WorksheetsBTEC Level 2 Engineering Revision Booklet
Total questions: 24
Worksheet time: 12mins
Read the three process descriptions shown. Identify the name of the process: A process which involves a metal being heated up and shaped by plastic deformation. It is usually applied by applying some kind of squeezing force (compression) such as hammer blows using a large power press.
Casting
Welding
Forging
Read the three process descriptions shown. Identify the name of the process: A process which involves pouring or injecting a liquid metal into a mould. The mould contains a cavity that takes the shape of the desired object where the metal is allowed to cool and solidify.
Casting
Welding
Forging
Read the three process descriptions shown. Identify the name of the process: A permanent fabrication process. Most methods use intense heat to fuse metal together using a number of energy sources (gas or electric arc, laser or ultra sound).
Casting
Welding
Forging
Sand casting is the oldest form of casting and involves pouring molten metal into a prepared cavity in a sand mould and allowing it to solidify. Select the two health and safety issues that most directly apply to sand casting operations.
Molten metal splashes causing burns
Respiratory exposure to silica sand dust
Electric shock from arc welding only
Cold stress from refrigerated storage
Sand casting is used to make components from a pattern in sand. Select the three applications that are well suited to sand casting.
Automotive engine blocks and cylinder heads
Pump housings and valve bodies
Decorative garden ornaments and plaques
Thin sheet-metal brackets that require precise bends
Considering typical outcomes of sand casting, select the two disadvantages.
Lower dimensional accuracy compared with precision processes
Rougher surface finish that may need machining
Extremely high tooling cost for steel dies
Inability to produce large parts
Considering typical outcomes of sand casting, select the two advantages.
Suitable for complex shapes at relatively low cost
Little waste produced because runners and risers can be re-melted (<10%)
Requires expensive hardened steel dies for every part
Only works with sheet metal rather than molten metal
Refer to the illustrated sand casting sequence. What is the first operation shown in the process?
Filling with sand
Ramming the sand
Turn over
Pouring the metal
In the sand casting sequence shown, which caption labels the final outcome of the process?
Remove both halves of the pattern
The finished product
Fit top half of the pattern and pegs for runner and riser
Fill with sand, then ram the sand
According to the sand casting sequence, which step specifically adds pegs for runner and riser?
Ramming the sand
Fit top half of the pattern and pegs for runner and riser
Turn over
Remove both halves of the pattern
Die casting is described in the introduction. Which statement best defines die casting?
Pouring molten metal into a sand mould by gravity
Forcing molten metal under high pressure into the cavities of steel moulds
Hammering solid metal into a shaped die
Heating a wax pattern to create a metal shell
According to the introduction, what are the moulds used in die casting called?
Patterns
Cores
Dies
Flasks
Cold-chamber die casting sequence: After the ladle adds molten metal, what happens next?
Die opens and part is removed
Molten metal is injected into the die
Machine ready for cycle
Die closes
In the cold-chamber die casting cycle shown, what is the final step?
Die closes
Molten metal is injected into the die
Ladle adds molten metal
Die opens and part is removed
From the schematic labelled Cold‑Chamber Die‑Casting, where is the molten metal introduced relative to the shot sleeve?
Directly from an attached furnace into the die cavity
Poured into a shot sleeve and driven by a plunger
Siphoned from the crucible through the fill stalk
Injected by pressurising gases from below
From the schematic labelled Hot‑Chamber Die‑Casting, which feature distinguishes this process from cold‑chamber?
A separate ladle transfers metal to a shot sleeve
The plunger forces molten metal directly from an integrated pot/furnace
Metal is poured only by gravity with no pressure
The die cavity is made of sand
In the Pressure Die Casting diagram, what drives the metal fill into the dies?
Manual ladling
Pressurising gases forcing metal up the fill stalk
Vibration of the mould
Gravity through a riser
Investment casting is also known by another name given in the introduction. What is it called?
Sand casting
Lost wax process
Permanent mould casting
Cold‑chamber die casting
According to the investment casting introduction, after the shell mould is built and the wax is melted out, what happens next?
The hollow mould is filled with molten metal by gravity and allowed to cool and solidify
The shell is broken and parts are cut off
The die closes and a plunger injects metal
A core is rammed into sand
In the investment casting sequence, which step comes after solidification of the poured metal?
Shell built and immersed into slurry
Break ceramic shell (vibration or water blasting)
Wax pattern injection molding
Ladle adds molten metal
Which description best characterizes gravity die casting as presented?
A low‑tech process using a die, suited to batch production of simple forms with metal poured by gravity
A high‑pressure injection of metal into steel dies for complex shapes
Building a ceramic shell around wax patterns for lost wax casting
Pouring metal into a sand mould made with a wooden pattern
From the comparison table, which process is noted for producing large quantities that need to be accurate?
Sand casting
Investment casting
Die casting
Permanent mould casting
According to the table, which process is used for complex shapes with a high degree of accuracy?
Sand casting
Investment casting
Permanent mould casting
Pressure die casting
From the table, which is an example product made using permanent mould casting that can withstand high pressures?
Man‑hole cover
Toy cars
Engine pistons
Compressor wheels
