) All the above
(ix) Which of the following is a casting defect?
(a) Warm tear (b) Cold tear

2
 (c) Hot tear (d) None of the above
(x) Which of the following is a material handling equipment?
(a) Magnetic separator (b) Muller
(c) Travelling cranes (d) Aerator

Section B

Q-2. Explain the advantages of the casting process with respect to

the following considerations:
(i) Design aspect
(ii) Process aspect
(iii) Metallurgical aspect [20]

Q-3. A casting is required to have the following composition:

C=3.25%, si=1.8%. P-0.5%, Mn=0.6%, S-01%. Determine the
weight of Pig iron from pile A and pile B to be picked up in
each metal charge if the casting (200 kg) is to contain pig iron
50% foundry return: 40% and purchased scrap; 10%. Analysis
of these metals is as follows: (loss of silicon during melting
10% of the amount present).

Metal Si% Mn% S% P%

Pigiron (Pile A) 2.40 0.90 0.05 0.40

Pigiron (Pile B) 1.40 0.95 0.05 0.35

Fdy. Returns 1.70 0.60 0.06 0.30

Purchased scrap 2.20 0.70 0.07 0.25

3
 [20]
Q-4. Two castings, one sphere and other cube are of the same metal
and having same surface area, find the ratio of solidification
time for the sphere to that of cube. [20]

Q-5. Explain the following processes along with their merits and
applications.
(i) Precision investment casting
(ii) Shell mould casting [20]

Q-6. (a) What are the methods available for the removal of gates and
risers from the casting? Explain. [10]
(b) How is the casting surface cleaned? [10]

Q-7. (a) What do you understand by casting defects? Name the basic
categories of casting defects. [10]
(b) Differentiate between destructive and non-destructive method
of testing castings. [10]

Q-8. (a) What is meant by modernization of foundries? Discuss how it

can help in improving the performance of the unit. [10]
(b) What are the main reasons of pollution in foundry shop? How
it can be controlled. [10]