Q1. The primary purpose of a pattern in sand casting is to:

A. Create the mould cavity B. Melt the metal C. Remove gases D. Measure hardness

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: A pattern produces the impression that becomes the mould cavity.

Q2. The allowance provided for easy withdrawal of a pattern is called:

A. Shrinkage allowance B. Draft allowance C. Machining allowance D. Distortion allowance

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Draft allowance provides taper so the pattern can be withdrawn without damaging the mould.

Q3. A riser is primarily used to:

A. Feed molten metal during solidification B. Increase mould hardness C. Remove the pattern D. Reduce pouring height

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: A riser acts as a reservoir and feeds liquid metal to compensate for solidification shrinkage.

Q4. The sprue in a gating system mainly:

A. Carries metal vertically downward B. Supports the core C. Removes sand D. Measures temperature

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: The sprue conveys molten metal from the pouring basin toward the runner and ingates.

Q5. The choke is the section that generally:

A. Controls metal flow rate B. Forms the core C. Increases pattern allowance D. Removes slag after solidification

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: The choke is the controlling minimum cross-sectional area in a pressurized or unpressurized gating system.

Q6. Green sand mould contains:

A. Moisture and bonding clay B. Only dry silica C. Only graphite D. Molten metal

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Green sand normally contains sand, clay binder, moisture and additives.

Q7. A core is used to produce:

A. An internal cavity B. A surface finish only C. A riser head D. A pouring basin

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: A core occupies space inside the mould to form an internal hole or passage.

Q8. A chaplet is used to:

A. Support and locate a core B. Increase fluidity C. Remove dross D. Provide draft

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Chaplets support cores against buoyancy and maintain their position.

Q9. A chill is provided to:

A. Increase local cooling rate B. Increase gas content C. Delay all solidification D. Reduce mould strength

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Chills extract heat rapidly and promote local directional solidification.

Q10. A skim bob helps in:

A. Trapping floating impurities B. Increasing riser volume C. Making the pattern D. Measuring shrinkage

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: A skim bob or skimming arrangement helps retain dross before metal enters the cavity.

Q11. Misrun is generally caused by:

A. Premature freezing before complete filling B. Excessive machining C. Too much riser feeding D. High permeability only

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: A misrun occurs when metal loses fluidity and fails to fill the mould completely.

Q12. Cold shut results when:

A. Two streams fail to fuse properly B. The pattern is withdrawn easily C. The riser is insulated D. The mould is too strong

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: A cold shut is an imperfect junction of two advancing metal fronts.

Q13. A blowhole is mainly associated with:

A. Gas entrapment B. Pattern draft C. Core support D. Excessive machining allowance

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Blowholes are cavities caused by trapped gas or gas released during solidification.

Q14. Shrinkage cavity occurs due to:

A. Insufficient feeding during contraction B. Excessive venting only C. High pattern hardness D. Low sand permeability only

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Metal contracts during solidification; inadequate feeding can produce shrinkage cavities.

Q15. Hot tears occur when:

A. Solidifying metal is restrained during contraction B. The mould is removed too early C. The metal is fully liquid D. The pattern has draft

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Hot tearing is associated with contraction stresses during late solidification and poor feeding/ductility conditions.

Q16. Permeability of moulding sand indicates its ability to:

A. Allow gases to escape B. Resist all heat transfer C. Increase metal density D. Prevent pattern removal

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Permeability is the capacity of moulding sand to pass gases through its interconnected pores.

Q17. Increasing moisture in green sand beyond the optimum generally:

A. Raises gas-related defect risk B. Always increases strength without limit C. Eliminates blowholes D. Makes sand dry

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Excess moisture can generate more gas and reduce mould quality if not controlled.

Q18. The parting line is:

A. The interface between cope and drag B. The centre of the riser C. The tip of the sprue D. The surface of the furnace

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: The parting line separates the two halves of the moulding flask.

Q19. Investment casting commonly uses:

A. A disposable wax pattern B. A permanent sand pattern C. Only a wooden core D. A steel ingot as pattern

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Investment casting uses a wax or polymer pattern that is removed during shell preparation.

Q20. In die casting, the mould is generally:

A. Metallic and reusable B. Made only of green sand C. Destroyed after every shot D. Made from wax

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Die casting uses reusable metal dies under pressure.

Q21. Centrifugal casting is especially suitable for:

A. Tubular components B. Tiny electronic chips C. Flat sheets only D. Wooden parts

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Rotation forces molten metal toward the mould wall, making it useful for pipes and rings.

Q22. Directional solidification aims to:

A. Promote feeding toward the riser B. Freeze the riser first C. Increase gas generation D. Eliminate the gating system

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Directional solidification encourages progressive freezing from remote regions toward the feeder.

Q23. Chvorinov's rule relates solidification time to:

A. Modulus raised to an exponent B. Pattern colour C. Sand grain number only D. Pouring basin depth only

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Chvorinov's rule is commonly written t_s = C(V/A)^n.

Q24. The modulus of a casting is:

A. Volume divided by cooling area B. Area divided by volume C. Mass divided by time D. Length divided by density

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Modulus M = V/A is a geometric indicator of relative solidification time.

Q25. A blind riser is:

A. Enclosed within the mould B. Open directly to atmosphere C. A type of core print D. A chill only

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: A blind riser is enclosed and can retain heat longer than an exposed riser.

Q26. The function of a pouring basin is to:

A. Receive and regulate incoming metal B. Create internal holes C. Support the cope D. Measure hardness

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: The pouring basin receives the ladle stream and helps reduce turbulence and spillage.

Q27. A runner is used to:

A. Distribute metal from sprue to ingates B. Hold the pattern C. Vent the core only D. Cool the riser

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: The runner is a horizontal passage distributing molten metal to one or more ingates.

Q28. A filter in a gating system can:

A. Reduce inclusions and turbulence B. Increase sand moisture C. Replace the riser D. Create draft

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Ceramic filters can trap inclusions and improve flow quality.

Q29. The main function of vents is to:

A. Permit gases to escape B. Increase metal viscosity C. Hold the pattern D. Increase shrinkage

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Vents provide escape paths for air and generated gases.

Q30. Shakeout means:

A. Removing the casting from the mould B. Pouring metal into the furnace C. Making a pattern D. Adding alloying elements

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Shakeout is the operation of breaking the mould and removing the solid casting.

Q31. Fettling includes:

A. Cleaning and removing unwanted projections B. Melting the pattern C. Making the core D. Measuring sand permeability only

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Fettling removes gates, risers, fins and adherent mould material.

Q32. A pattern material should generally have:

A. Dimensional stability and adequate strength B. Very high gas generation C. Zero rigidity D. High solubility in sand

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Patterns need adequate strength, wear resistance and dimensional stability.

Q33. The largest typical pattern shrinkage allowance is associated with:

A. Material having greater solid contraction B. Material with no contraction C. All materials equally D. Only wood

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Pattern shrinkage allowance depends on the alloy's contraction characteristics.

Q34. Inoculation is commonly used to:

A. Modify nucleation and microstructure B. Remove the pattern C. Increase mould permeability only D. Create the sprue

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Inoculants promote nucleation and influence grain structure and properties.

Q35. A skim gate is designed to:

A. Help separate floating impurities B. Increase core buoyancy C. Create a riser D. Reduce pattern size

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Skimming features allow lighter impurities to be retained before clean metal enters the cavity.

Q36. The mould cavity surface is formed by:

A. The pattern impression B. The furnace wall C. The ladle handle D. The riser sleeve only

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: The pattern displaces moulding material and creates the cavity geometry.

Q37. A pressurized gating system generally has:

A. Total ingate area smaller relative to sprue area B. No runner C. No sprue D. Only a riser

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: In a pressurized system, the total ingate area is commonly smaller than the sprue area, maintaining back pressure.

Q38. An unpressurized gating system generally aims to:

A. Reduce turbulence and aspiration B. Maximize pressure everywhere C. Eliminate vents D. Avoid all runners

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Unpressurized systems use larger total ingate area to reduce velocity and turbulence.

Q39. The metal flow velocity from a head h is approximated by:

A. sqrt(2gh) B. gh/2 C. 2g/h D. h/g

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Under ideal conditions, Torricelli's relation gives v = sqrt(2gh).

Q40. The density of a casting alloy affects:

A. Mass for a given volume B. Pattern draft only C. Sand colour only D. Parting line position only

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Mass is related to density and volume through m = rho V.

Q41. A mould with low permeability is more likely to cause:

A. Gas-related defects B. Better gas escape C. No pressure D. Automatic feeding

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Low permeability restricts gas escape and can promote blows or pinholes.

Q42. A core print is provided to:

A. Locate and support the core B. Increase pouring temperature C. Create the runner D. Remove slag

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Core prints create seats in the mould for accurate core positioning.

Q43. The purpose of machining allowance is to:

A. Provide material for later machining B. Allow pattern withdrawal C. Feed shrinkage D. Remove gas

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Extra metal is provided on surfaces that will be machined to final dimensions.

Q44. The purpose of distortion allowance is to:

A. Compensate for anticipated warpage B. Increase fluidity C. Reduce riser size D. Vent gases

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Distortion allowance anticipates shape changes due to uneven contraction and restraint.

Q45. Sand casting is generally preferred when:

A. Flexibility and low tooling cost are important B. Only extremely high precision is needed C. No mould is permitted D. The metal cannot melt

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Sand moulds are versatile and economical for many sizes and production quantities.

Q46. A casting has volume 120 cm³ and cooling area 60 cm². Its modulus is:

A. 0.5 cm B. 2 cm C. 60 cm D. 180 cm

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: M = V/A = 120/60 = 2 cm.

Q47. A casting volume is 800 cm³ and pouring time is 20 s. The average volumetric flow rate is:

A. 20 cm³/s B. 40 cm³/s C. 400 cm³/s D. 16000 cm³/s

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Q = V/t = 800/20 = 40 cm³/s.

Q48. For h = 0.20 m and g = 9.81 m/s², ideal metal velocity is approximately:

A. 0.99 m/s B. 1.98 m/s C. 3.92 m/s D. 9.81 m/s

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: v = sqrt(2gh) = sqrt(2×9.81×0.20) = sqrt(3.924) ≈ 1.98 m/s.

Q49. A cube has side 40 mm. Its volume is:

A. 6,400 mm³ B. 64,000 mm³ C. 160,000 mm³ D. 4,000 mm³

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: V = a³ = 40³ = 64,000 mm³.

Q50. A cube has side 50 mm. Its total surface area is:

A. 1,250 mm² B. 5,000 mm² C. 7,500 mm² D. 15,000 mm²

Check Answer

Correct Answer: D   |   Marks: 1

Explanation: A = 6a² = 6×50² = 15,000 mm².

Q51. A cylinder has radius 10 mm and height 50 mm. Its volume (π=3.14) is:

A. 1,570 mm³ B. 3,140 mm³ C. 15,700 mm³ D. 31,400 mm³

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: V = πr²h = 3.14×10²×50 = 15,700 mm³.

Q52. A sphere has radius 10 mm. Its volume (π=3.14) is approximately:

A. 314 mm³ B. 1,047 mm³ C. 4,187 mm³ D. 12,560 mm³

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: V = 4/3πr³ = 4/3×3.14×1000 ≈ 4,187 mm³.

Q53. For a casting with V=1000 cm³ and A=250 cm², modulus is:

A. 0.25 cm B. 2 cm C. 4 cm D. 250 cm

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: M = V/A = 1000/250 = 4 cm.

Q54. If t_s = C(V/A)^2, C=0.5 min/cm² and M=3 cm, t_s is:

A. 1.5 min B. 3 min C. 4.5 min D. 9 min

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: t_s = 0.5×3² = 4.5 min.

Q55. Two geometrically similar castings have moduli 2 cm and 3 cm. For n=2, the solidification-time ratio t2/t1 is:

A. 1.5 B. 2.00 C. 2.25 D. 3.00

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: t2/t1 = (M2/M1)² = (3/2)² = 2.25.

Q56. A metal volume of 2,400 cm³ is poured in 30 s. Flow rate is:

A. 8 cm³/s B. 80 cm³/s C. 800 cm³/s D. 72,000 cm³/s

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Q = 2400/30 = 80 cm³/s.

Q57. A sprue area is 100 mm² and velocity is 2,000 mm/s. Flow rate is:

A. 20,000 mm³/s B. 200,000 mm³/s C. 2,000,000 mm³/s D. 50 mm³/s

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Q = A v = 100×2000 = 200,000 mm³/s.

Q58. A cavity volume is 600,000 mm³ and flow rate is 200,000 mm³/s. Filling time is:

A. 0.3 s B. 3 s C. 30 s D. 120 s

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: t = V/Q = 600000/200000 = 3 s.

Q59. A metal has density 2.7 g/cm³ and volume 500 cm³. Its mass is:

A. 135 g B. 1,350 g C. 2,700 g D. 185 g

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: m = ρV = 2.7×500 = 1350 g.

Q60. A casting volume contracts by 5% from 1000 cm³. Final volume is:

A. 50 cm³ B. 950 cm³ C. 995 cm³ D. 1050 cm³

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Final volume = 1000(1−0.05) = 950 cm³.

Q61. A linear dimension is 200 mm and linear contraction is 1%. Final dimension is:

A. 198 mm B. 199 mm C. 201 mm D. 202 mm

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Final length = 200(1−0.01) = 198 mm.

Q62. A cube edge is 100 mm. If volume reduces by 7%, the final volume is:

A. 93,000 mm³ B. 930,000 mm³ C. 1,000,000 mm³ D. 1,070,000 mm³

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Initial V=100³=1,000,000 mm³; final V=0.93×1,000,000=930,000 mm³.

Q63. For a cylinder of radius 20 mm and height 40 mm, lateral area is (π=3.14):

A. 2,512 mm² B. 5,024 mm² C. 7,536 mm² D. 10,048 mm²

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Lateral area = 2πrh = 2×3.14×20×40 = 5,024 mm².

Q64. A cube has side 30 mm. Its modulus considering all six faces is:

A. 2.5 mm B. 5 mm C. 10 mm D. 15 mm

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: M=V/A=a³/(6a²)=a/6=30/6=5 mm.

Q65. A rectangular casting is 100×50×20 mm. Its volume is:

A. 10,000 mm³ B. 50,000 mm³ C. 100,000 mm³ D. 170,000 mm³

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: V=100×50×20=100,000 mm³.

Q66. A rectangular casting is 100×50×20 mm. Its total surface area is:

A. 7,000 mm² B. 14,000 mm² C. 16,000 mm² D. 20,000 mm²

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: A=2(lw+lh+wh)=2(5000+2000+1000)=16,000 mm².

Q67. A riser has V=900 cm³ and cooling area=150 cm². Its modulus is:

A. 0.167 cm B. 6 cm C. 150 cm D. 1050 cm

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: M=V/A=900/150=6 cm.

Q68. If solidification time is proportional to M², increasing modulus from 2 to 4 cm changes time by factor:

A. 2 B. 4 C. 8 D. 16

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: Time ratio=(4/2)²=2²=4.

Q69. A downsprue area is 250 mm² and velocity is 1,600 mm/s. Flow rate is:

A. 400,000 mm³/s B. 40,000 mm³/s C. 4,000 mm³/s D. 640,000 mm³/s

Check Answer

Correct Answer: A   |   Marks: 1

Explanation: Q=Av=250×1600=400,000 mm³/s.

Q70. A mould cavity volume is 1,200,000 mm³ and flow rate is 400,000 mm³/s. Filling time is:

A. 0.3 s B. 3 s C. 30 s D. 300 s

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: t=V/Q=1,200,000/400,000=3 s.

Q71. For h=0.50 m and g=9.81 m/s², ideal velocity is approximately:

A. 1.10 m/s B. 2.10 m/s C. 3.13 m/s D. 4.90 m/s

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: v=sqrt(2×9.81×0.50)=sqrt(9.81)=3.13 m/s.

Q72. A 10% linear shrinkage allowance is incorrectly applied to a 100 mm dimension. The pattern dimension becomes:

A. 90 mm B. 100 mm C. 110 mm D. 120 mm

Check Answer

Correct Answer: C   |   Marks: 1

Explanation: Pattern dimension = casting dimension×(1+0.10)=110 mm. Actual allowances depend on alloy and scale.

Q73. A cylinder and cube have equal volume. If their moduli are 5 cm and 4 cm respectively and n=2, t_cylinder/t_cube is:

A. 0.64 B. 0.80 C. 1.25 D. 1.56

Check Answer

Correct Answer: D   |   Marks: 1

Explanation: Time ratio=(5/4)²=25/16=1.5625≈1.56.

Q74. A casting weighs 8 kg and has volume 0.002 m³. Density is:

A. 400 kg/m³ B. 4000 kg/m³ C. 16 kg/m³ D. 0.00025 kg/m³

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: ρ=m/V=8/0.002=4000 kg/m³.

Q75. A riser must solidify 1.5 times as long as a casting. With n=2 and casting modulus 2 cm, required riser modulus is:

A. 1.22 cm B. 2.45 cm C. 3 cm D. 4.5 cm

Check Answer

Correct Answer: B   |   Marks: 1

Explanation: t_r/t_c=(M_r/M_c)²; M_r=2×sqrt(1.5)=2.45 cm.