Metal Casting Fundamentals Quiz: Test Your Knowledge

Question 1

What is the primary purpose of a pattern in sand casting?

Accepted Answer

To create a cavity in the mold that will shape the casting

Answer

To act as a heat sink during solidification

Answer

To support the mold during pouring

Question 2

Which of the following is NOT a common type of sand used in sand casting?

Accepted Answer

Quartz sand

Answer

Furan sand

Answer

Green sand

Answer

Dry sand

Question 3

What is the primary reason for using a riser in sand casting?

Accepted Answer

To compensate for shrinkage during solidification and prevent voids

Answer

To increase the strength of the casting

Answer

To prevent the mold from collapsing

Answer

To allow for easier pouring of the molten metal

Question 4

What is the primary factor that determines the pouring temperature for a particular metal in sand casting?

Accepted Answer

The melting point and fluidity of the metal

Answer

The size and shape of the casting

Answer

The type of sand used in the mold

Answer

The ambient temperature of the foundry

Question 5

Which of the following casting defects is most likely caused by improper venting of the mold?

Accepted Answer

Gas porosity

Answer

Cold shut

Answer

Misrun

Answer

Hot tear

Question 6

What is the primary purpose of a core in sand casting?

Accepted Answer

To create internal cavities or complex shapes in the casting

Answer

To increase the strength of the casting around it

Answer

To reduce the weight of the casting

Question 7

What is the purpose of a chill in sand casting?

Accepted Answer

To accelerate cooling and solidification in specific areas

Answer

To prevent the mold from collapsing

Answer

To act as a heat sink during pouring

Question 8

Which of the following is a common method for removing the casting from the sand mold?

Accepted Answer

Shakeout

Answer

Cutting

Answer

Grinding

Answer

Polishing

Question 9

What is the key difference between green sand and dry sand molds?

Accepted Answer

Green sand molds contain moisture, while dry sand molds are baked to remove moisture.

Answer

Green sand molds are stronger than dry sand molds.

Answer

Green sand molds are used for smaller castings, while dry sand molds are used for larger castings.

Question 10

How can you reduce the risk of sand inclusions in a sand casting?

Accepted Answer

Using fine-grained sand and ensuring proper venting

Answer

Increasing the pouring temperature

Answer

Adding more binder to the sand mixture

Question 11

Which of the following is NOT a typical step in the sand casting process?

Accepted Answer

Annealing

Answer

Solidification

Answer

Pattern making

Answer

Molding

Question 12

What is the main function of the sprue in a sand mold?

Accepted Answer

To guide molten metal into the mold cavity.

Answer

To allow gases to escape from the mold.

Answer

To provide structural support for the casting.

Answer

To act as a reservoir for molten metal.

Question 13

Which type of pattern is designed for multiple uses and made from a durable material?

Accepted Answer

Permanent pattern

Answer

Match-plate pattern

Answer

Loose pattern

Question 14

What is the primary purpose of a riser in sand casting?

Accepted Answer

To compensate for shrinkage during solidification.

Answer

To facilitate cleaning of the casting.

Answer

To reduce porosity in the casting.

Answer

To increase the strength of the casting.

Question 15

What is the main purpose of using a chill in a sand mold?

Accepted Answer

To accelerate cooling in a specific area of the casting.

Answer

To minimize shrinkage in the casting.

Answer

To enhance the surface finish of the casting.

Question 16

Which of the following casting defects results from the premature solidification of molten metal?

Accepted Answer

Cold shut

Answer

Shrinkage cavity

Answer

Porosity

Question 17

Why is solidification time a crucial factor in metal casting?

Accepted Answer

It significantly influences the microstructure and properties of the casting.

Answer

It affects the cooling rate of the casting.

Answer

It plays a role in mold design.

Question 18

What is a key advantage of using investment casting?

Accepted Answer

Production of complex and intricate castings with high precision.

Answer

Fast production time.

Answer

Low production cost.

Answer

Suitability for large castings.

Question 19

When selecting a molding material for sand casting, what is the most important consideration?

Accepted Answer

Refractoriness (resistance to heat and melting)

Answer

Collapsibility (ability to break down for easy removal)

Answer

Permeability (ability to allow gases to escape)

Answer

Strength (ability to withstand molding pressure)