MCQ on Metal Casting Process with Answers & Explanations

1. What is the primary purpose of the metal casting process?

a. Joining metals

b. Shaping metals

c. Heat treatment

d. Surface coating

Answer: b

Explanation: The primary purpose of the metal casting process is to shape metals by pouring molten metal into a mould to achieve the desired form.

2. Which of the following is not a commonly used casting material? 

a. Aluminium 

b. Copper 

c. Plastic 

d. Iron 

Answer: c 

Explanation: Plastic is not a metal and is not commonly used in metal casting processes.

3. What is the main advantage of sand casting? 

a. High accuracy 

b. Low cost 

c. Quick production 

d. Complex shapes 

Answer: b 

Explanation: Sand casting is known for its low cost, making it a costeffective method for producing metal castings.

4. Which moulding material is commonly used in investment casting? 

a. Green sand 

b. Plaster 

c. Ceramic 

d. Resin-bonded sand 

Answer: c 

Explanation: Ceramic is commonly used in investment casting to create moulds for intricate and detailed parts.

5. In die casting, molten metal is injected into a mould under: 

a. Low pressure 

b. High pressure 

c. No pressure 

d. Moderate pressure 

Answer: b 

Explanation: Die casting involves injecting molten metal into a mould under high pressure to achieve high precision and rapid production.

6. What is the purpose of the gating system in casting? 

a. To control the temperature of the molten metal 

b. To regulate the flow of molten metal into the mould 

c. To cool the casting rapidly 

d. To remove impurities from the metal 

Answer: b 

Explanation: The gating system, including the sprue, is designed to control and regulate the flow of molten metal into the mould cavity.

7. Which of the following is a disadvantage of permanent mould casting? 

a. High tooling cost 

b. Limited material choices 

c. Complex shapes are not achievable 

d. Slow production rate 

Answer: a 

Explanation: Permanent mould casting often involves higher tooling costs compared to other casting methods.

8. Which of the following is a characteristic of permanent mould casting? 

a. Low tooling cost 

b. Low production rate 

c. Limited material choices 

d. Complex shapes are achievable 

Answer: d 

Explanation: Permanent mould casting is known for its ability to produce complex shapes.

9. Which casting defect is characterized by a surface depression or concavity in the casting? 

a. Porosity 

b. Shrinkage cavity 

c. Cold shut 

d. Misrun 

Answer: b 

Explanation: Shrinkage cavity is a casting defect characterized by surface depressions or concavities caused by insufficient feeding of molten metal.

10. What is the primary disadvantage of sand casting? 

a. Low production rate 

b. High tooling cost 

c. Limited material choices 

d. Unsuitable for complex shapes 

Answer: c 

Explanation: Sand casting may have limited material choices compared to other casting methods.

11. What is the primary purpose of the chaplets in casting? 

a. To increase mould flexibility 

b. To improve mould strength 

c. To support cores 

d. To reduce shrinkage 

Answer: c 

Explanation: Chaplets are used to support cores in the mould cavity during the casting process.

12. Which metal casting process is suitable for high production volumes and precision parts? 

a. Sand casting 

b. Investment casting 

c. Die casting 

d. Centrifugal casting 

Answer: c 

Explanation: Die casting is suitable for high production volumes and precision parts due to its high-speed production capabilities.

13. What is the significance of the sprue in the gating system? 

a. It helps in venting gases from the mould 

b. It facilitates the removal of the casting 

c. It provides an entry point for molten metal into the mould 

d. It cools the casting during solidification. 

Answer: c 

Explanation: The sprue provides a pathway for molten metal to enter the mould cavity.

14. Which of the following casting process is commonly used for producing intricate and detailed sculptures? 

a. Investment casting 

b. Sand casting 

c. Die casting 

d. Permanent mould casting 

Answer: a 

Explanation: Investment casting is known for its ability to produce intricate and detailed shapes, making it suitable for sculptures.

15. What is the purpose of the core in casting? 

a. To provide additional metal during solidification 

b. To shape the interior of the casting 

c. To enhance the surface finish 

d. To regulate the flow of molten metal into the mould 

Answer: b 

Explanation: Cores are used in casting to shape the internal features of the casting.

16. Which casting process is commonly used for high-precision components with thin walls? 

a. Investment casting 

b. Sand casting 

c. Die casting 

d. Centrifugal casting 

Answer: c 

Explanation: Die casting is commonly used for high-precision components with thin walls.

17. What is the primary advantage of investment casting? 

a. Low cost 

b. High production rate 

c. Excellent surface finish 

d. Suitable for large parts 

Answer: c 

Explanation: Investment casting is known for its ability to produce castings with excellent surface finish and detail.

18. In shell moulding, the mould cavity is formed using: 

a. Sand and clay 

b. Resin-bonded sand 

c. Plaster 

d. Ceramic 

Answer: b 

Explanation: Shell moulding involves the use of resin-bonded sand to create a mould.

19. Shrinkage allowance is an extra amount of material provided on the pattern to compensate for: 

a. Expansion during solidification 

b. Contraction during solidification 

c. Porosity in the casting 

d. Wear and tear on the mould 

Answer: b 

Explanation: Metals shrink as they cool and solidify, and the allowance compensates for this.

20. What is the purpose of the runner in the gating system? 

a. To regulate the flow of molten metal into the mould 

b. To cool the casting rapidly 

c. To provide an entry point for molten metal into the mould 

d. To support cores 

Answer: a 

Explanation: The runner is a part of the gating system that regulates the flow of molten metal into the mould cavity.

21. Which casting process involves the use of a rotating mould to achieve cylindrical shapes? 

a. Centrifugal casting 

b. Die casting 

c. Investment casting 

d. Shell holding 

Answer: a 

Explanation: Centrifugal casting involves the use of a rotating mould to achieve cylindrical shapes.

22. What is the primary advantage of gravity die casting over other die casting methods? 

a. Lower tooling cost 

b. Faster production rate 

c. Reduced porosity 

d. Minimal draft requirements 

Answer: d 

Explanation: Gravity die casting allows for minimal draft requirements compared to other die casting methods.

23. In sand casting, what is the purpose of the parting line? 

a. To provide an entry point for molten metal into the mould 

b. To separate cope and drag 

c. To enhance the surface finish 

d. To cool the casting rapidly 

Answer: b 

Explanation: The parting line separates the cope and drag halves of the mould in sand casting.

24. Which casting process is commonly used for producing hollow and tubular parts? 

a. Sand casting 

b. Investment casting 

c. Centrifugal casting 

d. Die casting 

Answer: c 

Explanation: Centrifugal casting is commonly used for producing hollow and tubular parts by using the centrifugal force to distribute molten metal.

25. Which defect is characterized by a gap or unfilled section in the casting due to incomplete fusion of molten metal? 

a. Shrinkage cavity 

b. Misrun 

c. Cold shut 

d. Hot tear 

Answer: c 

Explanation: Cold shut is a casting defect caused by incomplete fusion of molten metal during solidification.

26. What is the purpose of the pouring basin in the gating system? 

a. To regulate the flow of molten metal into the mould 

b. To enhance the surface finish 

c. To cool the casting rapidly 

d. To provide an entry point for molten metal into the mould 

Answer: d 

Explanation: The pouring cup is a component of the gating system that provides an entry point for molten metal into the mould cavity.

27. Which type of pattern is used in investment casting to create intricate and detailed shapes? 

a. Split pattern 

b. Match plate pattern 

c. Sweep pattern 

d. Wax pattern 

Answer: d 

Explanation: Wax patterns are used in investment casting to create intricate and detailed shapes.

28. In centrifugal casting, the mould rotation speed affects: 

a. Surface finish 

b. Porosity 

c. Mould strength 

d. Casting temperature 

Answer: a 

Explanation: In centrifugal casting, the mould rotation speed can affect the surface finish of the casting.

29. What is the primary purpose of the sprue in the gating system? 

a. To provide an entry point for molten metal into the mould 

b. To regulate the flow of molten metal into the mould 

c. To cool the casting rapidly 

d. To support cores 

Answer: b 

Explanation: The sprue is designed to regulate the flow of molten metal into the mould cavity.

30. Which factor is NOT considered when choosing a metal casting process? 

a. Material 

b. Complexity of the part 

c. Production volume 

d. Colour of the metal 

Answer: d 

Explanation: While colour may be aesthetically relevant, it doesn't influence the casting process choice.

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