MT MSE PYQ

SOLUTIONS

MSE PAPER MARCH 2018

Q-Paper

Ans:
1. Need for Investment Casting, Process with Sketch, and Its Advantages &
Disadvantages
Need for Investment Casting
Investment casting (Lost-Wax Casting) is required when:
• Complex and intricate shapes need to be manufactured with high precision.
• High dimensional accuracy and smooth surface finish are essential, eliminating the
need for post-machining.
• Casting of hard-to-machine materials such as stainless steel, titanium, and
superalloys.
• Lightweight and high-strength components are needed, such as in aerospace and
medical applications.

Investment Casting Process

1. Pattern Making: A wax model of the component is created.
2. Assembly: Multiple wax patterns are attached to a sprue to form a tree-like structure.
3. Ceramic Coating: The wax pattern is coated with ceramic slurry and sand to create a
strong mould.
 4. Dewaxing: The mould is heated, melting away the wax to leave a hollow cavity.
5. Mould Firing: The ceramic mould is further heated to strengthen it and remove any
residual wax.
6. Metal Pouring: Molten metal is poured into the heated mould.
7. Cooling & Solidification: The metal cools and takes the shape of the mould.
8. Shell Removal: The ceramic mould is broken away to retrieve the cast part.
9. Finishing: The casting is cleaned, trimmed, and polished.

Advantages of Investment Casting

• Produces highly intricate and complex shapes.
• Excellent surface finish and dimensional accuracy.
• Suitable for aerospace, medical implants, and jewelry.
• Minimal machining required.
• Can cast high-temperature alloys.
Disadvantages of Investment Casting
• Expensive and time-consuming due to wax patterns and ceramic shells.
• Limited to small-to-medium-sized components.
• Not economical for large-scale production.

Question 2:
Elements of Gating System
The gating system is responsible for controlling the flow of molten metal into the mould
cavity in a controlled manner. It consists of the following elements:
1. Pouring Basin
o The initial reservoir where molten metal is poured.
o Helps in controlling flow rate and reducing turbulence.
2. Sprue
o A vertical channel that carries molten metal downward into the runner.
o Controls metal velocity and prevents splashing.
3. Runner
o A horizontal passage that distributes molten metal evenly.
o Ensures smooth flow to multiple cavities (if required).
4. Gate
o The entry point where molten metal enters the mould cavity.
o Designed to reduce turbulence and prevent defects.
5. Slag Trap/Filter (Optional)
o Removes impurities and prevents non-metallic inclusions in the casting.
QUESTION III:

ANSWER

Working Principle of Metal Inert Gas (MIG) Welding

Gas Metal Arc Welding (GMAW), also known as Metal Inert Gas (MIG) or Metal Active Gas
(MAG) welding, is a semi-automatic or automatic arc welding process.
It involves:
• A continuous, consumable wire electrode that feeds through a welding gun.
• A shielding gas supplied externally to protect the weld pool from atmospheric
contamination.
• An electric arc generated between the consumable wire electrode and the workpiece, which
melts the metal, forming a strong welded joint. The process allows high-speed welding with
good control over the weld bead.

Steps in MIG Welding:

1. Arc Formation: An electric arc is established between the consumable wire electrode
and the workpiece.
2. Electrode Melting: The continuous wire electrode melts due to heat, filling the joint.
3. Shielding Gas Protection: Inert gases like Argon or a mixture of Argon & CO₂
prevent oxidation.
4. Weld Formation: The molten metal cools and solidifies, forming a strong joint.
5. Automatic Feeding: The wire electrode continuously feeds through a spool,
maintaining a consistent weld.
QUESTION 4:

ANSWER
QUESTION V:
(a) Properties of Moulding Sand
Moulding sand plays a crucial role in metal casting, and its properties determine the quality
of the casting. Key properties include:
1. Refractoriness – Ability to withstand high temperatures without melting.
2. Permeability – Allows gases to escape, preventing porosity defects.
3. Cohesiveness – Ensures the sand maintains the mould shape.
4. Collapsibility – Enables easy removal of the casting without defects.
5. Grain Fineness – Affects surface finish and permeability.

(b) Die Casting

Die casting is a high-pressure metal casting process where molten metal is forced into a
reusable steel die (mould) to create precise and high-quality castings.
• Process Steps:
1. The die is clamped and lubricated.
2. Molten metal is injected into the die at high pressure.
3. The metal solidifies quickly.
4. The casting is ejected and trimmed.
• Types:
o Hot Chamber Die Casting – Used for low-melting metals like zinc,
magnesium.
o Cold Chamber Die Casting – Used for high-melting metals like aluminum,
brass.
• Applications: Automobile parts, electronics, aerospace components.

(c) Casting Defects

Casting defects are imperfections in metal castings caused by process irregularities.
Common defects include:
1. Porosity – Gas entrapment leading to tiny holes inside the casting.
2. Blowholes – Large gas bubbles near the surface due to poor sand permeability.
3. Shrinkage Cavity – Internal voids caused by improper solidification.
4. Cold Shut – Discontinuity due to improper metal fusion.
5. Misrun – Incomplete filling of the mould due to low pouring temperature.
Remedies:
• Improve mould permeability to prevent gas defects.
• Use proper riser design to compensate for shrinkage.
• Increase pouring temperature to avoid misruns.

(c) Foundry Mechanization

Foundry Mechanization refers to the automation of casting processes to improve efficiency,
quality, and production rate while reducing labor costs. It includes:
1. Moulding Mechanization – Use of moulding machines for consistent mould
production.
2. Core Making Mechanization – Automated core shooting machines for uniform
cores.
3. Metal Handling – Use of conveyors, cranes, and ladles for smooth metal transport.
4. Casting Cleaning & Finishing – Shot blasting and grinding machines to remove
excess material.
5. Quality Inspection Automation – X-ray and ultrasonic testing for defect detection.
Advantages:
• Increases productivity & reduces defects.
• Minimizes human effort & enhances safety.
• Improves accuracy & quality of castings.
2020 MARCH MT-1 MSE PAPER SOLUTIONS

SOURCE

QUESTION 1:

ANSWER:
(a) Why does grey cast-iron casting require less riser size than aluminium casting of the
same size? (1 Mark)
• Grey cast iron undergoes graphitization during solidification, where carbon
precipitates as graphite flakes, compensating for shrinkage.
• Aluminium contracts significantly upon cooling, requiring larger risers to
compensate for shrinkage.
• Thus, grey cast iron requires smaller risers compared to aluminium for the same
size casting.

(b) Should an allowance be provided for draft in expendable pattern moulding? Justify.
(1 Mark)
• Yes, a draft allowance is required to facilitate easy removal of the pattern from the
mould without damaging it.
• Draft angles reduce friction between the mould walls and the pattern, ensuring
defect-free moulds.
 • Without a draft, the mould can be damaged, leading to casting defects.

(c) How can slag be trapped in the pouring basin and runner? (1 Mark)
• Slag (impurities from molten metal) can be trapped by incorporating:
1. Slag Traps & Skim Baffles – Barriers in the gating system that block slag
flow.
2. Strainer Cores – Porous ceramic filters to remove slag before it reaches the
mould cavity.
3. Use of a Well-Designed Pouring Basin – Helps separate slag due to density
differences.

(d) Why is aluminium cast in cold chamber die casting instead of hot chamber die
casting? (1 Mark)
• Aluminium has a high melting point (~660°C), which would damage the
immersion chamber in hot chamber die casting.
• Cold chamber die casting keeps the molten aluminium separate from the injection
system, reducing thermal wear and oxidation.
• Hence, cold chamber die casting is preferred for aluminium.

(e) What is directional solidification, and why is it necessary for sound casting? (1 Mark)
• Directional solidification ensures that solidification starts from the farthest end of the
mould and moves towards the riser.
• This allows the riser to feed molten metal into shrinking areas, preventing voids
and shrinkage defects.
• Importance:
o Produces defect-free castings.
o Enhances mechanical strength.
o Ensures uniform grain structure.
QUESTION II:

ANSWER
a) Plasma and its Creation
• Plasma is the fourth state of matter, consisting of ionized gas with free electrons
and positive ions.
• It is created by applying high energy (heat or electrical discharge) to a gas, causing
ionization.
• In welding (Plasma Arc Welding - PAW), a constricted electric arc ionizes a gas
(argon/hydrogen), forming a high-energy plasma jet for deep-penetration welding.

(b) Horizontal Welding Position

• In horizontal welding, the weld axis remains horizontal, while the weld face may be
vertical or inclined.
• It is used in pipe welding, structural steel fabrication, and shipbuilding.
• Challenges: Gravity causes molten metal sagging, making it harder to control bead
shape.
• Requires proper electrode angle (15°-20°) and controlled heat input.

(c) Duty Cycle

• Duty cycle refers to the percentage of time a welding machine can operate at a
given current before overheating.
• Expressed as 10-minute cycles (e.g., 60% duty cycle at 300A means 6 minutes
welding, 4 minutes cooling).
• Higher duty cycle → More continuous welding capability.

(d) Selection of Polarity in Arc Welding

 • Polarity selection affects penetration, heat concentration, and weld quality.
• Types:
o Direct Current Electrode Positive (DCEP): Deep penetration, strong welds
(used in stick welding, TIG).
o Direct Current Electrode Negative (DCEN): Higher deposition rate, less
penetration (MIG, TIG for aluminium).
o Alternating Current (AC): Balanced penetration, used for aluminium and
magnetized materials.

(e) Constant Voltage Type Power Source and Its Applications

• Constant Voltage (CV) power sources maintain a steady voltage, automatically
adjusting current to maintain arc length.
• Used in MIG (GMAW) and Flux-Cored Arc Welding (FCAW), where wire feed
speed determines current.
• Applications:
o Automotive industry (robotic welding).
o Fabrication of steel structures.
o Pipeline welding.

QUESTION III:

ANSWER:
Preparation of Standard Test Specimen
A standard test specimen for permeability testing of green sand is a cylindrical sample
prepared using a sand rammer. The steps involved are:
1. Take a Sample of Moulding Sand – Green sand (moist sand) is used.
2. Fill the Sand into a Specimen Tube – A cylindrical permeability specimen tube
(5.08 cm diameter × 5.08 cm height) is used.
3. Compact Using a Sand Rammer – The sand is rammed with a standard force to
achieve uniform density.
 4. Remove the Specimen Carefully – The specimen is ejected from the tube for
testing.
5. Drying (Optional for Dry Permeability Test) – For green permeability, the test is
performed immediately.

Method to Determine Permeability Number

Permeability testing determines how easily air passes through the moulding sand, ensuring
proper gas escape during casting.
Equipment Used:
• Permeability Meter (A.F.S Permeability Tester)
• Standard Specimen Tube
• Air Supply System
• Manometer for Pressure Measurement
Procedure:
1. Place the Specimen in the Permeability Meter – It is sealed tightly in the testing
chamber.
2. Pass Air Through the Sample – A known volume of air (2000 cm³) is forced
through.
3. Measure Pressure Drop – The pressure difference is noted using a manometer.
4. Calculate Permeability Number (PPP)
QUESTION IV, V, VI DIRECT FROM NOTES
2023 MARCH MT-1 MSE PAPER SOLUTIONS

QUESTION 1 IN NOTES

QUESTION II:

ANSWER [ A, B, D ONLY]
QUESTION III, IV, V STRAIGHT FROM NOTES

2024 MARCH MT-1 MSE PAPER SOLUTIONS

QUESTION 1: [ONLY PART A, C]

ANSWER:
QUESTION III:

ANSWER:
Lighter impurities, such as slag, oxides, and dross, can enter the molten metal during
pouring, leading to casting defects. A well-designed gating system prevents these impurities
from reaching the mould cavity.

Methods to Trap Lighter Impurities in a Gating System

1. Skim Baffles and Slag Traps
o Baffles are placed in the runner system to deflect and trap floating
impurities.
o Slag and dross are prevented from flowing into the mould cavity.
2. Proper Pouring Basin Design
o A well-designed pouring basin helps settle impurities due to density
differences before metal enters the sprue.
o Impurities float to the top and do not enter the gating system.
3. Strainer Cores or Ceramic Filters
o Porous strainer cores allow only clean molten metal to pass.
o Ceramic foam filters effectively remove fine slag and inclusions.
4. Bottom Gating System (Preferred in critical castings)
o Molten metal enters from the bottom of the mould cavity instead of the top.
o Lighter impurities remain at the top and do not get carried into the mould.
REMAINING QUESTIONS FROM NOTES STRAIGHT UP