Manufacturing Processes Chapter 10
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, and (d) top riser?
(a) and (c).
In foundry work, a runner is which one of the following: (a) channel in the mold leading from the downsprue to the main mold cavity, (b) foundryman who moves the molten metal to the mold, or (c) vertical channel into which molten metal is poured into the mold?
(a).
Sand casting is which of the following types: (a) expendable mold or (b) permanent mold?
(a).
The upper half of a sand-casting mold is called which of the following: (a) cope or (b) drag?
(a).
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, or (d) time to give up the heat of fusion?
(a).
In a sand-casting mold, the V/A ratio of the riser should be (a) equal to, (b) greater than, or (c) smaller than the V/A ratio of the casting itself?
(b).
In casting, a flask is which one of the following: (a) beverage bottle for foundrymen, (b) box which holds the cope and drag, (c) container for holding liquid metal, or (d) metal which extrudes between the mold halves?
(b).
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, and (f) it increases total solidification time?
(c) and (d).
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, and (e) waste metal that is usually recycled?
(c), (d), and (e).
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, or (e) solidus?
(d).
Chvorinov's rule states that total solidification time is proportional to which one of the following quantities: (a) (A/V)n, (b) Hf, (c) Tm, (d) V, (e) V/A, or (f) (V/A)2; where A = surface area of casting, Hf = heat of fusion, Tm = melting temperature, and V = volume of casting?
(f).
What is a chill in casting?
A chill is a heat sink placed to encourage rapid freezing in certain regions of the casting.
What is a eutectic alloy?
A eutectic alloy is a particular composition in an alloy system for which the solidus and liquidus temperatures are equal. The temperature is called the eutectic temperature. Hence, solidification occurs at a single temperature, rather than over a temperature range.
What is a factory that performs casting operations usually called?
A foundry.
Identify some of the important advantages of shape-casting processes.
Advantages include (1) complex part geometries are possible; (2) some casting operations are net shape processes, meaning that no further manufacturing operations are needed to accomplish the final part shape; (3) very large parts are possible; (4) they are applicable to any metal that can be melted; and (5) some casting processes are suited to mass production.
What is the difference between an open mold and a closed mold?
An open mold is open to the atmosphere at the top; it is an open container in the desired shape which must be flat at the top. A closed mold has a cavity that is entirely enclosed by the mold, with a passageway (called the gating system) leading from the outside to the cavity. Molten metal is poured into this gating system to fill the mold.
What is the relationship known as Chvorinov's rule in casting?
Chvorinov's rule is summarized: TTS = Cm(V/A)2, where TTS = total solidification time, Cm = mold constant, V = volume of casting, and A = surface area of casting.
What are some of the limitations and disadvantages of casting?
Disadvantages include (1) limitations on mechanical strength properties; (2) porosity; (3) poor dimensional accuracy; (4) safety hazards due to handling of hot metals; and (5) environmental problems.
What does heat of fusion mean in casting?
Heat of fusion is the amount of heat energy required to transform the metal from solid state to liquid state.
Which casting process is the most important commercially?
Sand casting is the most important casting process.
What is meant by the term superheat?
Superheat is the temperature difference above the melting point at which the molten metal is poured. The term also refers to the amount of heat that is removed from the molten metal between pouring and solidification.
What is the continuity law as it applies to the flow of molten metal in casting?
The continuity law, or continuity equation, indicates that the volumetric flow rate is constant throughout the liquid flow.
What are some of the factors that affect the fluidity of a molten metal during pouring into a mold cavity?
The factors include (1) pouring temperature above the melting point, (2) metal alloy composition, (3) viscosity of the liquid metal, and (4) heat transfer to the surroundings.
What is the difference between a pattern and a core in sand molding?
The pattern determines the external shape of the cast part, while a core determines its internal geometry if the casting includes a cavity.
Identify the three sources of contraction in a metal casting after pouring.
The three contractions occur due to (1) contraction of the molten metal after pouring, (2) solidification shrinkage during transformation of state from liquid to solid, and (3) thermal contraction in the solid state.
Why should turbulent flow of molten metal into the mold be avoided?
Turbulence causes the following problems: (1) it accelerates formation of oxides in the solidified metal, and (2) it causes mold erosion or gradual wearing away of the mold due to impact of molten metal.
How does solidification of alloys differ from solidification of pure metals?
Pure metals solidify at a single temperature equal to the melting point. Most alloys (exceptions are eutectic alloys) start to solidify at the liquidus and complete solidification occurs at the solidus, where the liquidus is a higher temperature than the solidus.
Name the two basic mold types that distinguish casting processes.
The two mold types are (1) expendable molds and (2) permanent molds.
