ISE 2500 Exam 1

Which of the following alloying elements are most commonly associated with stainless steel (two best answers): (a) chromium, (b) manganese, (c) molybdenum, (d) nickel, and (e) tungsten?

a and d

The pattern that determines the geometry of the casting in expendable mold processes is usually made (a) oversized (b) the same size (c) undersized relative to the dimensions of the casting

a) oversize

From which of the following ores is aluminum derived: (a) alumina, (b) bauxite, (c) cementite, (d) hematite, or (e) scheelite?

b

Plain carbon steels are designated in the AISI code system by which of the following: (a) 01XX, (b) 10XX, (c) 11XX, (d) 12XX, or (e) 30XX

b

A unit operation is defined as a single manufacturing step in the sequence of steps required to transform a starting material into a final part or product: (a) true or (b) false

(a)

The term plant capacity refers to the maximum rate of production that a factory can achieve under assumed labor manning levels, hours of operation per week, and other operating conditions: (a) true or (b) false?

(a)

Which one of the following engineering materials is defined as a compound containing metallic and nonmetallic elements: (a) ceramic, (b) composite, (c) metal, or (d) polymer

(a)

Two important relationships that determine the flow of molten metal in casting are which of the following (two correct answers): (a) Bernoulli's theorem (b) Chvorinov's rule (c) continuity law (d) flow curve (e) Hooke's law (f) Ohm's law

(a) Bernoulli's theorem (c) continuity law

Which of the following metals would typically be used in die casting (three best answers): (a) aluminum, (b) cast iron, (c) steel, (d) tin, (e) tungsten, and (f) zinc

(a) aluminum, (d) tin (f) zinc

Which of the following are metals commonly cast in permanent mold casting (three best answers): (a) aluminum, (b) brass, (c) gold, d) magnesium, (e) nickel, (f) steel, and (g)tungsten

(a) aluminum, (b) brass d) magnesium,

Today, the two most important processes in steelmaking are which of the following (two correct answers): (a) basic oxygen furnace, (b) Bessemer converter, (c) electric arc furnace, (d) induction furnace, and (e) open hearth furnace?

(a) and (c).

Which of the following processes start with a material that is in a fluid or semifluid state and solidifies the material in a cavity (two correct answers): (a) casting, (b) forging, (c) machining, (d) molding, (e) pressing, and (f) turning

(a) and (d)

Which of the following are referred to as thin film deposition processes (two correct answers): (a) chemical vapor deposition, (b) electroplating, (c) extrusion, (d) painting, and (e) physical vapor deposition?

(a) and (e)

In sand casting, the volumetric size of the pattern is (a) bigger than (b) same size as (c) smaller than the cast part

(a) bigger than

Which of the following riser types are completely enclosed within the sand mold and connected to the main cavity by a channel to feed the molten metal (two correct answers): (a) blind riser (b) open riser (c) side riser (d) top riser

(a) blind riser (c) side riser

In casting processes, a runner is which one of the following: (a) channel in the mold leading from the downsprue to the main mold cavity (b) worker who moves the molten metal to the mold (c) vertical channel into which molten metal is poured into the mold

(a) channel in the mold leading from the downsprue to the main mold cavity

The upper half of a sand-casting mold is called which one of the following: (a) cope (b) drag (c) flask (d) pattern

(a) cope

The internal surfaces of a casting are determined during the casting process by means of which one of the following: (a) core (b) gating system (c) parting line (d) pattern (e) sprue

(a) core

Sand casting is which of the following types of casting process: (a) expendable mold (b) permanent mold

(a) expendable mold

Metal inserts in the walls of a sand mold cavity designed to remove heat from the molten metal more rapidly than the surrounding sand are called which one of the following: (a) external chills (b) internal chills (c) pipes (d) sprues

(a) external chills

Total solidification time is defined as which one of the following: (a) time between pouring and complete solidification (b) time between pouring and cooling to room temperature (c) time between solidification and cooling to room temperature (d) time to give up the heat of fusion

(a) time between pouring and complete solidification

A typical production cycle time consists of which of the following elements (three best answers): (a) actual processing time, (b) inspection time, (c) rest breaks for the worker, (d) time to withdraw starting materials from storage, (e) tool fabrication time, (f) tool handling time, and (g) work handling time?

(a), (f), and (g). It might be argued that inspection time should also be included if the work part must be inspected in each cycle.

Products purchased by companies to produce products or provide services are called which one of the following: (a) assembled products, (b) capital goods, (c) consumer goods, (d) final products, or (e) manufactured products?

(b)

An alloy is a metal composed of two or more elements, at least one of which is metallic. The two main categories of alloys are which two of the following: (a) alloids, (b) intermediate phases, (c) metal compounds, (d) phase solutions, and (e) solid solutions?

(b) and (e)

Ferrous metals include which of the following (two correct answers): (a) aluminum, (b) cast iron, (c) copper, (d) gold, and (e) steel?

(b) and (e)

In casting, a flask is which one of the following: (a) beverage bottle for workers who perform casting (b) box which holds the cope and drag (c) container for holding liquid metal (d) metal which extrudes between the mold halves

(b) box which holds the cope and drag

Cupolas are furnaces used to melt which of the following metals (one best answer): (a) aluminum, (b) cast iron, (c) steel, or (d) zinc

(b) cast iron

In hot-chamber die-casting machines, molten metal is poured into an unheated chamber from an external melting container, and a piston is used to inject the metal under high pressure into the die cavity: (a) true or (b) false

(b) false

For which one of the following reasons is a green mold named: (a) green is the color of the mold (b) moisture is contained in the mold (c) the mold is cured (d) the mold is dry

(b) moisture is contained in the mold

Mining is classified in which one of the following industry categories: (a) agricultural industry, (b) manufacturing industry, (c) primary industry, (d) secondary industry, (e) service industry, or (f) tertiary industry?

(c)

Silica sand has which one of the following compositions: (a) Al2O3 (b) SiO (c) SiO2 (d) SiSO4

(c) SiO2

A eutectic alloy is which of the following (two correct answers): (a) the composition in an alloy system at which the two elements are present in equal proportions, (b) the composition in an alloy system for which the solidus and liquidus are at different temperatures, (c) the composition in an alloy system for which the solidus and liquidus are at the same temperature, (d) the composition in an alloy system that has the highest melting point, and (e) the composition in an alloy system that has the lowest melting point?

(c) and (e)

Which of the following features and terms are associated with batch production: (a) cellular manufacturing, (b) mass production, (c) medium quantity production, (d) production equipment is dedicated to one product, and (e) setup time between batches is a disadvantage?

(c) and (e)

Which of the following properties or characteristics do not apply to metals (two correct answers): (a) good thermal conductivity, (b) high strength, (c) high electrical resistivity, (d) high stiffness, and (e) ionic bonding?

(c) and (e)

Which one of the following casting metals is most important commercially: (a) aluminum and its alloys, (b) bronze, (c) cast iron, (d) cast steel, or (e) zinc alloys

(c) cast iron

Solidification shrinkage in casting is defined as which one of the following: (a) liquid contraction during cooling prior to solidification (b) liquid contraction during cooling and solidification (c) contraction during the phase change from liquid to solid (d) thermal contraction of the solidified casting during cooling to room temperature

(c) contraction during the phase change from liquid to solid

Deformation processes include which of the following (two correct answers): (a) casting, (b) drilling, (c) extrusion, (d) forging, (e) milling, (f) painting, and (g) sintering

(c) extrusion, (d) forging

Which of the following casting processes are expendable mold operations (four correct answers): (a) centrifugal casting (b) die casting (c) investment casting (d) low pressure casting (e) sand casting (f) shell molding (g) slush casting (h) vacuum molding

(c) investment casting (e) sand casting (f) shell molding (h) vacuum molding

A misrun is which one of the following defects in casting: (a) globules of metal becoming entrapped in the casting, (b) metal is not properly poured into the downsprue, (c) metal solidifies before filling the cavity, (d) microporosity, and (e) "pipe" formation

(c) metal solidifies before filling the cavity

A riser in casting is described by which of the following (three correct answers): (a) an insert in the casting that inhibits buoyancy of the core (b) gating system in which the sprue feeds directly into the cavity (c) metal that is not part of the casting (d) source of molten metal to feed the casting and compensate for shrinkage during solidification (e) waste metal that is usually recycled

(c) metal that is not part of the casting (d) source of molten metal to feed the casting and compensate for shrinkage during solidification (e) waste metal that is usually recycled

An irregularity in the surface of the casting caused by erosion of the sand during pouring is called which one of the following sand casting defects: (a) penetration, (b) sand blow, (c) sand wash, or (d) scabs

(c) sand wash

Which one of the following is the name of the casting process in which molten metal is poured into a rotating mold to produce a tubular part: (a) centrifuge casting, (b) semicentrifugal casting, or (c) true centrifugal casting

(c) true centrifugal casting

Inventions of the Industrial Revolution include which one of the following: (a) automobile, (b) cannon, (c) printing press, (d) steam engine, or (e) sword?

(d)

During solidification of an alloy when a mixture of solid and liquid metals is present, the solid-liquid mixture is referred to as which one of the following: (a) eutectic composition (b) ingot segregation (c) liquidus (d) mushy zone e) solidus

(d) mushy zone

The term vulcanization is associated with which one of the following: (a) adhesives, (b) bronze, (c) fire, (d) rubber, or (e) wood?

(d) rubber

Which one of the following casting processes is the most widely used: (a) centrifugal casting (b) die casting (c) investment casting (d) sand casting (e) shell casting

(d) sand casting

High-volume production of assembled products is most closely associated with which one of the following layout types: (a) cellular layout, (b) fixed position layout, (c) process layout, or (d) product layout?

d

In the context of production equipment in a factory, the term availability is best defined by which one of the following: (a) downtime proportion, (b) hourly operating cost, (c) proportion of good products, (d) proportion uptime, or (e) utilization?

d

The iron tapped from the blast furnace is which one of the following: (a) cast iron, (b) low alloy steel, (c) low carbon steel, (d) pig iron, (e) pure iron, or (f) stainless steel?

d

The predominant phase in the iron-carbon alloy system for a composition with 99% iron at room temperature is which one of the following: (a) austenite, (b) cementite, (c) delta, (d) ferrite, or (e) gamma?

d

Which one of the following is a type of machine used to perform extrusion: (a) forge hammer, (b) milling machine, (c) rolling mill, (d) press, or (e) torch?

d

The Bayer process is associated with the production of which one of the following metals: (a) aluminum, (b) copper, (c) nickel, (d) titanium, or (e) zinc?

a

Which of the following cost categories are considered to be variable costs rather than fixed costs (two correct answers): (a) direct labor, (b) equipment, (c) insurance, (d) maintenance, (e) work material, and (f) research and development?

a) and (e)

High-speed steels are used in cutting tools for machining. Which of the following alloying elements are used in the highest proportion in high-speed steel (two correct answers): (a) carbon, (b) manganese, (c) molybdenum, (d) nickel, (e) tungsten, and (f) vanadium?

c and e

The strength and hardness of steel increases as carbon content (a) increases or (b) decreases?

a

Which of the following metals is noted for its good electrical conductivity (one best answer): (a) copper, (b) gold, (c) iron, (d) nickel, or (e) tungsten?

a

Which one of the following elements is the most important alloying ingredient in steel: (a) carbon, (b) chromium, (c) nickel, (d) molybdenum, or (e) vanadium?

a

Which one of the following metals has the lowest density: (a) aluminum, (b) magnesium, (c) manganese, (d) tin, (e) titanium, or (f) zinc?

b

Which one of the following metals is not one of the three metals used as the principal constituent in superalloys: (a) cobalt, (b) chromium, (c) iron, or (d) nickel?

b

Traditional brass is an alloy of which of the following metallic elements (two correct answers): (a) aluminum, (b) copper, (c) gold, (d) tin, and (e) zinc?

b and e

Which of the following casting processes are permanent mold operations (two correct answers): (a) centrifugal casting, (b) expanded polystyrene process, (c) sand casting, (d) shell molding, (e) slush casting, and (f) vacuum molding

(a) centrifugal casting (e) slush casting

The Antioch process is similar to plaster-mold casting but uses a mixture of sand and plaster to make the mold: (a) true (b) false

(a) true

The expanded polystyrene casting process uses a mold of sand packed around a polystyrene foam pattern that vaporizes when the molten metal is poured into the mold: (a) true (b) false

(a) true

Which of the following industries are classified as secondary industries (three correct answers): (a) beverages (b) financial services, (c) fishing, (d) power utilities, (e) publishing, and (f) transportation

(a), (d), and (e)

Shell molding is best described by which one of the following: (a) casting operation in which the molten metal has been poured out after a thin shell has been solidified in the mold (b) casting process in which the mold is a thin shell of sand bonded by a thermosetting resin (c) sand-casting operation in which the pattern is a shell rather than a solid form (d) casting operation used to make artificial sea shells

(b) casting process in which the mold is a thin shell of sand bonded by a thermosetting resin

A factory that performs casting processes is called which of the following (one best answer): (a) casting plant (b) foundry (c) ingot-making plant (d) metal working plant (e) molding plant

(b) foundry

In a sand-casting mold, the V/A ratio of the riser should be (a) equal to (b) greater than (c) smaller than the V/A ratio of the casting itself

(b) greater than

Which of the following qualifies as a precision-casting process (two correct answers): (a) ingot casting (b) investment casting (c) plaster-mold casting (d) sand casting (e) shell molding

(b) investment casting (c) plaster-mold casting

Which of the following names are applied to a process in which a molten metal is poured into a heated lower die, and the upper die is closed to create the mold cavity only after solidification begins (two correct answers): (a) liquid-metal casting, (b) liquid-metal forging, (c) rheocasting, (d) squeeze casting, or (e) thixocasting

(b) liquid-metal forging (d) squeeze casting

Turbulence during pouring of the molten metal is undesirable for which of the following reasons (two best answers): (a) it causes discoloration of the mold surfaces (b) it dissolves the binder used to hold together the sand mold (c) it increases erosion of the mold surfaces (d) it increases the formation of metallic oxides that can become entrapped during solidification (e) it increases the mold filling time (f) it increases total solidification time

(c) it increases erosion of the mold surfaces (d) it increases the formation of metallic oxides that can become entrapped during solidification

Which of the following operations are classified as material removal processes (three correct answers): (a) anodizing, (b) brazing, (c) forging, (d) grinding, (e) milling, (f) sintering, and (g) turning?

(d), (e), and (g)

Investment casting is also known by which one of the following names: (a) fast-payback molding (b) full-mold process (c) lost-foam process (d) lost-pattern process (e) lost-wax process

(e) lost-wax process

Heating a metal from room temperature to pouring temperature in a casting operation depends on all of the following properties except which one: (a) density (b) heat of fusion (c) melting temperature (d) specific heat (e) thermal expansion

(e) thermal expansion

The empirical relationship that determines total solidification time in casting is known as which one of the following: (a) Bernoulli's theorem (b) Chvorinov's rule (c) continuity law (d) flow curve (e) Hooke's law (f) Ohm's law

(f) Ohm's law

Particulate processing of metals involves which two of the following steps: (a) adhesive bonding, (b) deformation, (c) forging, (d) material removal, (e) melting, (f) pressing, and (g) sintering

(f) and (g)

Casting is a process in which molten metal flows into a mold where it solidifies in the shape of the mold cavity; the term casting also applies to the part that is made by this process: True or False

True

A binary phase diagram is a phase diagram indicating the phases of two metallic elements as a function of composition and temperature at atmospheric pressure: (a) true or (b) false?

a

As temperature is increased to slightly above 912C (1674F), pure iron transforms into which one of the following phases: (a) austenite, (b) cementite, (c) delta, or (d) ferrite?

a

The inverse lever rule is used to determine which one of the following in a binary phase diagram: (a) the compositions of the solid and liquid phases, (b) the proportions of each phase present at a given temperature, or (c) the temperatures of the solidus and liquidus for a given composition?

b

The principal ore used in the production of iron and steel is which one of the following: (a) bauxite, (b) hematite, (c) limestone, (d) magnetite, or (e) smithsonite?

b

Which of the following is the most important cast iron commercially: (a) ductile cast iron, (b) gray cast iron, (c) malleable iron, or (d) white cast iron?

b

A product's total manufacturing costs typically constitute what proportion of the product's selling price: (a) 10%, (b) 20%, (c) 40%, (d) 60%, or (e) 80%?

c

A steel with 1.0% carbon is known as which one of the following: (a) eutectoid, (b)hypoeutectoid, (c) hypereutectoid, or (d) wrought iron?

c

One of the first applications of digital computers in manufacturing was direct numerical control, which is best described by which one of the following: (a) computers used to count work units on a production line, (b) flexible manufacturing, (c) mainframe computers used to remotely control machine tools in a factory, (d) personal computers used to schedule production, or (e) shop floor control?

c

Which of the following metals has the highest density: (a) gold, (b) lead, (c) platinum, (d) silver, or (e) tungsten?

c

A production planning and control department accomplishes which of the following functions in its role of providing manufacturing support (two best answers): (a) designs and orders machine tools, (b) develops corporate strategic plans, (c) orders materials and purchased parts, (d) performs quality inspections, and (e) schedules the order of products on a machine?

c & e

The principal strengthening mechanism in high-strength low-alloy (HSLA) steels is which one of the following: (a) heat treatment, (b) high carbon content, (c) precipitation hardening, (d) solid solution alloying, or (e) work hardening?

d

Which one of the following metals has the lowest melting point: (a) aluminum, (b) lead, (c) magnesium, (d) tin, or (e) zinc?

d

Galvanized steel is steel that has been coated with which one of the following metals: (a) aluminum, (b) chromium, (c) nickel, (d) tin, or (e) zinc?

e

Which one of the following is not a common alloying ingredient in steel: (a) chromium, (b) manganese, (c) nickel, (d) vanadium, (e) zinc?

e

Which one of the following is the source of most commercially produced magnesium: (a) bauxite, (b) clay, (c) magnetite, (d) pentlandite, or (e) sea water?

e