MPA

8th Semester IQTM

Assignment No. 02-01 of Metal Casting To be submitted on: 21-11-11

Note: 2. 3. 4. 1. Submit one solution per group

Topic: Fundamentals

Marks: 10 Answer the questions in sequence Draw neat figures, where required, to explain your answers

Part-01: Short Questions

1. Identify some of the important advantages of shape casting processes. Advantages include (1) complex part geometries are possible; (2) some casting operations are net shape processes, meaning that no further manufacturing operations are needed to accomplish the final part shape; (3) very large parts are possible; (4) they are applicable to any metal that can be melted; and (5) some casting processes are suited to mass production. 2. What are some of the limitations and disadvantages of casting? Disadvantages include (1) limitations on mechanical strength properties; (2) porosity; (3) poor dimensional accuracy; (4) safety hazards due to handling of hot metals; and (5) environmental problems. 3. Name the two basic mold types that distinguish casting processes. The two mold types are (1) expendable molds and (2) permanent molds. 4. Which casting process is the most important commercially? Sand casting is the most important casting process. 5. What is the difference between a pattern and a core in sand molding? The pattern determines the external shape of the cast part, while a core determines its internal geometry if the casting includes a cavity. 6. What is the difference between a cavity and a core in sand molding? Core & cavity are words which are used in sand molding process. Core is a

sand or metal insert in a mold to shape the interior of the casting or that part of the casting that cannot be shaped by the mold pattern. It is the portion of the cast which forms the internal shape. While cavity is the portion of a cast in which molten metal is poured and it forms the external shape.
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MPA

8th Semester IQTM

7. What is meant by the term superheat? Superheat is the temperature difference above the melting point at which the molten metal is poured or the difference between melting temperature and pouring temperature of molten metal. The term also refers to the amount of heat that is removed from the molten metal between pouring and solidification. 8. What are some of the factors that affect the fluidity of a molten metal during pouring into a mold cavity? The factors include (1) pouring temperature above the melting point, (2) metal alloy composition, (3) viscosity of the liquid metal, and (4) heat transfer to the surroundings. 9. What does heat of fusion mean in casting? Heat of fusion is the amount of heat energy required to transform the metal from solid state to liquid state. 10. What is directional solidification?

Directional solidification describes solidification that occurs from farthest end of the casting and works its way towards the sprue or it is the solidification of molten metal in a casting in such a manner that liquid feed metal is always available for that portion that is just solidifying. 11. What is a chill in casting?

A chill is a heat sink placed to encourage rapid freezing in certain regions of the casting.

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