Chapter -1: Casting Process

1. Define the terms “Casting” and “Foundry”.

2. Why casting is preferred over other methods of
manufacturing? Discuss.
3. What are the common basic features to various
casting process.
4. What is a pattern?
5. What are the basic features common to various
casting processes? Discuss their relative merits
and demerits.
6. What considerations are necessary while
designing a pattern?
7. How is layout of a pattern made? State the
procedure for pattern construction.
8. Discuss briefly various types of pattern materials.
9. List the types of factors on which the various
types of patterns depend.
10. Enumerate the various types of commonly used
patterns.
11. With neat sketches explain briefly solid pattern,
skeleton pattern and loose piece pattern.
12. With neat sketches explain briefly the following
patterns:
(a) Segmental pattern (b) Cope and drag pattern
(c) Sweep pattern.
13. List the various types of allowances which are
usually provided in a pattern.
14. Explain briefly the following pattern allowances:
(a) Shrinkage allowance (b) Machining
allowance
(c) Rapping or shaking allowance(d) Distortion
allowance

Chapter -3: Mould Making

1. What are the main characteristics which a good

moulding sand should posses?
2. How does the characteristics of moulding sand
influence the performance during moulding and
casting?
3. Discuss briefly the materials which are added to
moulding sand to improve their moulding
properties.
4. Explain how the grain size and shape affect the
performance of foundry sand.
5. Discuss briefly the influence of water-content on
moulding sand properties.
6. Explain the process of sand preparation and
sand conditioning.
7. What is “Stop-off”? Explain briefly.
8. Explain briefly, parting sand, facing sand and
backing sand.
9. What are mould surface coatings? Explain.
10. Explain the process of sand preparation and
sand conditioning.
11. Why testing of foundry sand is necessary? What
are the common tests performed on foundry
sands?
12. What are the main characteristics of a good
core sand?
13. What are the main core binders? Discuss
their uses in making core sand.
14. Classify the different types of moulds and state
their advantages.
15. Draw the sketch of a typical mould and name its
principal parts.
16. What is stack moulding?
17. Sketch and describe the following
techniques, stating clearly their advantages and
special applications :
(a) use of false cope, (b) use of dry sand cores, (c)
use of drawbacks,
(d) bedding-in, (e) coping down.
18. How does machine moulding differ from hand
moulding? List the advantages and
disadvantages of moulding machines.
19. Discuss briefly moulding machines.
20. State the advantages of the following
(a) Dry sand mould over green sand mould,
(b) Loam mould over dry sand mould,
(c) Permanent mould over dry sand mould.
21. With a neat sketch explain briefly the
construction and working of a cupola furnace.
22. With a neat sketch explain briefly the electric
furnace.

Chapter -4: Gating Systems

1. What is a gate and list the functions of a gating

system.
2. With a neat sketch explain the different parts of
a gating system.
3. How a gate is designed?
4. What is meant by “risering”? State the
advantages that are provided by a riser.
5. What is the best shape and size of a riser? Why?
6. Write short notes on
(a) Use of padding (b) Use of exothermic
materials, and
7. With neat sketches explain the different types of
gating systems.
8. What is gating ratio? Explain.

Chapter -5: Cooling and Solidification

1. Explain briefly the process of crystallization of

pure metals.
2. What is dendritic solidification? Explain.
3. What is the critical size of nucleation that
nucleates from melt?
4. Deduce the expression for free energy concept in
solidification.
5. Explain the following:
(a) Normal segregation, (b) Gravity
segregation, (c) Micro-segregation
and (d) Macro-segregation.
6. What is the scope of chills in obtaining
directional solidification? Explain.

Chapter -6: Casting Processes

1. What are the steps involved in preparation of a

casting?
2. State the advantages and disadvantages of
casting process.
3. What are the basic rules for good casting design?
4. List the different types of casting processes.
5. With a neat sketch explain the sand casting
process.
6. Write short notes on:
(a) Shell-mould casting, (b) Plaster-
mould casting, (c) Ceramic-mould
casting, (d) Vacuum casting and
(e) Evaporative pattern casting.
7. With neat sketch’s explain the investment
casting process. List its advantages,
disadvantages and applications.
8. Explain briefly slush casting, electroslag casting,
precision casting, semi solid metal forming and
pressed casting.
9. What is centrifugal casting? For what type of
jobs would you recommend this casting process?
10. Explain briefly true centrifugal casting, semi-
centrifugal casting and centrifugal casting.
11. What is continuous casting? Explain the process
of continuous casting with a neat sketch.
12. List the advantages claimed by permanent
mould casting over sand casting.
13. Describe the pre-design consideration in the
design of castings.
14. List the factors which influence the choice of the
proper casting method.
15. Enumerate the methods of repairing and
salvaging defective castings.
16. What are the common defects of casting? State
their causes and remedies.
17. Explain briefly the different types of cleaning
operations performed on castings.
18. Discuss briefly the various methods employed to
inspect the castings.
Chapter -7: Hot working processes – Forging

1. What do you understand by the term forging?

2. How does hand forging differ from machine
forging?
3. State the advantages and disadvantages of
forging.
4. Explain briefly the following three basic
categories of forging:
(a) Open-die forging, (b) Impression-Die
forging, and (c) Closed-die forging.
5. What are the different operations carried out by
hand forging? Explain.
6. What are the different types of machines used in
machine forging? Explain.
7. What is forgeability? Explain.
8. Explain briefly the following forging processes:
(a) Precision forging and (b) Isothermal
forging.
9. Explain briefly various cold forging techniques.
10. What do you understand by the term draft on
forgings and why is it provided?
11. Describe briefly the following forging processes:
(a) Drop forging, (b) Press forging, and (c)
Machine forging.
12. Explain briefly the following types of forging
processes:
(a) Roll forging, (b) Rotary forging
or swaging, (c) High velocity forging,
(d)Orbital forging, (e) Incremental forging, (f)
Liquid metal forging, and (g) Gatorizing.
13. Explain briefly the various defects in forging.
14. How are forgings cleaned and finished? Explain
briefly.
 Chapter -8: Welding and Allied processes:

1. Define the term welding and name the various

welding techniques.
2. List out the advantages, disadvantages and
applications of welding.
3. Explain forge welding with their advantages and
disadvantages.
4. What is the principle of operation of resistance
electric welding?
5. Explain the following resistance electric welding
processes:
(a) Butt welding, (b) Flash welding, (c) spot
welding, (d) Seam welding, (e)
Projection welding, and (f) Percussion welding.
6. What do you understand by gas welding? List its
advantages, disadvantages and applications.
7. Describe in brief the equipment required for oxy-
acetylene gas welding.
8. What are the different types of flames obtained
in gas welding? Explain.
9. Explain the leftward and rightward methods of
gas welding.
10. With a neat sketch explain oxy-acetylene gas
welding.
11. Define soldering. Name types of solders.
12. Explain briefly the term ‘Flux” or ‘Soldering
fluid’. Enumerate the fluxes commonly used in
soldering process.
13. Describe briefly the equipments used in
soldering.
14. How is soldering process carried out?
15. What are the characteristics of a good soldering
joint?
16. State the applications of soldering.
17. Explain the term ‘Brazing’.
18. What is the action of a flux in brazing process?
Name the chief flux used in brazing.
19. Describe step wise the procedure of brazing.
20. Enumerate the applications of brazing.
21. What are the characteristics of a good weld?
22. Explain the different defects in welds.
23. Define weldability. What factors affect weldability
explain.
24. List the different tests carried out in inspecting
the welded joints.
25. What are the basic principles of welding design?

Chapter -9: Electric Arc Welding

1. What do you understand by electric arc welding?

List its advantages and disadvantages.
2. With neat sketches explain in brief the following
electric arc welding processes:
 ( a) Metallic arc welding, (b) Carbon arc
welding,
(c) Atomic arc welding, and (d) Shielded arc
welding.
3. What do you mean by arc blow? Explain.
4. How do you compare AC and DC for arc
welding?
5. What are the advantages of each of the several
sources of current for arc welding?
6. What do you understand by the term ‘polarity’
and what is the advantage and disadvantage of
having different polarity.
7. What are the different types of electrodes used in
electric arc welding? Explain.
8. What are the functions of coatings on shielded
electric arc electrodes?
9. With neat sketches explain the different types of
welding joints.
10. With neat sketches explain the different types of
welding positions.

Chapter -10: Special Welding Processes

1. Sketch and explain Thermit welding process.

List its advantages, limitation and applications.
2. With neat sketches explain TIG and MIG welding
processes. Also give their advantages, limitations
and applications.
3. Differentiate between TIG and MIG welding
processes.
4. Explain the following welding processes giving
neat sketches:
(a) Submerged arc welding, (b) Electro-slag
welding,
(c) Electro-gas welding.
5. Sketch and explain the electron beam welding
process.
6. With a neat sketch explain the ultrasonic
welding process.
7. Sketch and explain plasma arc welding process.
8. Giving the advantages and limitations explain
the laser beam welding process with a neat
sketch.
9. Explain the following non traditional welding
processes:
(a) Friction welding, (b) Explosive welding, (c)
Diffusion welding, (d) Induction welding, (e)
Induction welding, (f) Cold welding, (g)
Stud-arc welding, (h) Hydrodynamic welding, and
(h) under water welding