ASSIGNMENT-1

There are 15 correct answers in the following multiple choice questions (some
questions have multiple answers that are correct).
1. Sand casting is which of the following types:
(a) Expendable mold or (b) Permanent mold?
2. The upper half of a sand-casting mold is called
which of the following: (a) cope or (b) drag?
3. In casting, a flask is which one of the following:
(a) beverage bottle for foundrymen, (b) box which holds the cope and drag, (c)
container for holding liquid metal, or (d) metal which extrudes between the mold
halves?
4. In foundry work, a runner is which one of the following:
(a) channel in the mold leading from the downsprue to the main mold cavity, (b)
foundryman who moves the molten metal to the mold, or (c) vertical channel into
which molten metal is poured into the mold?
5. Turbulence during pouring of the molten metal is
undesirable for which of the following reasons (two best answers):
(a) it causes discoloration of the mold surfaces, (b) it dissolves the binder used
to hold together the sand mold, (c) it increases erosion of the mold surfaces, (d) it
increases the formation of metallic oxides that can become entrapped during
solidification, (e) it increases the mold filling time, and (f) it increases total
solidification time?
6. Total solidification time is defined as which one of the following:
(a) time between pouring and complete solidification, (b) time between pouring
and cooling to room temperature, (c) time between solidification and cooling to
room temperature, or (d) time to give up the heat of fusion?
7. During solidification of an alloy when a mixture of solid and liquid metals is
present, the solid-liquid mixture is referred to aswhich one of the following:
(a) eutectic composition, (b) ingot segregation,
(c) liquidus, (d) mushy zone, or (e) solidus?
8. Chvorinovs rule states that total solidification time is proportional to which one
of the following quantities:
(a) (A/V)n, (b) Hf, (c) Tm, (d) V, (e) V/A, or (f) (V/A)2; where A surface area
of casting, Hf heat of fusion, Tm melting temperature, and V volume of
casting?
9. Ariserincastingisdescribedbywhichofthefollowing (three correct answers):
(a) an insert in the casting thatinhibitsbuoyancyofthecore,(b)gatingsystem
in which the sprue feeds directly into the cavity, (c) metal that is not part of the
casting, (d) source of molten metal to feed the casting and compensate for
shrinkage during solidification, and (e) waste metal that is usually recycled?
10. In a sand-casting mold, the V/A ratio of the riser
should be (a) equal to, (b) greater than, or (c) smaller than the V/A ratio of the
casting itself?
11. Which of the following riser types are completely enclosed within the sand
mold and connected to the main cavity by a channel to feed the molten
metal (two correct answers):
(a) blind riser, (b) open riser, (c) side riser, and (d) top riser?

Answer the following.

1. What is the principle of casting?
2. What is casting? Give the complete classifification of casting.
3. State the the advantages and limitations of casting.
4. With a neat sketch of section of mould explain all the terms related to casting
5. In a sand-casting operation, what factors determine the time at which you would remove
the casting from the mold?
This question is an important one for any casting operation, not just sand
casting, because a decrease in production time will result in a decrease in product
cost. Therefore, a casting ideally should be removed at the earliest possible time.
Factors which affect time are the thermal conductivity of the mold-material and of
the cast metal, the thickness and the overall size of the casting, and the temperature
at which the metal is being poured.
6. Explain why a casting may have a slightly different shape than the pattern used to make
the mold.
After solidification, shrinkage continues until the casting cools to room
temperature. Also, due to surface tension, the solidifying metal will, when surface
tension is high enough, not fully conform to sharp corners and other intricate
surface features. Thus, the cast shape will generally be slightly different from that
of the pattern used.
7. Make a list of the mold and die materials used in the casting processes
described in this chapter. Under each type of material, list the casting
processes that are used, and explain why these processes are suitable for that
particular mold or die material.
This is an open-ended problem, and students should be encouraged to
develop an answer based on the contents of this chapter. An example of an
acceptable answer would, in a brief form, be:
 Sand: Used because of its ability to resist very high temperatures, availability, and
low cost. Used for sand, shell, expandedpattern, investment, and ceramic-mold
casting processes.
Metal: Such as steel or iron. Results in excellent surface finish and good
dimensional accuracy. Used for die, slush, pressure, centrifugal, and squeeze-
casting processes.
Graphite: Used for conditions similar to those for metal molds; however, lower
pressures should be employed for this material. Used mainly in pressure- and
centrifugal-casting.
Plaster of paris: Used in plaster-mold casting for the production of relatively
small components, such as fittings and valves.
8. List and briefly explain the three mechanisms by which metals shrink during casting.
Metals shrink by:
(a) Thermal contraction in the liquid phase from superheat temperature to
solidification temperature,
(b) Solidification shrinkage, and
(c) Thermal contraction in the solid phase from the solidification temperature to
room temperature.
9. Write the equatiom for Heat energy required to heat the metal to the
pouring temperature.

PROBLEMS.

Heating and Pouring

10.1. Adisk 40 cmin diameter and 5 cmthick is to be cast of pure aluminum in an open-mold
casting operation. The melting temperature of aluminum 660 0C, and the pouring temperature
will be 8000 C.Assumethat the amount of aluminum heated will be 5% more than what is needed
to fill themold cavity. Compute the amount of heat that must be added to the metal to heat it to
the pouring temperature, starting from a room temperature of 25 0C. The heat of fusion of
aluminum 389.3 J/g. Other properties can be obtained from Tables 4.1 and 4.2 in the text.
Assume the specific heat has the same value for solid and molten aluminum.
10.2. A sufficient amount of pure copper is to be heated for casting a large plate in an open mold.
The plate has dimensions: length 20 in, width 10 in, and thickness 3 in. Compute the
amount of heat that must be added to the metal to heat it to a temperature of 2150_F for pouring.
Assume that the amount of metal heated will be 10% more than what is needed to fill the mold
cavity. Properties of the metal are: density0.324 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
heat of fusion 80 Btu/lbm.
10.3. The downsprue leading into the runner of a certain mold has a length 175 mm. The
cross-sectional area at the base of the sprue is 400mm2. The mold cavity has a volume
0.001m3. Determine (a) the velocity of the molten metal flowing through the
base of the downsprue, (b) the volume rate of flow, and (c) the time required to fill the mold
cavity. 10.4. A mold has a ownsprue of length 6.0 in. The cross-sectional area at the bottom of
the sprue is 0.5 in2. The sprue leads into a horizontal runner which feeds the mold cavity, whose
volume 75 in3. Determine (a) the velocity of the molten metal flowing through the base of the
downsprue, (b) the volume rate of flow, and (c) the time required to fill the mold cavity.
10.5. The flow rate of liquid metal into the downsprue of a mold 1 L/s. The cross-sectional
area at the top of the sprue 800 mm2, and its length 175 mm. What area should be used at
the base of the sprue to avoid aspiration of the molten metal?
10.6. The volume rate of flow of molten metal into the downsprue from the pouring cup is 50
in3/sec. At the top where the pouring cup leads into the downsprue, the cross-sectional area1.0
in2.Determine what the area should be at the bottom of the sprue if its length 8.0 in. It is
desired to maintain a constant flow rate, top and bottom, in order to avoid aspiration of the liquid
metal.
10.7. Molten metal can be poured into the pouring cup of a sand mold at a steady rate of 1000
cm3/s. The molten metal overflows the pouring cup and flows into the downsprue. The cross-
section of the sprue is round, with a diameter at the top 3.4 cm. If the
sprue is 25cm long, determine the proper diameter at its base so as to maintain the same volume
flow rate.
10.8. During pouring into a sand mold, the molten metal can be poured into the downsprue at a
constant flow rate during the time it takes to fill the mold. At the end of pouring the sprue is
filled and there is negligible metal in the pouring cup. The downsprue is 6.0 in long. Its cross-
sectional area at the top0.8 in2 and at the base0.6 in2.The cross-sectional area of the runner
leading from the sprue also 0.6 in2, and it is 8.0 in long before leading into themold cavity,
whose volume65 in3. The volume of the riser located along the runner near the mold cavity
25 in3. It takes a total of 3.0 222 Chapter 10/Fundamentals of Metal Casting