Question 1

What is a common example of a product made using the casting process?

Accepted Answer

Engine blocks

Answer

Rubber gaskets

Answer

Plastic tubing

Answer

Electrical wiring

Question 2

Which mold type cannot be reused?

Accepted Answer

Expendable molds

Answer

Shell molds

Answer

Permanent molds

Answer

Composite molds

Question 3

What material is commonly used for sand casting?

Accepted Answer

Silica (SiO2)

Answer

Graphite

Answer

Zinc oxide

Answer

Calcium sulfate

Question 4

What is a characteristic of green-sand molds?

Accepted Answer

Moist sand when metal is poured

Answer

Uses metal bonding agents

Answer

Utilizes ceramic particles

Answer

Requires heating to harden

Question 5

What is the top part of a mold called in sand casting?

Accepted Answer

Cope

Answer

Sprue

Answer

Riser

Answer

Drag

Question 6

Which type of mold is formed by a cold-setting process with no heating required?

Accepted Answer

Cold-box mold

Answer

Composite mold

Answer

Shell mold

Answer

Green-sand mold

Question 7

Which component carries molten metal from the sprue to the cavity?

Accepted Answer

Runner system

Answer

Cope

Answer

Flask

Answer

Riser

Question 8

Which material is NOT suitable for making patterns in plaster-mold casting?

Accepted Answer

Wood

Answer

Aluminum alloys

Answer

Zinc alloys

Answer

Brass alloys

Question 9

What is the main disadvantage of plaster-mold casting?

Accepted Answer

Cannot withstand temperatures above 1200°C

Answer

Low dimensional accuracy

Answer

Poor surface finish

Answer

Difficult to remove pattern

Question 10

What is a key advantage of shell-mold casting?

Accepted Answer

Produces sharp corners and thin sections

Answer

Requires no heating process

Answer

Uses low-cost wooden patterns

Answer

Suitable for low production runs

Question 11

What is the primary material used in lost-foam casting patterns?

Accepted Answer

Polystyrene

Answer

Aluminum

Answer

Ceramic

Answer

Wax

Question 12

Which casting process is also known as the 'lost wax process'?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Vacuum casting

Answer

Die casting

Question 13

Which metals are commonly used in hot-chamber die casting?

Accepted Answer

Zinc, magnesium, tin, and lead

Answer

Nickel and chromium

Answer

Stainless steel and iron

Answer

Aluminum and copper

Question 14

What is the primary purpose of heating molds in permanent mold casting?

Accepted Answer

To aid metal flow and reduce thermal damage

Answer

To prevent mold cracking

Answer

To reduce solidification time

Answer

To improve the surface finish

Question 15

What process uses rotational inertia to distribute molten metal?

Accepted Answer

Centrifugal casting

Answer

Die casting

Answer

Vacuum casting

Answer

Pressure casting

Question 16

What is the purpose of chaplets in sand casting?

Accepted Answer

To hinder core shifting

Answer

To improve surface finish

Answer

To assist in metal flow

Answer

To cool the mold

Question 17

Which component supplies additional molten metal to the mold cavity?

Accepted Answer

Riser

Answer

Gate

Answer

Sprue

Answer

Flask

Question 18

What is the primary drawback of vacuum casting?

Accepted Answer

High equipment costs

Answer

Limited material compatibility

Answer

Poor surface finish

Answer

Low production speed

Question 19

What casting method combines elements of both casting and forging?

Accepted Answer

Squeeze casting

Answer

Slush casting

Answer

Die casting

Answer

Pressure casting

Question 20

What is the purpose of a draft angle in casting design?

Accepted Answer

To aid removal from the mold

Answer

To prevent gas formation

Answer

To increase mold strength

Answer

To improve cooling rate

Question 21

What method creates hollow castings with thin walls by pouring out excess metal?

Accepted Answer

Slush casting

Answer

Pressure casting

Answer

Die casting

Answer

Lost-foam casting

Question 22

Which casting process is ideal for producing complicated shapes with precision?

Accepted Answer

Ceramic-mold casting

Answer

Plaster-mold casting

Answer

Sand casting

Answer

Hot-chamber casting

Question 23

What is a common application for investment casting?

Accepted Answer

Office equipment

Answer

Structural beams

Answer

Engine blocks

Answer

Pipes and plumbing fixtures

Question 24

Why is fine sand used in shell-mold casting?

Accepted Answer

To achieve sharper corners and thinner sections

Answer

To enhance metal flow

Answer

To reduce mold weight

Answer

To increase permeability

Question 25

What material is often used to coat permanent molds for improved lifespan?

Accepted Answer

Graphite

Answer

Calcium sulfate

Answer

Aluminum powder

Answer

Zinc oxide

Question 26

What defect results from molten metal cooling too rapidly?

Accepted Answer

Cold shut

Answer

Sand inclusion

Answer

Shrinkage cavity

Answer

Blowhole

Question 27

Which casting defect occurs due to trapped gases?

Accepted Answer

Blowhole

Answer

Cold shut

Answer

Mold crack

Answer

Sand inclusion

Question 28

What type of casting defect appears as small, thin cracks on the surface?

Accepted Answer

Hot tears

Answer

Sand inclusion

Answer

Cold shut

Answer

Blowhole

Question 29

Which casting process achieves the best dimensional accuracy?

Accepted Answer

Investment casting

Answer

Lost-foam casting

Answer

Sand casting

Answer

Die casting

Question 30

What is the purpose of a core in sand casting?

Accepted Answer

To form internal cavities in castings

Answer

To reinforce the flask walls

Answer

To distribute molten metal evenly

Answer

To support the riser system

Question 31

What is a primary advantage of pressure casting?

Accepted Answer

Reduced porosity and improved surface finish

Answer

Minimal heat requirements

Answer

Simplified mold design

Answer

Lower equipment cost

Question 32

In cold-chamber die casting, why is the molten metal ladled into the chamber?

Accepted Answer

To prevent damage to the injection components

Answer

To improve cooling rate

Answer

To control gas release

Answer

To reduce metal oxidation

Question 33

What is a key benefit of squeeze casting?

Accepted Answer

Reduced porosity and high strength parts

Answer

Minimal material waste

Answer

Low mold maintenance

Answer

Quick mold preparation

Question 34

Match each process with its corresponding description

Question 35

Match each process with if its corresponding mold and pattern Pt. 1

Question 36

Match each process with if its corresponding mold and pattern Pt. 2

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