Metal Casting: Interactive Learning Quizzes for Manufacturing Technology

Question 1

Which of the following processes is NOT a type of casting process?

Accepted Answer

Welding

Answer

Die casting

Answer

Investment casting

Answer

Sand casting

Question 2

What is the primary purpose of a mold in casting?

Accepted Answer

To shape and contain molten metal as it solidifies

Answer

To regulate the temperature of the metal

Answer

To polish the finished product

Answer

To melt the metal

Question 3

Which property of cast metals makes them suitable for applications requiring high strength under tensile loads?

Accepted Answer

Tensile strength

Answer

Hardness

Answer

Malleability

Answer

Ductility

Question 4

What is the process of removing surface imperfections and excess material from a casting known as?

Accepted Answer

Finishing

Answer

Annealing

Answer

Sintering

Answer

Molding

Question 5

Which material is commonly used in investment casting to create a precise mold cavity?

Accepted Answer

Wax

Answer

Metal

Answer

Ceramic

Answer

Sand

Question 6

Which of the following factors is NOT typically considered when selecting the appropriate casting method?

Accepted Answer

Material strength

Answer

Production volume

Answer

Part complexity

Answer

Availability of equipment

Question 7

Which drawback is commonly associated with die casting?

Accepted Answer

High tooling costs

Answer

Limited material choices

Answer

Porosity

Answer

Slow production rates

Question 8

What is the primary function of a riser in casting?

Accepted Answer

To provide a reservoir of molten metal to compensate for solidification shrinkage and prevent internal voids

Answer

To strengthen the casting

Answer

To vent gases from the mold

Question 9

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

Accepted Answer

Crushed granite

Answer

Shell sand

Answer

Resin-bonded sand

Answer

Green sand

Question 10

What is the primary function of a gating system in casting?

Accepted Answer

To control the flow of molten metal into the mold cavity

Answer

To cool the molten metal before it enters the mold

Answer

To remove gases from the mold

Answer

To provide support for the mold

Question 11

What is a key advantage of investment casting?

Accepted Answer

Production of complex and intricate shapes with high precision

Answer

Simple mold making process

Answer

Low material cost

Answer

High production rate

Question 12

What is the main purpose of heat treatment in casting?

Accepted Answer

To modify the mechanical properties of the cast metal

Answer

To increase corrosion resistance

Answer

To enhance surface finish

Answer

To reduce porosity

Question 13

What is the primary function of a riser in casting?

Accepted Answer

To compensate for metal shrinkage during solidification

Answer

To improve the surface finish of the casting

Answer

To remove gases from the mold

Question 14

Which of the following is a crucial safety precaution when handling molten metal?

Accepted Answer

Wear appropriate protective gear, including gloves, apron, and face shield

Answer

Work alone

Answer

Handle molten metal with bare hands

Answer

Use a fan to ventilate the area

Question 15

Which casting method offers the highest precision and surface finish?

Accepted Answer

Investment Casting

Answer

Die Casting

Answer

Sand Casting

Answer

Centrifugal Casting

Question 16

The primary function of a sprue in mold design is to:

Accepted Answer

Facilitate the entry of molten metal into the mold cavity

Answer

Dissipate heat from the molten metal

Answer

Generate a vacuum within the mold cavity

Answer

Store a reserve of molten metal

Question 17

Which material is predominantly used in the creation of sand molds?

Accepted Answer

Silica Sand

Answer

Clay

Answer

Plaster

Answer

Metal

Question 18

Heat treatment of cast metals primarily enhances:

Accepted Answer

Strength

Answer

Conductivity

Answer

Corrosion resistance

Answer

Ductility

Question 19

The main purpose of a riser in a mold is to:

Accepted Answer

Provide additional molten metal to compensate for shrinkage

Answer

Allow gases to escape

Answer

Support the mold walls

Question 20

Which type of casting defect results from the presence of trapped air or gases in the molten metal?

Accepted Answer

Porosity

Answer

Cracking

Answer

Shrinkage

Answer

Cold shut

Question 21

The principal advantage of centrifugal casting is:

Accepted Answer

Improved material density and grain refinement

Answer

High production rate

Answer

Capability to produce intricate shapes

Answer

Reduced material waste

Question 22

Which essential safety precaution should be followed when operating a casting furnace?

Accepted Answer

Wear appropriate personal protective equipment

Answer

Handle molten metal with bare hands

Answer

Leave the furnace unattended

Answer

Extinguish metal fires with water

Question 23

Which type of mold is employed to produce castings with fine details and thin sections?

Accepted Answer

Investment Mold

Answer

Die Mold

Answer

Centrifugal Mold

Answer

Sand Mold

Question 24

Which of the following is NOT a significant factor that influences the selection of a casting process?

Accepted Answer

Material compatibility

Answer

Equipment availability

Answer

Production volume

Answer

Part complexity

Question 25

Which casting method is unique in that it does NOT utilize a mold to shape the molten metal?

Accepted Answer

Centrifugal casting

Answer

Investment casting

Answer

Die casting

Answer

Permanent mold casting

Question 26

What is the primary function of a riser in casting?

Accepted Answer

To provide additional molten metal to compensate for shrinkage during solidification, ensuring a sound casting.

Answer

To hold the mold together during the casting process.

Answer

To enhance the surface finish of the casting.

Question 27

Which material is commonly employed for creating molds in investment casting?

Accepted Answer

Ceramic

Answer

Sand

Answer

Metal

Answer

Plastic

Question 28

What is a key advantage of die casting over other casting methods?

Accepted Answer

High production rates and exceptional dimensional accuracy.

Answer

Low cost per part

Answer

Ability to cast complex shapes

Answer

Wide range of materials suitable for casting

Question 29

Which factor plays a critical role in determining the grain size of a casting?

Accepted Answer

Cooling rate

Answer

Mold material

Answer

Composition of the molten metal

Answer

Casting method

Question 30

What is the primary purpose of annealing in the context of casting?

Accepted Answer

To soften the metal, enhance its machinability, and relieve internal stresses.

Answer

To increase the strength and hardness of the metal

Answer

To prevent corrosion

Question 31

Which casting defect is characterized by the presence of gas bubbles trapped within the solidified metal?

Accepted Answer

Porosity

Answer

Cold shuts

Answer

Hot tears

Answer

Shrinkage

Question 32

Why is controlling grain flow important in casting?

Accepted Answer

It promotes strength and reduces the risk of cracking by aligning the grains in a favorable direction.

Answer

It ensures a uniform surface finish.

Answer

It improves the corrosion resistance of the casting.

Question 33

Which of the following is NOT a type of casting process?

Accepted Answer

Extrusion

Answer

Die casting

Answer

Investment casting

Answer

Centrifugal casting

Question 34

What is the primary purpose of a mold in casting?

Accepted Answer

To create a cavity into which molten metal is poured and solidified

Answer

To separate impurities from the molten metal

Answer

To provide support for the cast metal

Question 35

Which type of cast metal is known for its exceptional strength and hardness?

Accepted Answer

Steel

Answer

Aluminum

Answer

Copper

Question 36

What is the key factor that influences the strength of a cast metal?

Accepted Answer

Grain structure

Answer

Cooling rate

Answer

Chemical composition

Answer

Mold material

Question 37

What is the term used to refer to the molten metal employed in the casting process?

Accepted Answer

Foundry metal

Answer

Alloy

Answer

Stock material

Answer

Raw material

Question 38

Which of the following is a crucial safety measure when working with casting equipment?

Accepted Answer

Wear appropriate personal protective equipment (PPE)

Answer

Operate machinery without supervision

Answer

Leave molten metal unattended

Answer

Use flammable materials near molten metal

Question 39

What is the term for the process of creating a mold based on a pattern?

Accepted Answer

Mold making

Answer

Melting

Answer

Finishing

Answer

Casting

Question 40

Which of the following is an advantage of utilizing sand as a mold material in casting?

Accepted Answer

Sand is relatively inexpensive and readily available

Answer

Sand can withstand extremely high temperatures

Answer

Sand is compatible with all types of metals

Answer

Sand produces castings with polished surfaces

Question 41

Which of the following is NOT a type of casting method?

Accepted Answer

Forging

Answer

Investment casting

Answer

Sand casting

Answer

Die casting

Question 42

What is the primary purpose of a mold in casting?

Accepted Answer

To create a cavity that will be filled with molten metal

Answer

To prevent the molten metal from cooling too quickly

Answer

To control the flow of molten metal

Answer

To provide structural support for the casting

Question 43

Which of the following materials is most commonly used to make sand molds?

Accepted Answer

Silica sand

Answer

Metal

Answer

Plastic

Answer

Ceramic

Question 44

What is the term for the process of adding molten metal to a mold?

Accepted Answer

Pouring

Answer

Injection

Answer

Welding

Answer

Casting

Question 45

What is the function of a runner in a casting process?

Accepted Answer

To provide a channel for molten metal to flow into the mold cavity

Answer

To support the mold during pouring

Answer

To filter impurities from the molten metal

Answer

To create a vacuum in the mold

Question 46

Which of the following metals is commonly NOT used in casting?

Accepted Answer

Titanium

Answer

Aluminum

Answer

Copper

Answer

Iron

Question 47

What is the purpose of a sprue in a casting process?

Accepted Answer

To connect the runner to the mold cavity and allow molten metal to enter

Answer

To create a vacuum in the mold

Answer

To support the casting during cooling

Answer

To filter impurities from the molten metal

Question 48

Which of the following is a common defect that can occur during the casting process, leading to internal voids or weaknesses in the finished part?

Accepted Answer

Porosity

Answer

Warping

Answer

Corrosion

Answer

Fatigue

Question 49

What is the process of removing the casting from the mold called?

Accepted Answer

Shakeout

Answer

Casting

Answer

Ejection

Answer

Stripping

Question 50

Which casting method is best suited for creating intricate, thin-walled parts with complex shapes, often used in jewelry and turbine blades?

Accepted Answer

Investment casting

Answer

Centrifugal casting

Answer

Die casting

Answer

Sand casting

Question 51

What is the main purpose of a riser in a casting mold?

Accepted Answer

To provide extra molten metal to compensate for shrinkage as the metal cools and solidifies.

Answer

To provide a vent for gases during pouring.

Answer

To increase the cooling rate of the casting.

Answer

To improve the surface finish of the casting.

Question 52

Which casting defect is directly caused by air or gases trapped within the mold during the pouring process?

Accepted Answer

Gas porosity

Answer

Misruns

Answer

Sand inclusions

Answer

Hot tears

Question 53

For high-volume production runs, which material is preferred for creating casting patterns?

Accepted Answer

Metal

Answer

Plastic

Answer

Ceramic

Answer

Wood

Question 54

What is the key advantage of using a green sand mold compared to a dry sand mold in casting?

Accepted Answer

Green sand molds offer lower production costs and faster casting times.

Answer

Green sand molds offer higher dimensional accuracy for the casting.

Answer

Green sand molds produce a better surface finish on the casting.

Question 55

Which casting process uses a rotating mold to distribute molten metal evenly, creating cylindrical or tubular castings?

Accepted Answer

Centrifugal casting

Answer

Investment casting

Answer

Shell molding

Answer

Die casting

Question 56

What is the primary difference between a permanent mold and a sand mold in casting?

Accepted Answer

Permanent molds are reusable, while sand molds are disposable after a single casting.

Answer

Permanent molds produce castings with a smoother surface finish.

Answer

Permanent molds are used for higher-volume production.

Question 57

What is the main function of a gating system in a casting mold?

Accepted Answer

To control the flow of molten metal from the pouring basin into the mold cavity.

Answer

To vent gases during pouring.

Answer

To improve the cooling rate of the casting.

Question 58

Which of the following factors has the GREATEST impact on the strength and ductility of a cast metal?

Accepted Answer

The cooling rate during solidification.

Answer

The presence of a riser.

Answer

The size of the casting.

Answer

The type of sand used in the mold.