MENG3209

Ass#1 - Casting_Spring2018

Instructor: Dr. Mohamed Emara

1) Which casting process is the most important commercially? What is the difference between a
pattern and a core in sand molding?

2) 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. Verify your answer.

3) In a sand casting mold, the V/A ratio of the riser should be which one of the following
relative to the V/A ratio of the casting itself? (a) equal, (b) greater, or (c) smaller. Verify your
answer.

4) State the main difference between sand casting and lost foam casting.

5) Identify the three sources of contraction in a metal casting after pouring.

6) A disk 40 cm in diameter and 5 cm thick is to be casted of pure aluminum in an open mold

operation. The melting temperature of aluminum = 660 C and the pouring temperature will be
800C. Assume that the amount of aluminum heated will be 5% more than needed to fill the
mold cavity. Compute the amount of heat that must be added to the metal to heat it to the
pouring temperature, starting from a room temperature of 25 C. The heat of fusion of
aluminum = 389.3 J/g. Where, Density = 2.70 g/cm3 and specific heat C = 0.21 Cal/g-C = 0.88
J/g-C

7) The flow rate of liquid metal into the down sprue of a mold = 1 liter/sec. The cross-sectional
area at the top of the sprue = 800 mm2 and its length = 175 mm. What area should be used at
the base of the sprue to avoid aspiration of the molten metal?

8) What is the difference between expendable and non-expendable casting processes? What is the
main expendable casting process?

9) State the Chvorinov's rule. What is the role of using this formula? How do we use this formula to
specify where to place the riser in a sand casting?

10) What is the continuity law as it applies to the flow of molten metal in casting?