Final Exam

Question 1

Expendable mould processes – use a metallic mould which must be destroyed to remove casting.

Expendable mould processes – use a sand mould which must be destroyed to remove casting.

Expendable mould processes – use a mould made from sand which can be reused for multiple castings.

Expendable mould processes – use a mould made from metal which can be reused for multiple castings.

Answer 1

Expendable mould processes – use a sand mould which must be destroyed to remove casting.

Question 2

In the Permanent mould processes, the mould is made of metal and can be used to make a single casting.

In the Permanent mould processes, the mould is made of sand and can be used to make many castings.

In the Permanent mould processes, the mould is made of sand and can be used to make many castings.

In the Permanent mould processes, the mould is made of metal and can be used to make many castings.

Answer 2

In the Permanent mould processes, the mould is made of metal and can be used to make many castings.

Question 3

Only thermoplastics can be thermoformed, sheets of thermosetting or elastomeric polymers have already been cross‑linked and cannot be softened by reheating.

Only elastomers can be thermoformed, sheets of thermosetting or thermoplastic polymers have already been cross‑linked and cannot be softened by reheating.

Only elastomers cannot be thermoformed, sheets of thermosetting or thermoplastic polymers have already been cross‑linked and can be softened by reheating.

Only thermoplastics can be thermoformed, sheets of thermosetting or elastomeric polymers have already been cross‑linked and can be softened by reheating.

Answer 3

Only thermoplastics can be thermoformed, sheets of thermosetting or elastomeric polymers have already been cross‑linked and cannot be softened by reheating.

Question 4

Induction furnaces use a direct current passing through a coil to develop magnetic field in metal causing rapid heating and melting.

Induction furnaces use a direct current passing through a coil to develop magnetic field in metal causing slow heating and melting.

Induction furnaces use an alternating current passing through a coil to develop magnetic field in metal causing slow heating and melting.

Induction furnaces use an alternating current passing through a coil to develop magnetic field in metal rapid heating and melting.

Answer 4

Induction furnaces use an alternating current passing through a coil to develop magnetic field in metal rapid heating and melting.

Question 5

A pure metal solidifies at a constant temperature equal to its freezing point which is the same as its melting point and the rate of freezing depends on heat transfer into mould, as well as thermal properties of the metal.

An alloy solidifies at a constant temperature equal to its freezing point which is the same as its melting point and the rate of freezing depends on heat transfer into mould, as well as thermal properties of the metal.

A pure metal solidifies at a constant temperature less than its freezing point and the rate of freezing depends on heat transfer into mould, as well as thermal properties of the metal.

An alloy solidifies at a constant temperature less than its freezing point and the rate of freezing depends on heat transfer into mould, as well as thermal properties of the metal.

Answer 5

A pure metal solidifies at a constant temperature equal to its freezing point which is the same as its melting point and the rate of freezing depends on heat transfer into mould, as well as thermal properties of the metal.

Question 6

Most metals freeze over a temperature range and can display segregation of the components in the centre of the solidified alloy.

Most alloys freeze over a temperature range and never display segregation of the components in the centre of the solidified alloy.

Most alloys freeze over a temperature range and can display segregation of the components in the centre of the solidified alloy.

Most alloys freeze over a temperature range and can display segregation of the components at the edge of the solidified alloy.

Answer 6

Most alloys freeze over a temperature range and can display segregation of the components in the centre of the solidified alloy.

Question 7

Solidification Shrinkage occurs in nearly all metals because the liquid phase has a higher density than the solid phase.

Solidification Shrinkage occurs in nearly all metals because the solid phase has a lower density than the liquid phase.

Solidification Shrinkage occurs in nearly all metals because the solid phase has a higher density than the liquid phase.

Solidification Shrinkage occurs in nearly all metals because the solid phase has equal density to the liquid phase.

Answer 7

Solidification Shrinkage occurs in nearly all metals because the solid phase has a higher density than the liquid phase.

Question 8

A chaplet is a reservoir in the mould which is a source of liquid metal to compensate for shrinkage of the part during solidification.

A core is a reservoir in the mould which is a source of liquid metal to compensate for shrinkage of the part during solidification.

A riser is a reservoir in the mould which is a source of liquid metal to compensate for shrinkage of the part during solidification.

A pouring cup is a reservoir in the mould which is a source of liquid metal to compensate for shrinkage of the part during solidification.

Answer 8

A riser is a reservoir in the mould which is a source of liquid metal to compensate for shrinkage of the part during solidification.

Question 9

To minimize effects of shrinkage, it is desirable for regions of the casting most distant from casting itself to freeze first and for solidification to progress from these regions toward the casting itself.

To minimize effects of shrinkage, it is desirable for regions of the casting most distant from the liquid metal supply to freeze first and for solidification to progress from these regions toward the riser.

To minimize effects of shrinkage, it is desirable for regions of the casting nearest from the liquid metal supply to freeze first and for solidification to progress from these regions toward the riser.

To maximise effects of shrinkage, it is desirable for regions of the casting most distant from the liquid metal supply to freeze first and for solidification to progress from these regions toward the riser.

Answer 9

To minimize effects of shrinkage, it is desirable for regions of the casting most distant from the liquid metal supply to freeze first and for solidification to progress from these regions toward the riser.

Question 10

With the Expanded Polystyrene Process the pattern doesn’t need to be removed from the process, but there can be pattern miss-match and core shift defects.

With the Expanded Polystyrene Process the pattern doesn’t need to be removed from the process, and there are no pattern miss-match and core shift defects.

With the Expanded Polystyrene Process the pattern needs to be removed from the process and there can be pattern miss-match and core shift defects.

With the Expanded Polystyrene Process the pattern needs to be removed from the process but there are no pattern miss-match and core shift defects.

Answer 10

With the Expanded Polystyrene Process the pattern doesn’t need to be removed from the process, and there are no pattern miss-match and core shift defects.

Question 11

Investment casting is a precision process with no limits to the casting size and is inexpensive.

Investment casting is a precision process but is expensive and casting size is limited.

Investment casting is not a precision process, but it is inexpensive.

Investment casting is not a precision process, but with no limits to the casting size.

Answer 11

Investment casting is a precision process but is expensive and casting size is limited.

Question 12

Moulds used for casting steel must be made of refractory material (e.g., ceramic), due to the very high pouring temperatures required.

Moulds used for casting steel cannot be made of refractory material (e.g., ceramic), due to the very high pouring temperatures required.

Moulds used for casting steel must be made of copper due to the very high pouring temperatures required.

Moulds used for casting steel must be made of lead, due to the very high pouring temperatures required.

Answer 12

Moulds used for casting steel must be made of refractory material (e.g., ceramic), due to the very high pouring temperatures required.

Question 13

With semi-solid metal casting, to aid flow, the mixture must consist of solid metal dendrites in a liquid.

With semi-solid metal casting, to aid flow, the mixture must consist purely of solid metal globules.

With semi-solid metal casting, to aid flow, the mixture must be entirely liquid metal.

With semi-solid metal casting, to aid flow, the mixture must consist of solid metal globules in a liquid.

Answer 13

With semi-solid metal casting, to aid flow, the mixture must consist of solid metal globules in a liquid.

Question 14

The green strength of a powder metallurgy part when pressed is adequate for handling but far less than after sintering.

The green strength of a powder metallurgy part when pressed is adequate for handling and far more than after sintering.

The green strength of a powder metallurgy part when sintered is adequate for handling but far less than after pressing.

The green strength of a powder metallurgy part when pressed is inadequate for handling and more than after sintering.

Answer 14

The green strength of a powder metallurgy part when pressed is adequate for handling but far less than after sintering.

Question 15

Plastic moulding is a near net/net shape process and less energy is required than for metals, painting or plating is usually not required

Plastic moulding is a near net/net shape process and more energy is required than for metals, painting or plating is usually not required.

Plastic moulding is a near net/net shape process and less energy is required than for metals, painting or plating is usually required.

Plastic moulding is a near net/net shape process and more energy is required than for metals, painting or plating is usually required.

Answer 15

Plastic moulding is a near net/net shape process and less energy is required than for metals, painting or plating is usually not required

Question 16

Thermoplastics undergo a curing process during heating and shaping, causing a permanent change in molecular structure.

Thermosets undergo a curing process during heating and shaping, causing a permanent change in molecular structure.

Thermosets undergo a curing process during heating and shaping, causing a temporary change in molecular structure.

Thermosets undergo a curing process during heating and shaping, causing a momentary change in molecular structure.

Answer 16

Thermosets undergo a curing process during heating and shaping, causing a permanent change in molecular structure.

Question 17

Polymer melts must display viscosity which is a solid property that relates shear stress to shear rate during flow.

Polymer melts must display viscosity which is a Fluid property that relates shear stress to shear rate during flow.

Polymer melts must display viscosity which is a Fluid property that relates temperature to shear rate during flow.

Polymer melts must display viscosity which is a Fluid property that relates temperature to shear stress during flow.

Answer 17

Polymer melts must display viscosity which is a Fluid property that relates shear stress to shear rate during flow.

Question 18

Viscosity of a polymer melt increases with shear rate and so the fluid becomes thinner (flows more easily) at higher shear rates.

Viscosity of a polymer melt decreases with shear rate Thus the fluid becomes thicker (flows less easily) at higher shear rates.

Viscosity of a polymer melt decreases with shear rate Thus the fluid becomes thinner (flows more easily) at lower shear rates.

Viscosity of a polymer melt decreases with shear rate and so the fluid becomes thinner (flows more easily) at higher shear rates.

Answer 18

Viscosity of a polymer melt decreases with shear rate and so the fluid becomes thinner (flows more easily) at higher shear rates.

Question 19

During extrusion, material is forced to flow through a die orifice to provide a short, compact products – forces are compressive.

During extrusion, material is forced to flow through a die orifice to provide a long continuous product – forces are tensile.

During extrusion, material is forced to flow through a die orifice to provide a long continuous product – forces are compressive.

During extrusion, material is forced to flow through a die orifice to provide to provide a short, compact products – forces are compressive.

Answer 19

During extrusion, material is forced to flow through a die orifice to provide a long continuous product – forces are compressive.

Question 20

During injection moulding the polymer is heated to a highly plastic state and forced to flow under
high pressure into a mould cavity where it melts, and the moulding is then removed from cavity

During injection moulding the polymer is heated to a highly plastic state and forced to flow under
high pressure into a mould cavity where it solidifies, and the moulding is then removed from cavity

During injection moulding the polymer is heated to a highly plastic state and forced to flow under
high pressure into a mould cavity where it solidifies, and the moulding is then placed into the cavity

During injection moulding the polymer is heated to a highly plastic state and forced to flow under
high pressure into a mould cavity where it melts, and the moulding is then placed into the cavity

Answer 20

During injection moulding the polymer is heated to a highly plastic state and forced to flow under
high pressure into a mould cavity where it solidifies, and the moulding is then removed from cavity

Question 21

A reciprocating screw type injection moulding machine consists of barrel fed from one end by a
hopper containing supply of plastic pellets

A reciprocating screw type injection moulding machine consists of barrel fed from one end by a die
containing supply of plastic pellets.

A reciprocating screw type injection moulding machine consists of barrel fed from one end by a ram
containing supply of plastic pellets

A reciprocating saw type injection moulding machine consists of barrel fed from one end by a die
containing supply of plastic pellets

Answer 21

A reciprocating screw type injection moulding machine consists of barrel fed from one end by a
hopper containing supply of plastic pellets

Question 22

During the Blow moulding process, water is used to inflate soft plastic into a mould cavity,
production is typically organized for very low quantities.

During the Blow moulding process, air pressure is used to inflate soft plastic into a mould cavity,
production is typically organized for very high quantities.

During the Blow moulding process, air pressure is used to inflate soft plastic into a mould cavity,
production is typically organized for very low quantities.

During the Blow moulding process, water is used to inflate soft plastic into a mould cavity,
production is typically organized for very high quantities.

Answer 22

During the Blow moulding process, air pressure is used to inflate soft plastic into a mould cavity,
production is typically organized for very high quantities.

Question 23

In Stretch blow moulding the blowing rod stretches the soft parison for a more favourable stressing
of the polymer than conventional blow moulding creating a structure which is less rigid, less
transparent, and more impact resistant.

In Stretch blow moulding the blowing rod stretches the soft parison for a more favourable stressing
of the polymer than conventional blow moulding creating a structure which is more rigid, more
transparent, and more impact resistant.

In Stretch blow moulding the blowing rod stretches the soft parison for a more favourable stressing
of the polymer than conventional blow moulding creating a structure which is more rigid, more
transparent but less impact resistant.

In Stretch blow moulding the blowing rod stretches the soft parison for a more favourable stressing
of the polymer than conventional blow moulding creating a structure which is less rigid, more
transparent, and more impact resistant.

Answer 23

In Stretch blow moulding the blowing rod stretches the soft parison for a more favourable stressing
of the polymer than conventional blow moulding creating a structure which is more rigid, more
transparent, and more impact resistant.

Question 24

Most commercial castings are made of alloys rather than pure metals because alloys are generally
easier to cast, and properties of the product are better.

Most commercial castings are made of metals rather than alloys because pure metals are generally
easier to cast, and properties of the product are better.

Most commercial castings are made of alloys rather than pure metals because alloys are generally
harder to cast, and properties of the product are inferior.

Most commercial castings are made of metals rather than alloys because pure metals are generally
easier to cast, and properties of the product are inferior.

Answer 24

Most commercial castings are made of alloys rather than pure metals because alloys are generally
easier to cast, and properties of the product are better.

Question 25

The single most important reinforcing filler in rubber is carbon black, a colloidal form of carbon obtained by thermal decomposition of hydrocarbons (soot). It decreases tensile strength, resistance to abrasion, tearing of the final rubber product and provides protection from ultraviolet radiation The single most important reinforcing filler in rubber is carbon black, a colloidal form of carbon obtained by thermal decomposition of hydrocarbons (soot). It increases tensile strength and resistance to abrasion and tearing of the final rubber product and provides protection from ultraviolet radiation. The single most important reinforcing filler in rubber is carbon black, a colloidal form of coal tar obtained by thermal decomposition of hydrocarbons (soot) It increases tensile strength and resistance to abrasion and tearing of the final rubber product. Carbon black also provides protection from nuclear radiation. The single most important reinforcing filler in rubber is coal tar, a colloidal form of carbon obtained by thermal decomposition of hydrocarbons (soot). It increases tensile strength and resistance to abrasion and tearing of the final rubber product. Carbon black also provides protection from ultraviolet radiation.

Answer 25

The single most important reinforcing filler in rubber is carbon black, a colloidal form of carbon obtained by thermal decomposition of hydrocarbons (soot). It increases tensile strength and resistance to abrasion and tearing of the final rubber product and provides protection from ultraviolet radiation.

Question 26

A woven roving is like a cloth, but it consists of untwisted filaments rather than yarns and can be produced with unequal numbers of strands in the two directions so that they possess greater strength in one direction A woven roving is like a cloth, but it consists of twisted filaments rather than yarns and can be produced with unequal numbers of strands in the two directions so that they possess greater strength in one direction. A woven roving is like a cloth, but it consists of untwisted yarns rather than filaments and can be produced with unequal numbers of strands in the two directions so that they possess greater strength in one direction. A woven roving is like a cloth, but it consists of twisted filaments rather than yarns and can be produced with equal numbers of strands in the two directions so that they possess equal strength in one direction.

Answer 26

A woven roving is like a cloth, but it consists of untwisted filaments rather than yarns and can be produced with unequal numbers of strands in the two directions so that they possess greater strength in one direction

Question 27

Hand lay-up is a closed Mould FRP Process. Products made by this process are generally large in size but low in production quantity - not economical for high production. Hand lay-up is an Open Mould FRP Process. Products made by this process are generally small in size but high in production quantity - not economical for high production. Hand lay-up is a closed Mould FRP Process. Products made by this process are generally large in size but low in production quantity – very economical for high production. Hand lay-up is an Open Mould FRP Process. Products made by this process are generally large in size but low in production quantity - not economical for high production.

Answer 27

Hand lay-up is an Open Mould FRP Process. Products made by this process are generally large in size but low in production quantity - not economical for high production.

Question 28

A misrun in a casting occurs because melting has occurred before completely filling the mould cavity. A misrun in a casting occurs because solidification has occurred after completely filling the mould cavity. A misrun in a casting occurs because solidification has occurred before completely filling the mould cavity. A misrun in a casting occurs because melting has occurred after completely filling the mould cavity.

Answer 28

A misrun in a casting occurs because solidification has occurred before completely filling the mould cavity.

Question 29

Boring is performed on the outside diameter of an existing hole to enlarge it, turning is performed on the inside diameter of an existing cylinder. Boring is performed on the inside diameter of an existing hole to enlarge it, turning is performed on the outside diameter of an existing cylinder. Turning is performed on the inside diameter of an existing hole to enlarge it, boring is performed on the outside diameter of an existing cylinder. Boring and turning are both performed on the outside diameter of an existing cylinder.

Answer 29

Boring is performed on the inside diameter of an existing hole to enlarge it, turning is performed on the outside diameter of an existing cylinder.

Question 30

Annealing is performed to increase hardness and brittleness, to harden metals for machining or forming, to recrystallise cold worked metals and relieve residual stresses induced by shaping Annealing is performed to reduce hardness and increase brittleness, and to recrystallise cold worked metals and relieve residual stresses induced by shaping Annealing is performed to increase hardness and brittleness, to soften metals for machining or forming, to recrystallise cold worked metals and relieve residual stresses induced by shaping Annealing is performed to reduce hardness and brittleness, to soften metals for machining or forming, to recrystallise cold worked metals and relieve residual stresses induced by shaping.

Answer 30

Annealing is performed to reduce hardness and brittleness, to soften metals for machining or forming, to recrystallise cold worked metals and relieve residual stresses induced by shaping.

Question 31

During annealing, the metal is heated to a suitable temperature (above Tm), “soaked” at the temperature for a certain time and brought back to 70oC via slow, controlled cooling. During annealing, the metal is heated to a suitable temperature (below Tm), “soaked” at the temperature for a certain time and brought back to room temperature via very fast cooling. During annealing, the metal is heated to a suitable temperature (below Tm), “soaked” at the temperature for a certain time and brought back to room temperature via slow, controlled cooling. During annealing, the metal is held at room temperature for 3 hours and then quenched to below room temperature very quickly.

Answer 31

During annealing, the metal is heated to a suitable temperature (below Tm), “soaked” at the temperature for a certain time and brought back to room temperature via slow, controlled cooling.

Question 32

Different quenching media provide different cooling rates. Select the correct sequence for an INCREASE in cooling rate. Air, Still oil, Still fresh water, Agitated Brine Agitated Brine, Air, Still oil, Still fresh water Agitated Brine, Still oil, Still fresh water, Air Air, Still fresh water, Still oil, Agitated Brine

Answer 32

Air, Still oil, Still fresh water, Agitated Brine

Question 33

Age hardening forms large particles (“precipitates”) in the metallic structure which blocks the movement of dislocations, thus strengthening and hardening the metal. Age hardening forms fine particles (“precipitates”) in the metallic structure which blocks the movement of dislocations, thus strengthening and hardening the metal. Age hardening forms fine particles (“precipitates”) in the polymeric structure which blocks the movement of dislocations, thus strengthening and hardening the polymer. Age hardening forms fine particles (“precipitates”) in the metallic structure which facilitates the movement of dislocations, thus strengthening and hardening the metallic material.

Answer 33

Age hardening forms fine particles (“precipitates”) in the metallic structure which blocks the movement of dislocations, thus strengthening and hardening the metal.

Question 34

In the rheo-route of Semi solid metal processing, the liquid is sheared while cooling from liquid to liquid -solid range to form a semi-solid metal slurry, with a spheroidal microstructure. There is no intermediate solidification step. In the thixo-route of Semi solid metal processing, the liquid is sheared while cooling from liquid to liquid -solid range to form a semi-solid metal slurry, with a spheroidal microstructure. There is no intermediate solidification step. In the rheo-route of Semi solid metal processing, the liquid is sheared while cooling from liquid to liquid -solid range to form a semi-solid metal slurry, with a dendritic microstructure. There is no intermediate solidification step. In the thixo-route of Semi solid metal processing, the liquid is sheared while cooling from liquid to liquid -solid range to form a semi-solid metal slurry, with a dendritic microstructure. There is no intermediate solidification step.

Answer 34

In the rheo-route of Semi solid metal processing, the liquid is sheared while cooling from liquid to liquid -solid range to form a semi-solid metal slurry, with a spheroidal microstructure. There is no intermediate solidification step.

Question 35

During sintering, the initial total surface area of the powder is small and as bonds between the particles form, the area is increased. During sintering, the final total surface area of the powder is small and as bonds between the particles form, the area is decreased. During sintering, the initial total surface area of the powder is small and as bonds between the particles form, the area is increased. During sintering, the initial total surface area of the powder is large. As bonds between the particles form, the area is reduced. Thus, energy is released during sintering

Answer 35

During sintering, the initial total surface area of the powder is large. As bonds between the particles form, the area is reduced. Thus, energy is released during sintering

Question 36

Approximately 98% of the energy in machining is converted into heat Approximately 81% of the energy in machining is converted into heat Approximately 62% of the energy in machining is converted into heat Approximately 25% of the energy in machining is converted into heat

Answer 36

Approximately 98% of the energy in machining is converted into heat

Question 37

Grinding is characterised by low disc speeds, hence high temperatures and low friction. Most of the energy remains in the work surface, resulting in low surface temperatures. Grinding is characterised by high disc speeds, hence high temperatures and high friction. Most of the energy remains in the work surface, resulting in high surface temperatures. Grinding is characterised by high disc speeds, hence low temperatures and high friction. Most of the energy remains in the work surface, resulting in high surface temperatures. Grinding is characterised by low disc speeds, hence high temperatures and high friction. Most of the energy remains in the work surface, resulting in high surface temperatures.

Answer 37

Grinding is characterised by high disc speeds, hence high temperatures and high friction. Most of the energy remains in the work surface, resulting in high surface temperatures.

Question 38

Consider the effects of Temperature on Properties, label A to D in the following.

Answer 38

A = Tensile strength B = Yield strength C = Ductility D = Temperature

Question 39

Label the two plots (A and B) and both axes (C and D).

Answer 39

A = Pseudoplastic fluid B = Newtonian fluid C = Viscosity D = Shear rate

Question 40

Label the A to E in the moulding process shown in below.

Answer 40

A = upper mould B = punch C = charge D = cavity E = knock out pin

Question 41

Label the following:

Answer 41

A = Elastic region B = Yield C = Necking D= Projected curve if necking had not occurred.

Question 42

Label the following diagram.

Answer 42

A = Carrier film B = Resin Paste C = Take up spool D = Chopper

Question 43

Label the following winding diagram.

Answer 43

A = Rotating mandrel B = Drive Box C = Resin bath D = Continuous roving

Question 44

Label the following plastic film manufacturing diagram.

Answer 44

A = Blown plastic film B = Extruder C = Pinch Rolls D = Frost line

Question 45

Label the following diagram.

Answer 45

A = Tread B = Steel wires C = Sidewall D = Filler

Question 46

Label the following diagram

Answer 46

A = Grinding Wheel B = Work Table C = Wheel Guard D = Bed

Question 47

Label the axis (A, B) and the steps in precipitation hardening (C, D)

Answer 47

A. Temperature B. Time C. Solution Treatment D. Precipitation Treatment

Question 48

Label the graph of tool wear as a function of cutting time

Answer 48

A. Rapid Initial Wear B. Failure region C. Accelerating wear rate D. Steady state wear region

Question 49

Label the following diagram

Answer 49

A. Punch B. Blank C. Die D. Guide Pins

Question 50

Label the following atomisation diagram

Answer 50

A. Gas B. Metal powder C. Collection chamber D. Molten metal

Question 51

Label the following atomisation diagram

Answer 51

A. Collection chamber B. Molten metal C. Metal Powder D. Water

Question 52

Label the following Sintering diagram

Answer 52

A. Sinter B. Cool Down C. Temperature D. Preheat

Question 53

Label the following rolling diagram

Answer 53

A. Powder B. Resintering furnace C. Green strip D. Cold rolling mill