Test your knowledge...GATE, IES & IAS questions

Aug 30, 2016
11 min read

IES‐2001

The main purpose of chaplets is

(a) To ensure directional solidification

(b) To provide efficient venting

(d) To support the cores

IES‐1996

Which of the following methods are used for obtaining directional solidification for riser design?

1. Suitable placement of chills

2. Suitable placement of chaplets

3. Employing padding

Select the correct answer.

(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3

IES 2007

Which one of the following is the correct statement?

Gate is provided in moulds to

(a) Feed the casting at a constant rate

(b) Give passage to gases

(d) Avoid cavities

GATE‐2009

Match the items in Column I and Column II.

Column I Column II

P. Metallic Chills 1. Support for the core

Q. Metallic Chaplets 2. Reservoir of the molten metal

R. Riser 3. Control cooling of critical sections

S. Exothermic Padding 4. Progressive solidification

(a) P‐1,Q‐3, R‐2, S‐4 (b) P‐1,Q‐4, R‐2, S‐3

GATE‐1992

In a green‐sand moulding process, uniform ramming leads to

(a) Less chance of gas porosity

(b) Uniform flow of molten metal into the mould cavity

(d) Less sand expansion type of casting defect

GATE 2011

Green sand mould indicates that

(a) polymeric mould has been cured

(b) mould has been totally dried

(d) mould contains moisture

IES‐1995

Which one of the following materials will require the largest size of riser for the same size of casting?

(a) Aluminium

(b) Cast iron

(d) Copper

GATE‐1999

Which of the following materials requires the largest shrinkage allowance, while making a pattern for casting?

(a) Aluminium

(b) Brass

(d) Plain Carbon Steel

IES‐1999

In solidification of metal during casting, compensation for solid contraction is

(a) Provided by the oversize pattern

(b) Achieved by properly placed risers

(d) Made by providing chills

GATE‐2001

Shrinkage allowance on pattern is provided to compensate for shrinkage when

(a) The temperature of liquid metal drops from pouring to freezing temperature

(b) The metal changes from liquid to solid state at freezing temperature

(d) The temperature of metal drops from pouring to room temperature

GATE‐2004

Gray cast iron blocks 200 x 100 x 10 mm are to be cast in sand moulds. Shrinkage allowance for pattern making is 1%. The ratio of the volume of pattern to that of the casting will be

(a) 0.97 (b) 0.99 (c) 1.01 (d) 1.03

GATE‐2008

While cooling, a cubical casting of side 40 mm undergoes 3%, 4% and 5% volume shrinkage during the liquid state, phase transition and solid state, respectively. The volume of metal compensated from the riser is

(a) 2% (b) 7% (c) 8% (d) 9%

GATE 2011

A cubic casting of 50 mm side undergoes volumetric solidification shrinkage and volumetric solid contraction of 4% and 6% respectively. No riser is used. Assume uniform cooling in all directions. The side of the cube after solidification and contraction is

(a) 48.32 mm

(b) 49.90 mm

(d) 49.96 mm

IAS‐1995

Assertion (A): A pattern is made exactly similar to the part to be cast.

Reason (R): Pattern is used to make the mould cavity for pouring in molten for casting.

(a) Both A and R are individually true and R is the correct explanation of A

(b) Both A and R are individually true but R is not the correct explanation of A

(d) A is false but R is true

IAS‐2003

Match List I (Material to be cast) with List II (Shrinkage Allowance in mm/m) and select the correct answer using the codes given below the lists:

List‐I List‐II

(Material to Cast) (Shrinkage Allowance in mm/m)

(A) Grey cast iron 1. 7 ‐ 10

(B) Brass 2. 15

(D) Zinc 4. 24

Codes:

A B C D A B C D A B C D A B C D

(a) 1 2 3 4 (b) 3 4 1 2 (c) 1 4 3 2 (d) 3 2 1 4

IES‐1994

Which of the following materials can be used for making patterns?

1. Aluminium 2.Wax 3. Mercury 4. Lead

Select the correct answer using the codes given below:

Codes:

(a) 1,3 and 4 (b) 2,3 and 4 (c) 1, 2 and 4 (d) 1, 2 and 3

GATE‐2000

Disposable patterns are made of

(a) Wood (b) Rubber (c) Metal (d) Polystyrene

IES‐2008

The pattern adopted for those castings where there are some portions which are structurally weak and are likely to break by the force of ramming are called:

(a) Loose piece pattern (b) Follow board pattern (c) Skelton pattern (d) Single piece pattern

IES‐2002

Assertion (A): In CO2 casting process, the mould or core attains maximum strength.

Reason (R): The optimum gassing time of CO2 through the mould or core forms Silica Gel which imparts sufficient strength to the mould or core.

(a) Both A and R are individually true and R is the correct explanation of A

(b) Both A and R are individually true but R is not the correct explanation of A

(d) A is false but R is true

IES‐2008

Small amount of carbonaceous material sprinkled on the inner surface of mould cavity is called

(a) Backing sand (b) Facing sand (c) Green sand (d) Dry sand

IES‐2002

In the grain ‐size determination using standard charts, the relation between the given size number n and the average number of grains 'N' per square inch at a magnification of 100 X is

(a) N = 2^n (b) N = 2^n ‐ l (c) N = 2^n + 1 (d) N = 2^n + 1

IES 2011

In light metal casting, runner should be so designed that:

1. It avoids aspiration 2. It avoids turbulence

3. The path of runner is reduced in area so that unequal volume of flow through each gate takes place

(a) 1 and 2 only (b) 1 and 3 only (c) 2 and 3 only (d) 1, 2 and 3

IES 2011

Match List –I with List –II and select the correct answer using the code given below the lists :

List – I List – II

A. Top gate 1. Heavy and large castings

B. Bottom gate 2. Most widely used and economical

C. Parting Gate 3. Turbulence

D. Step Gate 4. Unfavorable temperature gradient

Codes

A B C D A B C D

(a) 3 4 2 1 (b) 1 4 2 3

IES‐1998

A sand casting mould assembly is shown in the above figure. The elements marked A and B are respectively

(a) Sprue and riser (b) Ingate and riser (c) Drag and runner (d) Riser and runner

GATE‐2002

The primary purpose of a sprue in a casting mould is to

(a)Feed the casting at a rate consistent with the rate of solidification

(b)Act as a reservoir for molten metal

(c)Feed molten metal from the pouring basin to the gate

(d)Help feed the casting until all solidification takes place

IES‐1998

Which of the following are the requirements of an ideal gating system?

The molten metal should enter the mould cavity with as high a velocity as possible.
It should facilitate complete filling of the mould cavity.
It should be able to prevent the absorption of air or gases from the surroundings on the molten metal while flowing through it.

Select the correct answer using the codes given below:

(a) 1, 2 and 3 (b) 1 and 2 (c) 2 and 3 (d) 1 and 3

IES‐2009

Consider the following statements:

1. The actual entry point through which the molten metal enters the mould cavity is called ingate.

2. Bottom gate in case of a mould creates unfavorable temperature gradient.

3. Sprue in case of a mould is made tapered to avoid air inclusion.

Which of the above statements is/are correct?

(a) 1 only (b) 1 and 2 (c) 2 and 3 (d) 1 and 3

GATE‐2001

The height of the down sprue is 175 mm and its cross‐sectional area at the base is 200 mm^2. The cross-sectional area of the horizontal runner is also 200 mm^2. Assuming no losses, indicate the correct choice for the time (in seconds) required to fill a mould cavity of volume 106 mm3. (Use g = 10m/s^2).

(a) 2.67 (b) 8.45 (c) 26.72 (d) 84.50

GATE‐2007

A 200 mm long down sprue has an area of cross section of 650 mm2 where the pouring basin meets the down sprue (i.e. at the beginning of the down sprue). A constant head of molten metal is maintained by the pouring basin. The molten metal flow rate is 6.5 × 105 mm3/s. Considering the end of down sprue to be open to atmosphere and an acceleration due to gravity of 104mm/s2, the area of the down sprue in mm2 at its end (avoiding aspiration effect) should be

(a) 650.0 (b) 350.0 (c) 290.7 (d) 190.0

IES‐2003

A gating ratio of 1: 2: 4 is used to design the gating system for magnesium alloy casting. This gating ratio refers to the cross∙ section areas of the various gating elements as given below:

1. Down sprue 2. Runner bar 3. Ingates

The correct sequence of the above elements in the ratio 1: 2: 4 is

(a) 1, 2 and 3 (b) 1,3 and 2 (c) 2, 3 and 1 (d) 3, 1 an 2

IES‐2005

The gating ratio 2: 8: 1 for copper in gating system design refers to the ratio of areas of:

(a) Sprue: Runner: Ingate (b) Runner: Ingate: Sprue (c) Runner: Sprue: Ingate (d) Ingate: Runner: Sprue

GATE‐2010

In a gating system, the ratio 1:2:4 represents

(a) Sprue base area: runner area: ingate area (b) Pouring basin area : ingate area : runner area

IAS‐1999

Assertion (A): The rate of flow of metal through sprue is NOT a function of the cross‐sectional areas of sprue, runner and gate.

Reason (R): If respective cross‐sectional areas of sprue, runner and gate are in the ratio of 1: 2: 2, the system is known as unpressurised gating system.

(a) Both A and R are individually true and R is the correct explanation of A

(b) Both A and R are individually true but R is not the correct explanation of A

(d) A is false but R is true

IES‐1994

Assertion (A): In a mould, a riser is designed and placed so that the riser will solidify after the casting has solidified.

Reason (R): A riser is a reservoir of molten metal which will supply molten metal where a shrinkage cavity would have occurred.

(a) Both A and R are individually true and R is the correct explanation of A

(b) Both A and R are individually true but R is not the correct explanation of A

(d) A is false but R is true

IES 2011

The relationship between total freezing time t, volume of the casting V and its surface area A, according to Chvorinov’s rule is:

t = k (v / A)
t = k (A / v)
t = k (A / v)^2
t = k (v / A)^2

Where K is a constant

IES‐1998

A spherical drop of molten metal of radius 2 mm was found to solidify in 10 seconds. A similar drop of radius 4 mm would solidify in

(a) 14.14 seconds (b) 20 seconds (c) 28.30 seconds (d) 40 seconds

GATE‐2003

With a solidification factor of 0.97 x 106 s/m2, the solidification time (in seconds) for a spherical casting of 200 mm diameter is

(a) 539 (b) 1078 (c) 4311 (d) 3233

IES‐2006

According to Chvorinov's equation, the solidification time of a casting is proportional to:

(a) v^2 (b) v (c) 1/v (d) 1/(v^2)

Where, v = volume of casting

IES‐2008

Calculate the size of a cylindrical riser (height and diameter equal) necessary to feed a steel slab casting of dimensions 30 x 30 x 6 cm with a side riser, casting poured horizontally into the mould. [Use Modulus Method]

Conventional Question IES‐2007

Calculate the size of a cylindrical riser (height and diameter equal) necessary to feed a steel slab casting of dimensions 25 x 25 x 5 cm with a side riser, casting poured horizontally into the mould. [Use Caine’sMethod]

IES‐1995

Directional solidification in castings can be improved by using

(a) Chills and chaplets (b) Chills and padding (c) Chaplets and padding (d) Chills, chaplets and padding

GATE‐1998, 2007

Chills are used in moulds to

(a) Achieve directional solidification (b) Reduce the possibility of blowholes (c) Reduce freezing time

(d) Smoothen metal flow for reducing splatter

IAS 1994

Chills are used in casting moulds to

(a) Achieve directional solidification (b) Reduce possibility of blow holes

IES‐1997

Assertion (A): Steel can be melted in hot blast cupola.

Reason (R): In hot blast cupola, the flue gases are used to preheat the air blast to the cupola so that the temperature in the furnace is considerably higher than that in a conventional cupola.

(a) Both A and R are individually true and R is the correct explanation of A

(b) Both A and R are individually true but R is not the correct explanation of A

(d) A is false but R is true

GATE‐1996

Light impurities in the molten metal are prevented from reaching the mould cavity by providing

(a) Strainer (b) Button well (c) Skim bob (d) All of the above

GATE‐2005

A mould has a down sprue whose length is 20 cm and the cross sectional area at the base of the down sprue is 1sq.cm. The down sprue feeds a horizontal runner leading into the mould cavity of volume 1000 cm3. The time required to fill the mould cavity will be

(a) 4.05 s (b) 5.05 s (c) 6.05 s (d) 7.25 s

GATE‐2006

In a sand casting operation, the total liquid head is maintained constant such that it is equal to the mould height. The time taken to fill the mould with a top gate is tA. If the same mould is filled with a bottom gate, then the time taken is tB. Ignore the time required to fill the runner and frictional effects. Assume atmospheric pressure at the top molten metal surfaces. The relation between tA and tB is

(a) tb = ta (b) tb = 2 ta (c) tb = ta / (d) tb =2 ta

GATE‐2004

Misrun is a casting defect which occurs due to

(a) Very high pouring temperature of the metal (b) Insufficient fluidity of the molten metal

GATE‐2009

Two streams of liquid metal which are not hot enough to fuse properly result into a casting defect known as

(a) Cold shut (b) Swell (c) Sand wash (d) Scab

IES‐2001

Scab is a

(a) Sand casting defect (b) Machining defect (c) Welding defect (d) Forging defect

IAS‐2004

Match List‐I (Casting Defects) with List‐II (Explanation) and select the correct answer using the codes given below the lists:

List‐I List‐II

(Casting Defects) (Explanation)

A. Metallic projections 1. Consist of rounded or rough internal or exposed cavities including blow holes and pin holes

B. Cavities 2. Formed during melting, solidification and moulding.

C. Inclusions 3. Includes single folds, laps, scars adhering sand layers and oxide scale

D. Discontinuities 4. Include cracks, cold or hot tearing and cold shuts

5.Consist of fins, flash or massive projections and rough surfaces

Codes:

A B C D A B C D A B C D A B C D

(a) 1 5 3 2 (b) 1 5 2 4 (c) 5 1 2 4 (d) 5 1 3 2

GATE‐2003

Hardness of green sand mould increases with

(a) Increase in moisture content beyond 6 percent (b) Increase in permeability

IES‐1998

Assertion (A): Stiffening members, such as webs and ribs, used on a casting should be liberally provided.

Reason (R): They will provide additional strength to a cast member.

(a) Both A and R are individually true and R is the correct explanation of A

(b) Both A and R are individually true but R is not the correct explanation of A

(d) A is false but R is true

IES‐2005

In gating system design, which one of the following is the correct sequence in which choke area, pouring time, pouring basin and sprue sizes are calculated?

(a) Choke area ‐ Pouring time ‐ Pouring basin – Sprue (b) Pouring basin ‐ Sprue ‐ Choke area ‐ Pouring time

IES‐1997

If the melting ratio of a cupola is 10: 1, then the coke requirement for one ton melt will be

(a) 0.1 ton (b) 10 tons (c) 1 ton (d) 11 tons

IES‐2009

In which one of the following furnaces most of the non‐ferrous alloys are melted?

(a) Reverberatory furnace (b) Induction furnace (c) Crucible furnace (d) Pot furnace

IAS‐2001

Which of the following pattern‐materials are used in Precision Casting?

1. Plaster of Paris 2. Plastics 3. Anodized Aluminium Alloy 4. Frozen Mercury

Select the correct answer using the codes given below:

(a) 1 and 2 (b) 2 and 4 (c)3 and 4 (d) 1 and 3

IAS‐2004

Which one of the following gating systems is best suited to obtain directional solidification?

(a) Top gating (b) Part‐line gating (c) Bottom gating (d) Stepped gating

IES 2011

In the designation of Aluminium casting A514.0 indicates :

(a) Aluminium purity (b) Aluminium content (c) Percentage of alloy element (d) Magnesium Content

Manufacturing Process

Test your knowledge...GATE, IES & IAS questions

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