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WorksheetsFoundry and Casting Quiz
Total questions: 100
Worksheet time: 50mins
The most used material for patterns in sand casting is:
Wax
Metal
Plastic
Wood
A pattern is used in foundry for:
Pouring molten metal
Making mould cavity
Cooling the casting
Strengthening the sand
The allowance given to a pattern for metal contraction during cooling is:
Draft allowance
Machining allowance
Shrinkage allowance
Rapping allowance
The box used to hold the moulding sand is called:
Hopper
Cope and drag
Furnace
Ladle
The tool used for ramming sand in mould is:
Rammer
Strike-off bar
Riddle
Trowel
The property of moulding sand that allows gases to pass through is:
Cohesiveness
Permeability
Adhesiveness
Collapsibility
The function of a core in moulding is to:
Provide internal cavities
Provide external shape
Support the mould box
Increase cooling rate
Non-ferrous metals such as aluminum are melted in:
Cupola furnace
Blast furnace
Crucible furnace
Open hearth furnace
In a crucible furnace, metal is melted in:
Crucible pot
Hearth
Lining
Chamber
The energy source for an electric arc furnace is:
Coal
Oil
Gas
Electricity
Casting is a process of:
Forging metal
Rolling metal sheets
Pouring molten metal into a mould and solidifying
Welding two parts
Green sand in sand casting means:
Sand with moisture
Sand of green color
Dry sand mixed with clay
Sand with chemicals
In gravity die casting, molten metal enters the mould:
By suction
By pressure
By centrifugal force
By gravity alone
Pressure die casting is used for:
Large castings
Open mould castings
Small, precise castings
Sand moulds
In hot chamber die casting, the metal is:
Melted inside the casting machine
Brought from outside furnace
Heated by centrifugal force
Cooled quickly
The casting process best suited for hollow cylindrical parts is:
Die casting
Centrifugal casting
Continuous casting
Sand casting
In centrifugal casting, the driving force is:
Pressure
Gravity
Centrifugal force
Suction
A major advantage of continuous casting is:
Better machining allowance
No mould needed
No heat required
Continuous production without ingots
Cold shut occurs when:
Two streams of molten metal do not fuse properly
Sand particles mix with metal
Metal cools too slowly
Mould is not preheated
Welding is a process of:
Joining two metals by mechanical fastening
Joining two metals by fusion with or without filler
Cutting metals into pieces
Casting metals into moulds
Arc welding uses heat generated by:
Chemical reaction
Gas combustion
Electric arc between electrode and workpiece
Frictional heat
The power source used in arc welding can be:
Transformer
Battery
Engine
Inverter
The flux covering on electrodes in arc welding mainly provides:
Mechanical strength
Electrical insulation
Cooling effect
Arc stability and shielding gas
The most commonly used arc welding method in industries is:
Carbon arc welding
Metal arc welding
Gas welding
Friction welding
In MIG welding, the term MIG stands for:
Metal Inert Gas
Metal Internal Gas
Mechanical Inert Gas
Molten Inert Graphite
The shielding gas used in TIG welding is commonly:
Oxygen
Carbon dioxide
Hydrogen
Argon
TIG welding gives:
Excellent quality, precision welds
High welding speed, less control
Poor weld quality
Welding only for cast iron
The reducing (carburizing) flame in gas welding is used for:
Stainless steel
Aluminum and nickel
Cutting
Cast iron
The neutral flame in oxy-acetylene welding is best suited for:
Cast iron and mild steel
Brass and bronze
Cutting operations
Plastics
Spot welding is preferred for sheet metals because:
It requires no filler metal
It needs less operator skill
It gives localized joints quickly
It uses less power
Seam welding is widely used in fuel tanks and drums because:
It requires no electrodes
It saves more material
It is cheaper than spot welding
It provides leak-proof continuous welds
Soldering is weaker than brazing because:
It uses cheaper electrodes
Solder has low melting point and strength
It requires high temperature
It is performed in vacuum
Destructive tests are avoided in production because:
The specimen is damaged permanently
They take more time
They are inaccurate
They use expensive machines
Radiography is useful for detecting:
External porosity only
Hardness variation
Internal defects like voids and blowholes
Surface roughness
Slag inclusion defects can be avoided by:
Using smaller electrodes
Cleaning each weld pass properly
Applying more current
Using less flux
Arc eye or eye injuries in welding occur mainly because:
Dust enters the eye
Sparks hit the face
Helmet is too heavy
UV rays from arc damage the retina
Heat in resistance welding is produced due to:
Electrical resistance
Chemical reaction
Friction
Magnetic induction
Electrodes used in resistance welding are usually made of:
Steel
Copper alloys
Aluminum
Cast iron
Hard facing is used to:
Improve wear resistance
Reduce hardness
Reduce welding current
Save electrodes
Hot working is generally done:
Below recrystallization temperature
At room temperature
Below 0°C
Above recrystallization temperature
Hot working improves:
Machinability
Thermal conductivity
Ductility and toughness
Electrical resistance
The process of reducing thickness of metal by passing between rolls is:
Forging
Rolling
Extrusion
Drawing
Hot working removes:
Blow holes and porosity
Surface cracks
Rust only
Scale only
The forging operation that increases length and reduces cross-section is:
Drawing out
Upsetting
Piercing
Bending
Press forging gives better dimensional accuracy than hammer forging because:
It uses dies with no impact load
It requires less heating
It applies slow, continuous pressure
It uses lighter machines
Upset forging is widely used in bolt head making because:
It increases diameter by shortening the length
It reduces diameter by lengthening the section
It improves toughness by slow cooling rate
It enhances ductility without
Press forging ensures better accuracy than hammer forging since:
It applies slow continuous pressure on the work
It strikes repeated high-speed blows on metal
It heats the work uniformly in small furnaces
It allows rolling action between two shaped dies
Roll forging is mostly used for axles and rods because:
The hammer blows distribute heat uniformly
The dies are kept open to allow free expansion
The operation is carried out at room temperature
The shaped rolls gradually reduce cross-section
Forged components are stronger than castings due to:
The melting process reduces internal porosity
The cooling rate makes grains finer and harder
The grain flow follows the overall shape of part
The machining removes defects from the surface
A press in which power is transmitted by a crankshaft is called:
Mechanical press
Hydraulic press
Pneumatic press
Screw press
The press working operation used to bend sheet into angles is:
Curling
Drawing
Angle bending
Shearing
The operation in which the edge of the sheet is rolled into a circle is known as:
Notching
Piercing
Shaving
Curling
The operation in which a desired shape is completely cut from the sheet is called:
Piercing
Blanking
Notching
Trimming
The operation in which holes are punched without removing material is:
Lancing
Shaving
Trimming
Curling
A mechanical press is more suitable for blanking because:
It applies uniform pressure throughout stroke
It reduces burrs on pierced holes
It delivers high-speed strokes for cutting
It requires less heating of the sheet
A hydraulic press is preferred for deep drawing because:
It consumes less power in shearing
It provides steady pressure during stroke
It avoids springback during bending
It works at higher speed than mechanical press
Angle bending is mainly used to:
Form simple L or V shapes in sheets
Avoid cracks during trimming
Reduce thickness of sheet edges
Remove burrs after piercing holes
Curling operation is carried out to:
Improve tensile strength of sheets
Eliminate sharp sheet edges by rolling
Increase sheet hardness by pressing
Avoid cracks during lancing process
Blanking and piercing differ in that:
In blanking, sheet edges remain scrap; in piercing, edges are product
In blanking, dies are smaller than in piercing
In blanking, more power is needed than piercing
In blanking, the cut part is product; in piercing, the hole is product
First step in powder metallurgy is:
Sintering
Compacting
Powder production
Sizing
In powder metallurgy, which method is most widely used to produce metal powders?
Chemical reduction
Atomization
Electrolysis
Mechanical pulverization
Purpose of sizing is:
Powder production
Improve dimensional accuracy
Mixing particles
Increase powder flow
In atomization, metal powder is produced by:
Reducing metal oxides
Spraying molten metal with gas or water jets
Breaking solid metal
Electroplating
Which of the following produces the highest purity metal powders?
Atomization
Reduction
Electrolysis
Milling
Reduction process involves:
Adding oxygen to oxides
Reducing metal oxides using gases
Melting and pouring
Forging into shape
The product obtained after compaction but before sintering is called:
Finished part
Sintered part
Porous product
Green compact
Which of the following is a typical use for powder metallurgy in the automotive industry?
Brake rotors
Crankshafts
Pistons
Bearings
Self-lubricating parts are made by:
Forging
Extrusion
Powder metallurgy with porosity
Welding
Hot pressing combines:
Melting and atomizing
Compaction and sintering
Electrolysis and infiltration
Milling and forging
Heat treatment is done primarily to:
Melt the metal
Change chemical composition
Improve mechanical properties
Change color
Which property is improved by heat treatment?
Printability
Transparency
Hardness
Gloss
What is the primary purpose of the annealing process in heat treatment?
To increase hardness
To remove internal stresses and soften the material
To change color
To improve gloss
What effect does the normalizing process have on the grain structure of a material?
It refines the grain structure
It coarsens the grain structure
It eliminates grain boundaries
It causes no change in the grain structure
What is the purpose of tempering the steel?
To reduce the brittleness
To remove the ductility
To increase the hardness
To increase the brittleness
The iron-carbon equilibrium diagram shows relationship between:
Oxygen and iron
Iron and carbon
Hydrogen and carbon
Steel and aluminum
Pearlite is a mixture of:
Iron and carbon
Austenite and ferrite
Ferrite and cementite
Graphite and carbide
The eutectoid point occurs at:
1130°C
723°C
912°C
600°C
Which of the following form of iron is magnetic in nature?
α (Alpha)
δ (Beta)
γ (Gamma)
λ (Delta)
Which medium is fastest for quenching?
Air
Water
Oil
Salt bath
Identify the device used to hold irregularly shaped workpieces on a lathe.
Steady rest
Faceplate
Chuck
Mandrel
Which of the following is used to hold a job between centers on a lathe?
Drive plate and carrier
Chuck
Mandrel
Angle plate
Name the device used to support long slender workpieces during turning.
Tailstock
Steady rest
Mandrel
Chuck
The power tool used to tighten or loosen nuts and bolts quickly is:
Circular saw
Impact wrench
Jigsaw
Chainsaw
Why is a steady rest required in lathe operations?
To increase cutting speed
To support long workpieces
To reduce tool wear
To hold small parts
A mandrel is primarily used for:
External turning
Internal grinding
Holding hollow workpieces
Supporting centers
Which device provides precise angular indexing for machining operations?
Tailstock
Drill chuck
Faceplate
Indexing head
Which tool holds small round workpieces with high concentric accuracy?
Four-jaw chuck
Faceplate
Magnetic chuck
Collet
The function of a turret indexing mechanism is to:
Rotate workpiece
Change cutting tools quickly
Hold cutting fluids
Control feed rate
The function of an indexing head is:
To control depth of cut
To rotate the workpiece by a precise angle
To increase spindle speed
To support heavy workpieces
The difference between steady rest and follower rest is:
Steady rest supports near the tool, follower rest moves with tool
Steady rest moves, follower rest fixed
Both are same
None of the above
A catch plate is used with:
Mandrel
Chuck
Steady rest
Vice
Identify the device used for accurate angular positioning of workpiece.
Indexing head
Mandrel
Chuck
Faceplate
The function of a four-way tool post is:
Hold four workpieces
Hold and change tools quickly
Hold centers
Support tailstock
The advantage of using collets over chucks is:
Higher accuracy and speed
Low cost
Heavy-duty work
Manual operation
Select the proper device to machine a long shaft with minimum deflection.
Steady rest
Mandrel
Faceplate
Chuck
Choose the correct tool-holding device for drilling multiple holes at different angles.
Adapter
Turret
Arbor
Collet
If a job must be turned between centers, which setup should be used?
Drive plate + carrier
Chuck only
Mandrel
V-block
To machine a component requiring equal divisions, which device is suitable?
Indexing head
Vice
Mandrel
V-block
In foundry practice, what is the "cope" in a mould?
The lower half of the moulding box
The upper half of the moulding box
The pattern used for casting
The sand used for moulding
Which of the following is a common defect found in casting due to entrapped gas?
Shrinkage cavity
Cold shut
Blow holes / Gas porosity
Sand inclusion
