AWCP - 2 Marks

1. Define – Metal Casting

Metal casting involves pouring molten metal into a mould containing a cavity
of the desired shape to produce a metal product. The casting is then
removed from the mould and excess metal is removed, often using shot
blasting, grinding or welding processes

2. What is the volumetrically contraction of Cast Iron & steel , describe

suitable moulding practices?

Volumetric solidification contraction of Cast Iron – 1 to 2%

Volumetric solidification contraction of Steel – 2.5 to 3%

Moulding Methods : Cast Iron  1. Green sand Moulding 2. Shell Moulding

Moulding Methods : Steel  1. CO2 sand Moulding 2. Resin Bonded sand

Moulding

3. Shell Moulding 4. Investment Casting process

3. What is Hypo-eutectoid steel?

Steel of Carbon 0.022 % to 0.8 % region is called as Hypo eutectoid steel.

4. Define – Ferrite & Cemetite

Ferrite (alpha) It is an interstitial solid solution of a small amount of C

dissolved in Alpha BCC iron. The maximun solubility is 0.025% C at 723°C &
it’s dissolves only 0.008%C at room temperature. It is the softest structure
appeared on the diagram

Cementite or Iron Carbide: Fe3C contains 6.67% Carbonby weight. It is a

typical hard and brittle interstitial compound of low tensile strengh (approx.
5000 psi) but high compressive strength. It is the hardest structure that
appears on the diagram. Its crystal structure is orthorhombic.

5. What is the effect of Chromium & Molybdenum in Steel?

 Chromium (Cr)

- Chromium can dissolve in either alpha- or gama-iron, but, in the presence of

carbon, the carbides formed are cementite (FeCr)3C

- When the chromium exceeds 1,1% in low-carbon steels an inert passive film
is formed on the surface which resists attack by oxidizing reagents.

- Still higher chromium contents are found in heat-resisting steel.

- Chromium steels are easier to machine than nickel steels of similar tensile
strength.

- The chrome steels are used wherever extreme hardness is required, such as
in dies, ball bearings, plates for safes, rolls, files and tools. High chromium
content is also found in certain permanent magnets

Molybdenum (Mo)

- Molybdenum dissolves in both alpha- and gama-iron and in the presence of

carbon forms complex carbides (FeMo)6C, Fe21Mo2C6, Mo2C.

- Additions of 0,5% molybdenum have been made to plain carbon steels to

give increased strength at boiler temperatures of 400°C, but the element is
mainly used in combination with other alloying elements.

- Ni-Cr-Mo steels are widely used for ordnance, turbine rotors and other large
articles, since molybdenum tends to minimize temper brittleness and reduces
mass effect.

- Molybdenum is also a constituent in some high-speed steels, magnet alloys,

heat-resisting and corrosion-resisting steels.

6. What are the types of Cast Iron?

• Grey Cast Iron

• Ductile Iron or Spheroidal Graphite Iron (SG Iron)

• Malleable Cast Iron

• White Cast Iron

7. What are the recommended practices of using Silicon in Cast Iron?

• Si - determines the relative proportions of combined and graphitic iron

• Recommended practices

1. Less Silicon for High Carbon iron

2. More Silicon for Low Carbon Iron

8. Define – Inoculation & Nodularizing

Inoculation

 Silicon dissolves and diffuses uniformly in all directions forming a small

spherical region of high silicon concentration

 Since silicon reduces the solubility of carbon in iron, graphite is precipitated

through-out this region

Nodularizing

1. Ferro silicon magnesium alloy (3 to 6% Mg, 40 to 50% Si, small

traces of calcium, aluminium and rare earths)

2. Most of the reputed SG iron foundries nowadays use this material as

it is less costly compared to Ni – Mg alloys

3. The ultimate aim of treatment process is to obtain very good

nodularity and nodule count. This can be achieved only when the
percentage magnesium recovery in the liquid metal after treatment
is between 0.03% and 0.06% of Mg

9. What are all the superior properties of Aluminium ?

Lightness - Aluminium is light, one third the weight of steel.

Non-rusting- Aluminium does not rust and can normally be used unpainted.
However, the strongest alloys will corrode in some hostile environments and
may
need protection.
Extrusion process-This technique, the standard way of producing
aluminium sections, is vastly more versatile than the rolling procedures in
steel. It is a major feature in aluminium design.
Weldability- Most of the alloys can be arc welded as readily as steel, using
gas shielded processes. Welding speeds are faster.
Machinability - Milling can be an economic fabrication technique for
aluminium, because of the high metal removal rates that are possible.
Glueing- The use of adhesive bonding is well established as a valid method
for making structural joints in aluminium.
Low-temperature performance -Aluminium is eminently suitable for
cryogenic applications, because it is not prone to brittle fracture at low
temperature in the way that steel is.Its mechanical properties steadily
improve as the temperature goes down.
10. State the Applications of Magnesium alloys
- Typical applications include transmission casings,valve covers, intake manifolds,
brackets, pumps,etc.
- steering wheels, gearbox housings, seat frames and instrument panels