SOM Questions

1) Why we call this as SOM?

Ans – it is study of different stress and different loading condition, object is to keep the
particular object safe, for that we need to load it lesser than it’s strength.

2) What is strength?

Ans – max. stress that material can sustain without failure.

3) Stress-strain diagram for mild steel, copper and cast iron.

Ans – copper – ductile, cast iron – hard.

4) Out of 3 which is more tough?

Ans – mild steel ( Combination of strength and ductility, making it very tough.

Does not fracture easily, instead deforms significantly before failure.)

5) Stress-strain curve after cold rolling of mild steel steel passed n times.

Ans – after every pass strength inc., ductility dec., strain hardening takes place, yield strength
inc. in each pass.

6) A bar made up of ductile or brittle material, how this bar going to fail , in which plane and
which stress and why? Draw mohr’s circle also.
7) What is Stress?

Ans – internal force developed per unit area at a point. Or internal resistence offered by body
against deformation.

8) Example where there is a stress but strain is 0.

Ans – body subjected to heating and constrained.

9) What is bending stress and it’s nature?

Ans - stress induced in a material when an external load causes it to bend, resulting in tensile
stress on one side and compressive stress on the other.

10) Bending equation and it’s assumptions taken.

Ans – Mat. of beam is homogenous and isotropic. Stresses are within propotional limit.

11) What is section modulus?

Ans – Z - measure of strength of beam. (max. applicable bending moment or moment of
resistence). Depends on shape and size of object.

12) What is elasticity, rigidity and stiffness?

Ans- elasticity is the property of material to regain it’s original position after removal of load.

Rigidity is the ability of material to resist deformation under applied load.

Stiffness is the ability of object to resist elastic deformation. (Force per unit displacement).

13) What is thermal stresses?

Ans – stress induced in body due to temp. change in body but it’s expansion or contraction is
restricted.

14) What is axial Rigidity ?

Ans – ability to resist deformation under axial loading. (EA)

15) Why we study of stresses in this instead of forces?

Ans – allows to analyse material regardless of the size. It will helps in understanding internal
effects (force distribution) within material by bending , shear and Torsional stress.

16) is there any shear stress ,if plate constrained from both sides and heating is provided?

Ans – calculate sigma1 , sigma2 and draw mohr’s circle , shear is 0. ( sigma x = sigma y and T = 0).

`17) stress-strain curve for copper and rubber.

Ans – study in depth all the necessary details.

17) If BMD is rectangle then draw it’s SFD.

Ans - beam subjected to pure bending.

18) What is poison’s ratio? What is the ratio if both strain are postitive?

Ans – ratio of lateral strain to longitudinal strain. Ratio is –ve in some exceptional cases.

19) If we have a plate such that it’s dimensions are increasing in both sides by increasing temp,
what will be it’s effect on ratio then?

Ans – posion’s ratio is defind only for mechanical stress not thermal, so can’t say anything or not
define.

20) What are elastic constant?

Ans – Young’s modulus (Modulus of elasticity), shear Modulus (Modulus of Rigidity), Bulk
Modulus.

21) How do you find the modulus of rigidity?

Ans – shear stress / shear strain or tan(phi).

22) What is the mohr’s circle for sigma1 = sigma2 ? what is the Tmax in that case?

Ans – it will be point with radius = 0 and center = (sigma,0). Tmax = 0. (Hydrostatic Condition).

23) In which case shear stress is zero? Even for 2D also.

Ans – Hydrostatic case, or biaxial equal loading case (sigma x = sigma y).

24) What is bulk modulus? What is use of calculation of it ? How it is related to

compressibility?

Ans – Negative Ratio of excessive pressure to volumetric strain (-ve because as volume dec. with
inc. in pressure) or it positive ratio of normal stress to density strain. It tells about the change in
volume or density when subjected to stress or uniform pressure. It is invserse of compressibility.

25) Which theory of failure is used for copper ? what is it other name?

Ans – Von Mises Theory or Tresca’s theory.

26) What different type of stresses subjected by spring?

Ans – in spring tensile or compressive loading leads to development of not only tensile and
compressive stress but also torsional shear stress in it’s wire, Direct shear stress also experience
by helical spring. Bending stress by leaf and flat spring.

27) What are the different type of springs? Their applications and why?

Ans - Use Helical Springs for lightweight, flexible, and compact applications like cars,
motorcycles, and industrial machinery for shock absorption under tensile or compressive
loading. Use Leaf Springs for heavy-duty load-bearing applications like trucks, buses, and
railways as it can support large weight and impact forces, used for transverse loading.

28) Assumptions for bending equations.

Ans – material should be isotropic, homogenous and elastic. Beam must be straight. Transverse
section must be plane. Stresses are under propotional limit.

29) What Is homogenous and isotropic properties?

Ans – properties of material are same at all points in a particular direction, properties are same
in all direction at a point.

30) Can we rewrite Hook’s law as strain is propotinal to stress?

Ans – no, strain is generated because of external loading.

31) What is resilience?

Ans – ability of material to absorb strain energy without plastic deformation.

32) Why we use theory of failure? For which material which theory is used?

Ans -

33) What is Engineering stress and true stress? Which one is used where and why?

Ans – strain measures the deformation under stress. Ratio of change in length to original or
instantaneous length. Engineering stress are used for small deformation (elastic region) ex –
Structural design. True stress are used in case of large deformation (plastic) ex – metal forming.

34) Why there is elastic recovery in plastic region also?

Ans – part of elastic deformation is present in total.

35) Effect on hardness and ductility in plastic deformation

Ans – hardness - inc. , ductility – dec. and yield strength inc.

36) A long column subjected to axial load, in which direction it is going to buckle?

Ans – Based on Euler’s Buckling Theory, a long column under compressive axial load can buckle
in direction of least flexural rigidity i.e( Ix > Iy, beam will buckle in y direction because EI tells
about the resistence to bending). circular column can buckle in any direction, it has equal I in
all direction, that’s why column is made circular.

37) How short column get fail? In which plane and due to because of which stress on axial
loading?

Ans – as it is column, axial stress will be there and of compressive nature, it will fail in shear
plane.

38) Define ductile and brittle material

Ans – for ductile material plastic deformation is more 5% (mild steel, aluminium, copper) and for
brittle is less than 5% (cast iron ,high carbon steel).

39) Which has higher E out of Aluminium and copper.

Ans – copper , copper is stiffer and less elastic as compared to Aluminium.

40) Draw stress strain diagram for non-linear elastic , linear elastic + perfectly plastic material.
41) How do you find the yield point for non-linear elastic material?

Ans – offset method, by drawing a line of same slope of elastic line at the strain of 0.2% from the
strain axis to the curve, the point where these 2 line intersect is yield strength.

42) do brittle material have yield strength?

Ans – No, they don’t have well defined yield strength because they do not exhibit significant
plastic deformation before fracture, they suddenly fails when applied stress exceeds their
ultimate strength.
 43) stress strain diagram for mild steel in case of shear loading

Ans – it is different as compared to tensile loading condition.

1. Elastic Region (Hooke’s Law Applies)

o Linear Relationship: Shear stress (τ) is proportional to shear strain (γ).

o Slope = Shear Modulus (G): τ = Gγ .
o No Permanent Deformation: Material returns to its original state upon unloading.
2. Yield Point (Shear Yield Strength, τy)
o Mild steel exhibits a distinct yield point in tension, but in shear, it follows a more
gradual transition into plasticity.
o The shear yield strength is approximately τy≈0.577σy (from von Mises yield criterion).
o Mild Steel Example: If σy (Yield Strength in tension) = 250 MPa, then τy≈144MPa.
3. Plastic Region (Non-Linear, Strain Hardening)
o Permanent deformation begins as slip occurs along crystal planes.
o Shear stress increases beyond τy due to strain hardening.
o The curve rises gradually but at a decreasing rate.
4. Ultimate Shear Strength (τmax)
o The material reaches its maximum shear stress before failure.
o Typically, τmax≈0.8τy for mild steel.
5. Fracture Point (Sudden Failure)
o Brittle materials fail suddenly after reaching ultimate strength.
o Mild steel, being ductile, undergoes some plastic deformation before shear fracture.

2. Comparison with Tensile Stress-Strain Curve

 Shear loading doesn’t show a sharp yield point like tensile loading.
 Shear strain (γ) is larger than normal strain (ε) for the same applied force.
 Mild steel undergoes plastic deformation before final failure in shear, making it ductile.

44) Variation of Elastic constant.

Ans – Young’s Modulus remain same for normal loading (tensile, compressive) similarly shear
Modulus also remain same for shear loading (Bending, direct and torsion).

45) what type of test can be done in UTM? what type of diagram do we get through it? Will
this diagram remain same for different specimen of particular material? What about
stress strain curve?

Ans – many tests including tensile, compressive, shear loading test can be done. Load vs
deformation diagram is created by UTM, and it’s slope defines the stiffness, which varies with
type of loading (Gradual, Sudden and impact) or loading (normal or shear) or with the cross
section of the specimen of same material. While the stress strain curve defines the property of
material (Young’s modulus for tensile or compressive, shear modulus for shear loading) vary in
particular loading case (normal , shear). It remain same for different specimen of same material
and in case of different loading condition (gradual, sudden and Impact) also.
46) What information gives by load deflection diagram.

Ans – Stiffness (slope of curve), Energy absorption and Toughness (area of curve).

47) What is difference between pressure and stress?

Ans – pressure is always normal and compressive while stresses not. Pressure is due to external
force or intermolecular force (for liquids) while stress is due to resistive force induced.

48) Can pressure leads to stress?

Ans – yes, Stress can be induced by force as well as pressure (in pressure vessel i.e Hoop and
circumferential stress), LPG Cylinder.

49) What is pure bending? Example with SFD.

Ans – no shear force acts in that section or in complete beam.

50) What is section modulus? It’s significance. And shapes whose Z is high.

Ans – Moment of inertia / Y max. it tells about the strength of beam under loading. If Z is high
then more M needs to be applied to bend the beam. I section has highest Z. because it’s mass is
away from centroidal axis.

51) Why depth of beam is kept high than it’s width?

Ans – to increase Z, means it can sustain more bending moment without bending.

52) Point of contraflexure, example of loading where it forms and it’s significance.

Ans – point where BMD changes it’s sign. Either there is internal hinge or there is moment acting
(ex – point load acting on a fixed beam, 2 point of contraflexure exist in this case). As that point
nature of bending changes, so it indicates where reinforcement should be placed in reinforced
concrete beams.

53) Why there is a need to form reinforced concrete beams?

Ans – as ductile fails in shear and concrete (brittle) fails in tensile loading and have higher
crushing strength, therefore to give combined effect they are reinforced together.

54) What are rigid and flexible bodies?

Ans – rigid body doest not deform under applied forces (stress induced in zero), while flexible
body deforms. In SOM we study deformable bodies not pure rigid bodies (ideally) to study
stress, strain, bending, torsion.

55) What happens when ballon is squeezed?

Ans - when a balloon is squeezed, its shape changes, but the volume remains nearly constant (if
no air escapes). The squeezed region experiences compressive stress, while the bulging region
undergoes tensile stress, making it more likely to burst there (stress exceeds the elastic limit of
the balloon material). Internal pressure may slightly increase due to material stretching.
56) What is gauge length?

Ans – actual working length on which observation is made.

57) What is strength and Young’s modulus under tensile and compressive loading?

Ans – E is Same for both the loading case. Compressive strength is smaller than tensile.

58) Brittle material fail in which plane in case of torque and normal load?

Ans – fail in cup cone shape in torque and transverse in normal load.

59) Range of poison’s ration.

Ans - -1 to 0.5

60) What are principal stresses?

Ans – max and min normal stresses acting on plane (principal) where shear stress is zero.

61) Example where thermal stress study is important.

Ans – Bridges and Rail tracks (expansion joints are provided to prevent buckling), Pipelines (high
temp. variations cause expansion/contraction leads to stress build up.

62) Can thermal stress be induced without any restriction. If yes, give practical example.

Ans – yes, Due to presence of temp. gradient. Ex – rapid cooling of hot glass.

63) Why stress is defined as internal resistance per unit area not external force per unit area?

Ans - External force is applied from outside, but stress is what the material internally resists to
maintain equilibrium. if an external force is uniformly applied, the internal stress distribution
may not be uniform. Ha value same hoti h pr, we can define it interms of it as external = intenal
force in equilibrium, but it is better to define in this format as later strength concept comes.

64) Pressure vessel example, Which pressure vessel have more stress? Which is preffered?

Ans = LPG cylinder, Pressure cooker. sphere pressure vessel, still cylindrical is preffered because
of easy manufacturing , handling and require less space, but spherical vessel have more volume.

65) Why do we define strain instead of just using deformation?

Ans – strain gives a measure of material deformation under loading, regardless of its length.

66) Why ductility dec. in strain hardening?

Ans – in strain hardening, if we unload thoda elastic recovery hoga, ab already material deform
ho gya h kuch , islie uski ductility kam gai.

67) What is bending stresses?

 Ans - Bending stress is internal stress induced in a material when subjected to a bending
moment. It causes the material to experience compression on one side and tension on other.

68) What is creep and fatigue?

Ans – creep is constant load acting over a long period of time. It’s value is less than yield
strength. Fatigue is a cycling progressive loading.

69) Why welding is done in middle of gas cylinder?

Ans – to balance upper and lower longitudinal forces.

70) Poison ratio for mild steel.

Ans – 0.3

71) Find the Tmax and principal stresses, if perimeter of the moh’s circle is given.

Ans – radius of circle = Tmax, and if center is given, it’s easy to find the principal stresses also.

78) what is pressure vessel?

Ans - "pressure vessel" refers to a closed container designed to hold fluids or gases at a pressure
significantly different from the surrounding environment, meaning it can withstand high internal
pressure and is typically analyzed for stresses induced by that pressure.

80) test performed in UTM.

Ans – tensile, compressive, or simple shear.

79) how to measure toughess of material?

Ans – The Charpy Impact Test is used to measure a material's toughness by determining the
energy absorbed during fracture under sudden impact loading. A notched specimen is placed
horizontally on supports, and a pendulum hammer strikes it at high speed. The energy absorbed
is calculated from the difference in the hammer’s height before and after impact, indicating the
material's resistance to impact. Ductile materials absorb more energy, while brittle materials
absorb less and fracture suddenly. This test helps in material selection, quality control, and
understanding temperature.

80) if mohr’s circle is point on ductile and compressive loading, in which plane ductile and
brittle material fail?

81) failure for sigma1 = sigma2 = sigma 3

82) As we all know, even if strain is 0, a body can still have induced stress (thermal stress).
Then why is stress 0 in a rigid body with 0 strain in them?

Ans - Real materials (even stiff ones) can have stress without visible strain. Rigid bodies are
theoretical concept and cannot have any strain, so they also cannot develop stress.

83) out of all elastic constants which has high value?

 Ans – Young’s Modulus.

84) at what point beam fails?

Ans – at the point of max. bending moment, fails due to bending stress.

Manufacturing Engineering Questions

Casting
 Welding

1) Categorize welding process.

Ans –
 i) autogeneous welding – where no filler material is used, and the base materials
themselves are melted and joined together. Ex – solid state, resistance welding

ii) homogeneous welding – both the base and the filler materials (if used) are made of
the same material. Ex – Gas, Arc welding.

iii) heterogeneous welding - where dissimilar materials (insoluble) are joined. The base
metals being welded are of different types, such as welding steel to aluminum, copper to
brass, or other dissimilar combinations. Ex – soldering, Brazing and Braze welding.

Also they can be categorize as solid, liquid (fusion), solid/liquid state welding.

2) What is solid state welding?

Ans - welding process in which materials are joined without melting, relying on pressure,
heat, or both to create a strong bond. It produces high-strength joints with minimal
heat-affected zones. Ex – diffusion, ultrasonic, explosive, friction and forge welding.

3) What is spot welding? Comes in which category?

Ans – it is electric resistance welding where two metal sheets are placed between 2
copper electrode, joined by applying pressure and passing a high electric current
through small contact points. The heat generated by electrical resistance melts the
metal, forming a weld. It is commonly used in automotive and sheet metal industries.

4) What is friction welding?

Ans - a solid-state welding process used for joining of large and high strength material,
Making contact of rotating object to fixed object, due to continuous contact because of
friction heat will be generated at the contact of surface. After this stopping the rotation
and applying force, they fuse together. Ex – joining drill to shank. Knife to handle.

5) What type of welding are there in your household?

Ans – Arc welding -> Repairing Gates, fences -> provide strong joints. Various metal can
be weld.

Gas welding -> plumbing pipe, bicycle frame -> offer good heat control and good
for soft metal like copper.

TIG -> for stainless steel cookware repair -> clean weld without impurity.

6) Is there any welding in pressure cooker? and it’s material

Ans – though it is made by deep drawing process, also TIG welding is used at the lid and
body junction, Friction Welding in some high-end cookers, to bond layers of metal,
improving strength and durability. Material are Aluminium, stainless steel.

7) Size of welding electrode.

Ans – 15 to 20 cm.
8) What is the material of flux and it’s function.

Ans – de-oxidizing material (graphite, alumina)

Slag formation compound (oxides of iron, titanium)

Protect the liquid metal from atmospheric gasses contact, it will increase the strength of
joint, maintains the viscocity of liquid metal, Forms a slag layer that protects the weld as
it cools and can be easily removed afterward.

9) What are the problems associated by overhead welding? How to overcome?

Ans - welding position where the metal is above the welder, and the welding is done
from underneath the joint. short-circuit transfer welding method is used because it
produce small, controlled droplets, reducing the risk of falling. Also required less heat
input and provides good penetration with minimum spatter and weld defects.

Problems -> weld pool dripping, poor visibility and access, spatter issues, not proper
molten metal flow

Solutions -> use of fast-freezing electrodes and reduce heat input, use good lighting,
reduce arc length.

10) Mode of metal transfer.

Ans – refers to how molten metal moves from electrode or wire to weld pool.

i) Short-Circuit Transfer – The wire touches the weld pool, creating a short circuit,
then melts and transfers metal in small droplets. Used for thin materials and low
heat input.
ii) Globular Transfer – Larger, irregular molten metal droplets transfer due to
gravity. Common in CO₂ welding but causes more spatter.
iii) Spray Transfer – Fine, small metal droplets are continuously sprayed across the
arc, providing smooth welds with less spatter. Requires high voltage.

11) what are the welding defects associated with very high current flow?

Ans – excessive spatter formation, burn through thin metal may create hole in them,
rapid melting and cooling can trap gases in weld result in weakening of it, increases
residual stresses, leads to cracks in weld pool.

12) What is arc blow?

Ans – deflection of electric arc towards the workpiece at the beginning and end, due to
deflection of magnetic flux line. Due to this, heat concentration on metal at end and
beginning will reduce and weld spatter is formed. Generally occur in DC as magnetic field
become unbalanced or eddies formation is there.

Remedies -> provide extra material at the beginning and end of metal, reduce the
intensity of current, provide flux coating on electrode.
13) What is difference in AC and DC source of welding?

Ans – due to continuously changing the polarity, uniform heat will be generated on
electrode and workpiece, depth of penetration is between as compared to DC, as in DC
we can adjust the heat penetration as per the requirement. In DC we have arc blow at
start and end of welding.

14) What is electroslag welding? What is its advantages?

Ans – initially arc will be generated between workpiece and electrode, results in mixing
of melt metal with flux to form slag. With increase in height of molten metal arc will
extinguished due to short circuit. By supply high current to resistance slag, high heat
generation will continue. This type of welding used for vertical + high thickness objects.

Advantages -> high penetration, high deposition rate.

15) What type of welding in LPG cylinder? Why?

Ans – submerged arc welding is used, as it is used for high thickness material, ensure
stronger perfect weld joint than the parent material as required in cylinder to sustain
high pressure.

16) What is the material of electrode in spot welding?

Ans – copper electrodes are used. They are highly conductive and offer less resistance.

17) What are the advantages in spot welding?

Ans –

Advantages -> No need for consumable filler material. Cost-effective and automated for
mass production.

Disadvantages -> limited ability to weld thick material, deforms the base material, not
suitable to weld all material.

18) Temp in arc and gas welding?

Ans – Arc welding – (5000 – 20000), Gas welding – (1275 – 3300).

19) Welding method for Aluminium? Why? Why not Arc welding?

Ans – TIG is used, AC power supply is used in process in which oxide is removed in
reverse polarity called cathodic cleaning, as Al oxide has much high temp than Al
therefore its needs to remove it, process is carried in inert atmosphere to prevent
further oxidation of Al.

20) Neutral flames is used for which material?

Ans – it is general purpose flame, used for welding mild steel, low carbon steel, Al, etc

21) Brazing and soldering materials and applications?

Ans –

Brazing – filler material is an alloy of Cu and Zn, Cu and Al known as spelter, melting
temp is more than 427. Used for high temp and high strength applications such as Heat
Exchangers, automotive, etc.

Soldering – filler material is an alloy of lead and tin known as solder, melting temp is less
than 427. Used for low temp applications such as electronics, jewelry, etc.

22) What is explosive welding? Applications?

Ans - Explosive welding is a solid-state welding process that uses controlled explosions
to bond two dissimilar metals (cladding). The explosive force causes the metals to be
rapidly accelerated toward each other, creating a high-velocity impact that results in a
strong, durable metallurgical bond without melting the materials.

Applications -> bond Cu/Al to steel in HX, provides high thermal conductivity and
corrosion resistance, produce corrosion-resistant plates for marine environments (steel
+ Al).

23) What is penetration? It should be deep or not?

Ans - the depth to which the base metal is melted and fused during the welding process.
It is a critical factor that determines the strength and quality of the weld joint. deep
penetration is crucial in applications involving high loads or pressure. However,
excessive penetration can lead to overheating, distortion, and weld defects.

24) Disadvantages of plasma arc welding?

Ans – can’t weld very thick plates, high initial cost, complex setup, higher energy
consumption, safety risks.

25) Electrodes used in TIG and MIG

Ans – TIG – Non consumable tungsten electrode, MIG – consumable electrode.

26) What is flux cored electrode?

Ans – here in this, electrode flux is inside center of electrode and metal is surrounded it.

27) What are the significance of constant current and current voltage curve?

Ans – CC covers concepts such that, small change in current with the small change in arc
voltage (arc length), used in manual welding, variable arc length is there, as variation in
current leads to improper power supply and heat to joint. CV covers concept that high
change in current for a small change in arc voltage, used for automatic welding where
small variation in arc length takes place. Used for leak proof joint.

28) What are welding defects? And remedies.

Ans – i) Gas porosity -> liquid metal absorb gas and they will trapped inside weld bead.
 Remedy – provide inert atmosphere, provide sufficient flux.

ii) Slag inculsion -> slag trapped inside liquid metal due to lack of heat input or
improper positioning of welding torch.

Remedy – provide sufficient heat and position the weld torch properly.

iii)weld spatter -> liquid metal splash to metal due to excessive heat.

Remedy – Provide sufficient amount heat input, optimum welding speed.

iv)Lack of fusion and Penetration – filler metal not fused properly with metal,

depth of penetration is less, due to lack of heat input and high weld speed.

Remedy – Provide optimum weld speed and sufficient heat input.

v)Cracks – when stress > strength of material then cracks form. due to non
uniform cooling, internal stresses will develop inside weld pool.

Remedy – preheat the electrode before welding, provide uniform cooling by

preheating and postheating.

29) Explain Welding process resembling casting, where it is used? Source of energy?

Ans – thermit welding, as in this process molten iron, enters and solidify to fill the gap.
Used in repair works of railway rails and joining of thick plate. The process relies on
chemical energy from the exothermic reaction of aluminum and iron oxide, producing
molten iron that acts as the filler metal. No external electricity or fuel is required.

30) Difference in casting and welding process, which has more strength? Why?

Ans – in casting, Entire metal is melted and reshaped. Molten metal is poured into a
mold and solidifies to take shape. Suitable for complex shapes and large parts.

In welding, Only the joint area is melted and fused. Two or more metal parts are joined
by melting and fusing them together. Used for joining parts, not creating complex
shapes.

Welding offer more strength as compared to casting, due to fine grain structure (fast
cooling rate compare to casting), involves melting of defined area only, minimizes
defects like shrinkage and porosity found in casting.

31) Why cast iron called so?

Ans – Cast iron is made by melting pig iron and pouring it into molds, where it solidifies
into the desired shape. This casting process gives it the name "cast iron”. Due to its high
carbon content (2-4%), cast iron is hard and brittle, making it unsuitable for welding or
forging like steel. Instead, it is shaped directly by casting.
32) What is Flowability? How do you measure it?

Ans – ability of moulding sand to enter into all the corner of mould box due to ramming
force. Depends of %water in sand.

33) What is rod test in casting?

Ans - In this test, metal is poured into a rod-shaped mold, and the length it fills before
solidifying is measured. A longer filled length indicates better fluidity.

34) Most common casting process?

Ans - Sand casting.

35) Why green sand called so? Is moisture good or bad?

Ans - denotes the presence of moisture in molding sand and indicates that the mold is
not baked or dried. Moisture is required for maintaining sand strength and moldability,
but excessive moisture leads to faster cooling of molten material, poor permeability gas
defects and poor casting quality.

36) Define strength of sand. How to increase it?

Ans – ability of sand to retain shape of cavity and to withstand the forces applied by
liquid metal on the mould surface.

Maintain the right amount of moisture to improve bonding. Adding Binders like clay,
resin, or sodium silicate to enhance cohesion. Proper ramming ensures better strength.

37) which decreases more permeability, adding moisture or ramming process?

Ans - Ramming process decreases permeability more than adding moisture because
excessive ramming compacts the sand tightly, reducing air and gas escape paths.

38) Gating design. Components.

Ans – gating system should be design such that liquid metal can be enter into cavity
within a given time with optimum velocity without causing turblance, splashing of liqud
metal, mould erosion and air aspiration effect. Casting yield needs to be maximum.

Components 

Pouring basin – design to reduce the velocity of liquid metal which is enter to sprue.

Sprue – reduce air aspiration effect, allow the metal to enter.

Runner – to minimize turbulence and discharge losses of liquid metal.

Riser – to compensate solidification shrinkage.

Gate – to enter the material to mould.

 39) What is the ratio in sprue runner and gate? Ratio depends on?

Ans – gating ration - 3:2:1, 1:2:2 , ratio depends on the type of casting (pressurised,
unpressurised casting)

40) Why riser is used? What is the best shape for it ? why?

Ans – to compensate the solidification shrinkage. Ideally its sphere because of max value
of (V/A) ratio, means max solidification time but due to availability of liquid metal at
center, not possible to insert into mold. cylinder riser is choosen.

41) How many riser in a mould cavity have?

Ans – depends on the requirement to compensate shrinkage and avoid metal waste.

42) Top gate and bottom gate.

Ans – Top Gate – liquid metal directly enter into mould cavity from the bottom of sprue.
Velocity of liquid metal enters is high, possibility of turbulence and splashing of liquid
metal, used for ferrous material with min. depth of cavity, temp. gradient is less.

Bottom Gate – gate is provided at bottom of cavity. liquid metal enter into mould cavity
from the bottom to top. Velocity of liquid metal enters is low. No possibility of
turbulence and splashing of liquid metal, used for non ferrous material. temp. gradient is
high.

43) Melting point and pouring temp. difference is more in ferrous or non ferrous?

Ans – Non-ferrous metal. Non-ferrous metals like Al, Cu require a higher superheat to
improve fluidity and mold filling, whereas ferrous metals like steel and cast iron already
have good fluidity with a smaller temperature difference.

44) Advantages and disadvantages with high pouring temp. which defects occur?

Ans – Advantages – leads to eliminate misrun and coldshut defects, increase fluidity.

Disadvantages – higher shrinkage – cause dimensional inaccuacies, erosion of mould

cavity.

Defects Due to High Pouring Temperature:

 Gas porosity – Due to excessive gas absorption.

 Rat tail – irregular cracks or lines due to mold expansion when metal is too hot, low
mold strength, poor ventilation.
 Hot tears – Cracks from uneven cooling.
 Sand fusion – Mold sand fuses with metal, causing surface defects.
 Shrinkage cavities – Due to excessive metal contraction.

45) What is aspiration?

 Ans – atmospheric gases can be absorb in gating element will mix with liquid metal and
form gas defect, to overcome this effect, ideal shape of sprue is parabola, but to reduce
manufacturing difficulties tapered cylinder is choosen.

46) Explain Casting defects.

Ans – Gas defects –

Blow hole and open blow – gas defect formed inside casting, formed on surface.
Scar – shallow blow which form on surface. Blister – scar covered by thin layer of metal.
Pin hole porosity – small size gas hole formed due to hydrogen gas.

Remedies – Heat the metal in furnace upto pouring temp, convert green sand in
dry sand mould before filling, select permeable moulding sand, provide vent holes.

Moulding Sand –

Drop and Dirt – moulding sand will drop from core box to drag box, forms a
projection on casting surface due to improper ramming. Cuts and Washes – moulding
sand will be eroded will produce cuts and washes due to lack of hardness and high
velocity of liquid metal due to improper ramming.

Pouring metal –

Misrun – liquid metal get solidify before reaching the cavity due to lack of
fluidity and pouring temp. Cold shut – two streams of liquid metal not fused properly.

Remedies – heat the metal upto pouring temp, inc. the surface finish of
cavity, design the gating system properly.

Metallurgical –

Hot tears and cracks – cracks will form when stress > strength of material due
to non-uniform cooling internal stresses can be develop in casting.

Remedy – provide chills and padding. (Chills are metal inserts placed in the
mold to absorb heat and increase the rate of solidification).

47) Investment casting called so? Applications of it.

Ans – the term "investment" refers to the process of coating or surrounding (investing) the
wax pattern with a ceramic or refractory material to form the mold. This ceramic shell is
then used to cast the final metal part after the wax is removed.

Applications – used for mass production and high surface finish. Gas turbine blades, medical
implants, dentures, gold ornaments.

48) Applications of shell moulding process.

Ans - used in industries requiring precision, smooth surface finish, and complex shapes.
Used in valve plates of refrigerator, cylinder blocks of air cooled IC Engine.
49) Casting process for blades of turbine, dentist tool.

Ans – investment casting, due to smooth surface finish, high precision, and complex
shape.

50) Which has high surface finish, Investment casting or shell mould casting?

Ans - investment casting generally produces a higher surface finish due to the very
precise ceramic molds used in the process

51) Tractor’s agricultural component material and casting process?

Ans – cast iron, carbon steel. because of high strength and wear resistance for working
in tough soil conditions. Good toughness to withstand impact load.

Sand casting is the most common casting process for agricultural components. It's a
cost-effective and versatile method that can produce large, complex parts.

52) Explain Casting process for irrigation pipes.

Ans – Cast iron irrigation pipes are typically manufactured using the centrifugal casting
process. This method is preferred because it produces seamless, strong, and defect-free
pipes by utilizing centrifugal force to distribute molten metal evenly inside a rotating
mold. It ensures uniform thickness, high density, and minimal porosity, making the
pipes more durable and resistant to pressure. Additionally, centrifugal casting helps
remove impurities, improving the overall quality of the pipes. Due to these advantages,
it is widely used for the mass production of cast iron pipes in irrigation and water supply
systems.

53) Permanent mould casting

Ans -

54) Die casting

Ans - Die casting is a permanent mold casting process where molten metal is poured
into a mold cavity using either gravity or pressure. In gravity die casting, metal flows
into the mold naturally due to gravity, making it suitable for thicker sections and
stronger parts like engine components. In pressure die casting, metal is injected under
high pressure for faster production and finer details. Pressure die casting is further
classified into hot chamber and cold chamber methods. Hot chamber die casting melts
the metal inside the machine, making it ideal for low-melting metals like zinc and
magnesium. Cold chamber die casting melts the metal separately before injection, used
for high-melting metals copper. Die casting is widely used in automobile, electronics,
and industrial applications due to its high accuracy, strength, and production efficiency.

55) Which casting is used for ferrous and non – ferrous material (Mg, lead, Al).

Ans – ferrous – sand or investment casting, non-ferrous -> die casting.

For High melting point temp. cold chamber die casting is used (Cu, Brass, Al), for low
melting point temp. hot chamber die casting is used (Mg, Tin, Lead). Exception – Al has
low melting point temp. but due to sticking property it is used in cold die casting.

56) What is cheek?

Ans – middle part, in big size casting, cheek is used to support cope and drag

57) Gate, riser is placed in cope or drag?

Ans - depends on gating system (bottom, top), on cope mostly.

58) What are chills, chapplets.

Ans - chills are metal inserts placed in the mold to increase the cooling rate (along
sharp corners or edges high stresses) of molten metal in specific areas. They help in
controlling solidification, reducing shrinkage defects, and improving mechanical
properties. Chills can be internal (embedded in the mold) or external (placed on the
mold surface).

Chaplets are small metal supports used to hold the core in place inside the mold cavity.
They prevent core displacement due to molten metal pressure and eventually fuse with
the casting. Chaplets are made from materials compatible with the casting metal to
avoid defects.

59) What is parting sand.

Ans - Parting sand is a fine, dry, non-sticky sand used in molding to prevent the mold
halves from sticking together. It is sprinkled on the parting surface of the flask, between
the cope and drag, and on pattern surfaces to ensure easy separation after molding.
Parting sand improves mold release, reduces defects, and enhances casting accuracy.

60) Which welding is used for mass production?

Ans - Metal Inert Gas (MIG) Welding (GMAW): Widely used in manufacturing and
automotive industries for its high speed, minimal spatter.

61) Which require less skill, welding or casting?

Ans – in welding we still require some amount of skill because like it is having high
chance of getting disproportionate, it was harder to get weld correctly instead of cast, as
in casting various support are there like alignment pin, patter is also premade we just
had to ram it together, even some types of errors can be absorbed due to allowances
provided in casting, but in welding we had to get the penetration, flow and arc length
exactly correct otherwise the weld get usless.

62) Welding as cutting

Ans – Welding can also be used as a cutting process. In gas welding, instead of allowing
the hot metal to fuse together, the gas is used at high pressure to blow away the molten
metal. Similarly, in other melting processes, if we impart heat at a very high temperature
and high rate while also blowing away the molten metal, it results in cutting rather than
joining. Essentially, in welding, we impart heat and wait for the metal to fuse together,
whereas in cutting, we focus on rapid heating and metal removal.

63) EBW , under water welding( plasma arc welding).

Ans –

64) Duty cycle?

Ans - the percentage of time that a machine will safely operate (or weld), within a
certain time period, at a given amperage. It is around 60%

65) What is the value of open circuit voltage, running voltage and short circuit current.

Ans – 80V, 30-40V, 100 – 250 amp.

66) What is short circuit current?

Ans - In welding, short circuit current is the current that flows when the electrode
touches the workpiece, creating a temporary short circuit that melts the electrode and
deposits the metal onto the joint.

67) Why electrode stuck to the metal sometimes?

Ans – if electrode is too close, or in the beginning the electrode is not removed quickly,
molten metal may stick to electrode, arc get extinguish.

68) Person protective equiment used in welding.

Ans – thick gloves, welding glass for arc protection, face mask. Apron.