PRODUCTION
PRODUCTION
(CLASS WORK & PRACTICE QUESTIONS)
CONTENTS
Unit Chapters Page No.
1 Material Science 2 - 26
2 Casting 27 - 43
3 Welding 44 - 60
4 Forming 61 - 83
5 Metal Cutting 84 - 94
6 Machining 95 - 105
7 Sheet Metal Operations 106 - 115
8 Non Traditional Machining Methods 116 - 127
9 Advanced Machining Methods 128 - 135
10 Metrology 136 - 147
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Published at : Ascent Gate Academy
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MECHANICAL ENGINEERING
1 MATERIAL SCIENCE
CLASS ROOM OBJECTIVE & PRACTICE QUEESTIONS :
1 In low carbon steels, presence of small quantities sulphur improves.
(a) weldability
(b) formability
(c) machinability
(d) hardenability
2 Consider the following statements:
Addition of silicon to cast iron
1. Promotes graphite module formation
2. Promote graphite flake formation
3. Increases the fluidity of the molten metal
4. Improves the ductility of cast iron
Of these statements
(a) 1 and 4 are correct
(b) 2 and 3 are correct
(c) 1 and 3 are correct
(d) 3 and 4 are correct
3 Match list-I with List-II and select the correct answer using the codes given below the lists:
List-I List-II
Heat Treatment Effect on the properties
A.Annealing - 1. Refined grain structure
B. Nitriding - 2. Improves the hardness of the whole mass.
C. Martempering - 3. Increases surface hardness
D. Normalising - 4. Improves ductility
Codes:
ABCD
(a) 4 3 2 1
(b) 1 3 4 2
(c) 4 2 1 3
(d) 2 1 3 4
4. Eutectoid reaction occurs at
(a) 6000C (b) 7230C (c) 1140C (d) 14930C
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PRODUCTION
5 Match list - I with List - II and select the correct answer using the codes give below the lists:
List - I List - II
(Name of material) (% Carbon Range)
1. Hypo-eutectoid steel 1. 4.3 - 6.67
2. Hyper-eutectoid steel 2. 2.0 - 4.3
3. Hypo-eutectic cast iron 3. 0.8 - 2.0
4. Hyper-eutectic cast iron 4. 0.008 - 0.8
Codes:
ABCD
(a) 4 3 2 1
(b) 1 3 4 2
(c) 4 1 2 3
(d) 1 2 3 4
6. Which one of the following sets of constituents is expected in equlibrium cooling of a
hyper-eutectoid steel from austenitic state ?
(a) Ferrite and pearlite (b) Cementite and pearlite
(c) Ferrite and bainite (d) Cementite and martensite
7 Match List - I with List - II and select the correct answer using the codes give below the lists:
List - I List- II
(Alloy) (Use)
A. Low carbon steel 1. Bearing
B. Hadfield manganese steel 2. Thermocouple
C. Constantan 3. Wire nails
D. Babbitt alloy 4. Buldozer blades
Codes:
ABCD
(a) 1 2 3 4
(b) 3 4 1 2
(c) 3 2 1 4
(d) 3 4 2 1
8 The structure of polymer is shown in the given fig. The polymer finds special application in .
FF
CC
FF
(a) packaging (b) adhesives
(c) bearings (d) fertilizer
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MECHANICAL ENGINEERING
9 Addition of magnesium to cast iron increases its.
(a) hardness (b) ductility and strength in tension
(c) Corrosion resistance (b) creep strength
10 18 / 8 stainless steel contains .
(a) 18% stainless, 8% chromium (b) 18% Chromium, 8% Nickel
(c) 18% tungsten, 8% nickel (d) 18% tungsten, 8% chromium
11 Tin base white metals are used where the bearings are subjected to.
(a) large surface wear (b) elevated temperature
(c) light load and pressure (d) high pressure & load
12 Alloy steel which is work hardenable and which is used to make the blades of bulldozers,
bucket wheel excavtors and other earth moving equipment contain iron, carbon and.
(a) chromium (b) silicon (c) manganese (d) magnesium
13 Consider the following statements:
Thermosetting plastic are
1. Formed by addition polymerization
2. Formed by condensation polymerization
3. Softened on heating and hardened on cooling for any number of times.
4. modulated by heating and cooling
Of these statements
(a) 1 and 3 are correct (b) 2 and 4 are correct
(c) 1 and 4 are correct (d) 2 and 4 are correct
14 Match list - I and list - II and select the correct answer
List - I List - II
A. Polyethylene 1. Adhesive
B. Cyanoacrylate 2. Film
C. Cyanoacrylate 3. Wire
D. Nylon 4. Foam
Codes:
ABCD
(a) 2 4 3 1
(b) 4 2 3 1
(c) 2 4 1 3
(d) 4 2 1 3
15 Consider the following statements
Fibre Reinforced plastic are
1. Made of thermosetting resins and glass fibre.
2. Made of thermoplastic resins and glass fibre.
3. Anisotropic 4. Isotropic
Of these statements which are correct?
(a) 1 and 4 (b) 1 and 3 (c) 2 and 3 (d) 2 and 4
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PRODUCTION
16 During tensile- testing of a specimen using Universal Testing Machine, the parameters actually
measured include.
1. True stress and true strain
2. Poisson’s ratio and Young’s modulus
3. Engineering stress and engineering strain.
4. load and elongation
17 Consider the following statements
When a metal or alloy is cold worked
1. It is worked below room temperature
2. It is worked below recrystallization temperature.
3. Its hardness and strength increases
4. Its hardness increases but strength does not increase
Of these statements
(a) 1 and 3 are correct
(b) 1 and 2 are correct
(c) 2 and 3 are correct
(d) 2 and 4 are correct
18 Which of the following pairs regarding the effect of
alloying elements in steel are correctly matched ?
1. Molybdenum : Forms abrasion resisting particles
2. Phosphorus : Improves machinability in free cutting steels
3. Cobalt : Contributes to red hardness by hardening ferrite.
4. Silicon Reduces oxidation resistance
The correct answer using the codes given below :
(a) 2, 3 and 4 (b) 1, 3 and 4
(c) 1, 2 and 3 (d) 1, 2 and 4
19 Machines tool guideways are usually hardness by
(a) vaccum hardening
(b) martempering
(c) induction hardening
(d) flame hardening
20 Guideway of lathe beds are hardened by
(a) carburizing
(b) cyaniding
(c) nitriding
(d) flame hardening
21 A given steel test specimen is studied under metallurgical microscope. Magnification used is
100 X. In that different phases are observed. One of them is Fe3C.
The observed phase Fe3C is also known as.
(a) ferrite (b) cementite
(c) austenite (c) martensite
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MECHANICAL ENGINEERING
22 Match list- I with List- II and select the correct answer using the codes given below the lists:
List - I List - II
A. Tougness 1. Moment area method
B. Endurance strength 2. Hardness
C. Resistance to abrasion 3. Energy absorbed before fracture in a tension test.
D. Deflection in beam. 4. Fatigue loading
Codes :
ABCD
(a) 4 3 1 2
(b) 4 3 2 1
(c) 3 4 2 1
(d) 3 4 1 2
23 In metals subjected to cold working, strain hardening effect is due to
(a) slip mechanism
(b) twining mechanism
(c) dislocation mechanism
(d) fracture mechanism
24 Match list - I with list - II and select the correct answer using the codes given below the lists:
List - I List - II
A. Neoprene 1. Electric switches
B. Bakelite 2. Adhesive
C. Foamed polyurethane 3. Thermal insulator
D. Araldite 4. Oil seal
Codes:
ABCD
(a) 4 1 2 3
(b) 1 4 2 3
(c) 4 1 3 2
(d) 1 4 3 2
25 Which one of the following materials is used for car tyres as a standard material ?
(a) Styrene-butadiene rubber (SBR)
(b) Butyl rubber
(c) Nitrile rubber
(d) Any one of the above depending upon the need
26 Which one of the following refractory materials is recommonded for steel furnaces containing
CaO slag?
(a)Alumina (b) Silica (c) Magnesia (d) Fireclay
27 Which one of the following properties of a solid are dependent on crystal imperfections ?
1. Yield stress 2. Melting point
3. semiconductivity 4. Ductility
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PRODUCTION
28 Which of the following components can be manufactured by power metallurgy methods ?
1. Carbide tool tips 2. Bearings 3. Filters 4. Brake linings
Select the correct answer using the codes given below:
(a) 1, 3 and 4 (b) 2 and 3
(c) 1, 2 and 4 (d) 1, 2, 3 and 4
29 Assertion (A) : The notch sensitivity of cast iron component is zero.
Reason (R) : Cast iron does not have yield point.
30 Assertion (A) : Austenitic stainless steel contains 18% chromium and 8% nickel. Since it
retains its austenitic structure at room temperature, it is called austenitic stainless steel.
Reason (R) : Chromium present in the steel improves its corrosion resistance by forming a thin
film of chromium oxide on the surface.
(a) Both Aand R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
31 Match list - I (Alloying element in steel) with List - II (Property conferred on steel by the
element) and select the correct answer using the codes given below the lists:
List - I List - II
A. Nickel 1. Corrosion resistance
B. Chromium 2. Magnetic permeability
C. Tungsten 3. Heat resistance
D. Silicon 4. Hardenability
Codes:
ABCD
(a) 4 1 3 2
(b) 4 1 2 3
(c) 1 4 3 2
(d) 1 4 2 3
33 Match List - I (Alloys) with List - II (Applications) and select the correct answer using the
codes given below the lists:
List - I List - II
A. Chromel 1. Journal bearing
B. Babbit alloy 2. Milling cutter
C. Nimonic alloy 3. Thermocouple wire
D. High speed steel 4. Gas turbine blades
Codes:
ABCD
(a) 3 1 4 2
(b) 3 4 1 2
(c) 2 4 1 3
(d) 2 1 4 3
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MECHANICAL ENGINEERING
35 Match list - I (Materials) with List - II (Structure) and select the correct answer using the codes
given below the lists:
List - I List - II
A. Charcoal 1. F.C.C.
B. Graphite 2. H.C.P.
C. Chromium 3. Amorphous
D. Copper 4. B.C.C.
Codes:
ABCD
(a) 3 2 1 4
(b) 3 2 4 1
(c) 2 3 4 1
(d) 2 3 1 4
Direction : The following items consist of two statements, one labelled the ‘ Assertion (A)’and the
other labelled the ‘Reason (R)’, You are to examine these two statements carefully and decide if theAsser-
tion (A) and the Reason (R) are individually true and if so, whether the Reason is a correct explanation of the
Assertion. Select the your answer to these items using the codes given below and mark
your answer sheet accordingly.
Codes :
(a) Both Aand R are individually true and R is the correct explanation of A.
(b) BothA and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
36 Assertion (A) : Refining the grain size of polycrystal line material renders it harder and
stronger.
Reason (R) : Grain boundaries provide easy paths to dislocation motion.
37 Assertion (A) : Plastic deformation in metals and
alloys is a permanent deformation under load. This property is useful in obtaining products by
cold rolling.
Reason (R) : Plastic or permanent deformation in metal or alloy is caused by movement or
dislocations.
38 Assertion (A) : Carbon would form an interstital solid solution with iron.
Reason (R) : The atomic radius of iron is smaller than that of carbon.
39 Assertion (A) : Cast iron is generally hard, brittle and wear resistant.
Reason (R) : Cast iron contains more than 20% carbon and as such the percentage cementite in
it is higher.
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PRODUCTION
40 Consider the following statemens:
The strength of the fibre reinforced plastic product.
1. Depends upon the strength of the fibre alone
2. Depends upon the fibre and plastic
3. Is isotropic
4. Is anisotropic
Which of these statements are correct ?
(a) 1 and 3
(b) 1 and 4
(c) 2 and 3
(d) 2 and 4
41 Match list - I (Crystal structure) with list - II (Atomic packing factor) and select the correct answer
using the codes given below the lists:
List - I List - II
A. Simple cubic 1. 74%
B. Body centered cubic2. 74%
C. Face centered cubic 3. 52%
D. Hexagonal close packed 4. 68%
Codes:
ABCD
(a) 3 4 2 1
(b) 4 3 2 1
(c) 3 4 1 2
(d) 4 3 1 2
42 Consider the following pairs of plastics and their distinct characteristics:
1. Acrylics ........ Very good transparency to light
2. Polycarbonate...... Poor impact resistance
3. PTFE ....... Low coefficient of friction
4. Polypropylene ...... Excellent fatigue strength
Which of these statements are correct?
(a) 2 and 3
(b) 1 and 3
(c) 1 and 4
(d) 2 and 4
43 Gibb’s phase rule is given by
(F = number of degree of freedom ,
C = number of components , P = number of phases)
(a) F = C + P
(b) F = C + P - 2
(c) F = C - P - 2
(d) F = C - P + 2
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MECHANICAL ENGINEERING
45 Match list - I (Material) with list - II (Applications) and select the correct answer using the
codes given below the lists :
List - I List - II
A. Tungsten carbide 1.Abrasive wheels
B. Silicon nitride 2. Heating elements
C.Aluminium oxide conveying 3. Pipes for metals liquid.
D. Silicon carbide 4. Drawing dies
Codes:
ABCD
(a) 3 4 1 2
(b) 4 3 2 1
(c) 3 4 2 1
(d) 4 3 1 2
46 Heating the hypo-eutectoid steels to 300C above the upper critical temperature line, soaking at
the temperature and then cooling slowly to room temperature to form a pearlite and ferrite
structure, is known as.
(a) Hardening (b) Normalising (c) Tempering (d)Annealing
47 Ina eutectic system, two elements are completely.
(a) In soluble in solid and liquid state
(b) Soluble liquid state
(c) Soluble in solid state
(d) Insoluble in liquid state
48 Assertion (A) : Specimens for impact testing are never notched.
Reason (R) : Anotch introduces triaxial tensile stresses which cause brittle fracture.
49 Assertion (A) : Carbon forms interstital solid solution when added to iron.
Reason (R) : The atomic radius of carbon atom is much smaller than that of iron.
Codes :
(a) Both Aand R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
50 Which one of the following features improves the fatigue strength of a metallic material ?
(a) Increasing the temperature (b) Scratching the surface
(c) Overstressing (d) Understressing
51 Percentages of various alloying elements present in
different steel materials are given below :
1. 18% W; 4% Cr; 1% V; 5% Co; 0.7% C 2. 8% Mo; 4% Cr; 2% V; 6% W; 0.7% C
3. 27% Cr; 3% Ni; 5% Mo; 0.25% C 4. 18% Cr; 8% Ni; 0.15% C
Which of these relate to that of high speed steel?
(a) 1 and 3 (b) 1 and 2 (b) 2 and 3 (d) 2 and 4
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PRODUCTION
52 Pearlite consists of
(a) 6.67% C and 93.33 ferrite (b) 12% Fe and 87% cementite
(c) 13% C and 87% ferrite (d) 13% cementite and 87% ferrite
53 Addition of vanadium to steel results in improvement of.
(a) heat treatability by quenching
(b) hardenability
(c) fatigue strength
(d) resistance to oxidation at elevated temperature
54 Atomic packing factor (APF) in the case of copper
crystal is.
(a) 0.52 (b) 0.68 (c) 0.74 (d) 1.633
55 During peritectic solidification, one liquid.
(a) combines with one solid to form a second new solid
(b) Solidifies in to two different solids
(c) forms one solid
(d) forms one solid and another liquid
56 Assertion (A) : Addition polymerization is a primary summation of individual molecules in to
long chains.
Reason (R) : In addition polymerization, the reaction produces a small molecule as by-product.
57 Assertion (A) : Normalized steel will have lower hardness than annealed steel.
Reason (R) : The pearlite of normalized steel is finer and has lower intermolecular space.
Codes :
(a) Both Aand R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
58 Martensite is a supersaturated solution of a carbon in.
(a) alpha iron (b) beta iron (c) gamma iron (d) delta iron
59 The correct sequence of creep deformation in a creep curve in order of their elongation is.
(a) steady state, transient, accelerated (b) transient, steady state, accelerated
(c) transient, accelerated, steady state (d) accelerated, steady state, transient
60 Nodular grey cast iron is obtained from the grey cast iron by adding a small amount of
(a) Manganese (b) Phosphorus
(c) Magnesium (d) Chromium
61 Which one of the following pairs of axis lengths (a,b,c) and interaxial angles (α,β,γ) represents
the tetragonal crystal system ?
(a) a = b = c ; α = β = γ = 900
(b) a = b ≠ c ; α = β = γ = 900
(c) a ≠ b ≠ c ; α = β = γ = 900
(d) a = b = c ; α = β = γ ≠ 900
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MECHANICAL ENGINEERING
62 Consider the following quenching media:
1. Oil 2. Water 3. Water + NaoH 4. Brine
The correct sequence of these media in order of increasing hardness of steel undergoing heat
treatment is.
(a) 1, 3, 2, 4 (b) 2, 1, 3, 4 (c) 1, 2, 3, 4 (d) 4, 3, 2, 1
63 The alloy steel designated as 40 Cr 18 Ni 2 by Bureau of Indian standards contains
(a) 0.4% C, 18% Cr and 2% Ni (b) 4.0% C, 1.8% Cr and 0.2% Ni
(c) 0.4% C, 1.8% Cr and 2% Ni (d) 0.4 $ C, 1.8% Cr and 0.2% Ni
64 ‘ Tempering’of quenched martensitic steel is necessary to improve the
(a) hardness of the metal (b) surface texture of the metal
(c) corrosion resistance of the metal (d) ductility of the metal
65 The molecular weight of vinyl chloride is 62.5 Thus the molecular weight of a polyvinyl
chloride with a degree of polymerization of 20000 is.
(a) 20000 (b) 62.5
62.5 20000
(c) 62.5 x 20000 (d) 20000
66 Match list - I (Name of the element) with list - II (crystal structure) and select the correct answer
using the codes given below the Lists:
List - I List - II
A. Fluorspar 1. Body-centered cubic
B.Alpha iron 2. Hexagonal close packed
C. Silver 3. Simple cubic
D. Zinc 4. Face centered cubic.
Codes :
ABCD
(a) 3 2 4 1
(b) 4 1 3 2
(c) 4 2 3 1
(d) 3 1 4 2
67 Which of the following factors govern solubility to two non- ferrous metals both in liquid state
as well as in solid state ?
1. Crystal structure 2. Relative size factor
3. Chemical affinity factor 4. Relative valence factor
Select the correct answer using the codes given below:
(a) 1, 2 and 3 (b) 2, 3 and 4 (c) 1 and 4 (d) 1, 2, 3 and 4
68 Which of the following are fabricated using engineering plastics ?
1. Surface plate 2. Gears
3. Guide ways for machine tools 4. Foundry patterns
Select the correct answer using the codes given below:
(a) 1, 2 and 3 (b) 1 (b) 2, 3 and 4 (d) 1, 2, 3 and 4
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PRODUCTION
69 Consider the following statements:
Polytetrafluroethene is
1. a thermoplastic material
2. having low friction coefficient.
3. a thermosetting material.
4. having low friction coefficient
5. an electric inulator
6. non sticking to surfaces.
Which of the above statements are correct?
(a) 1, 2 and 5 (b) 2, 3 and 6 (c) 3, 4 and 5 (d) 3, 2 and 5
70 Which of the following fibre materials are used for reinforcement in composite material:
1. Glass 2. Boron carbide 3. Graphite
Select the correct answer using the codes given below:
(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3
71 Match list - I (Phase diagram) with list - II (Characteristic) and select the correct answer using
the codes given below the lists:
List - I List - II
A. Isomorphous system1. One liquid decomposes into another liquid and solid.
B. Eutectic system 2. Onde liquid and another solid combine to form a new solid.
C. Peritectic system 3. Two metals are completerly in soluble in solid state
D. Monotectic system 4. Two metals, soluble in solid andliquid state.
Codes:
ABCD
(a) 2 3 4 1
(b) 4 1 2 3
(c) 2 1 4 3
(d) 4 3 2 1
72 Match list - I (Material) with list - II (Application) and select the correct answer using the codes
given below the lists:
List - I List - II
A. Ceramics 1. Construction of chemical plants
B. Refractories 2. Columns and pillars
C. Stones 3. Lining of furnaces
D. High silica glass 4. Tiles
Codes:
ABCD
(a) 4 3 2 1
(b) 2 1 4 3
(c) 4 1 2 3
(d) 2 3 4 1
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MECHANICAL ENGINEERING
73 T.T.T. diagram indicates time and temperature transformation of
(a) Cementite (b) Pearlite (c) Ferrite (d) Austenite
74 The correct composition of austenitic stainless steel used for domestic utensils is.
(a) 0.08% C, 18% Cr, 8% Ni, 2% Mn, 1% Si
(b) 0.08% C, 24% Cr, 12% Ni, 2% Mn, 1% Si
(c) 0.15% C, 12% Cr, 0.5% Ni, 1% Mn, 1% Si
(d) 0.30% C, 12% Cr, 0.4% Ni, 1% Mn, 1% Si
75 Which one of the following is true?
(a) Structure of metallic consists of atoms having valence of 5,6 or 7
(b) Ceramic materials have long range electron matrix ond
(c) Polymers are composed of long chain of repeating molecules.
(d) Ceramics are weaker than metals because of weak electrostatic bond.
76 In the grain size determination using standard charts, the relation between the given size num
ber n and the average number of grains ‘N’ per square inch at a magnification of 100 X is.
(a) N = 2n. (b) N = 2n - 1. (c) N = 2n + 1. (b) N = 2n + 1
77 Chemicals attack atoms with in grain boundaries preferentially because they have.
(a) lower energy than those in the grains
(b) higher energy than those in the grains
(c) higher number of atoms than in the grains.
(d) lower number of atoms than in the grains.
78 As per Gibb’s phase rule, if number of components is equal to 2 then the number of phases will
be. (b) ≤ 3 (c) ≤ 4 (d) ≤ 5
(a) ≤ 2
79 Assertion (A) : The hardness test is a slow, expensive method of assessing the mechanical
properties of materials
Reason (R): The hardness is a function of yield stress and the work hardening rate of material.
(a) Both Aand R are individually true and R is the correct explanation of A.
(b) BothA and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
80 Monel metal is an alloy of
(a) iron and carbon (b) Copper and zinc
(c)Aluminium and copper (d) Copper and nickel
81 Primary object of full annealing is to
(a) Increase toughness and yield point
(b) Reduce ductility and resilience
(c) Remove foreign impurities and improve surface finish
(d) Increase ductility and machinability
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PRODUCTION
82 Globular form of cementite in the structure of steel is obtained through.
(a) Normalising (b) Malleabilising
(c) Spheroidising (d) Carbonizing
83 Gunmetal, which is used in journal bearings, contains
(a) 88% Cu, 10% Sn, 2% Zn
(b) 80% Cu, 10% Zn, 10% Al
(c) 85% Cu, 5% Mg, 10% Al
(d) 85% Cu, 5% Sn, 10% Pb
84 The correct sequence of elements of 18-4-1 HSS tool is
(a) W, Cr, V (b) Mo, Cr, V
(c) Cr, Ni, C (d) Cu, Zn, Sn
85 Teflon is a
(a) Thermosetting flurocarbon polymer
(b) Thermoplastic flurocarbon polymer
(c) Inorganic compound of fluorine and carbon
(d) Laminated phenolic material
86 In the case of rubber, vulcanization refers to the process of producing a
(a) Linear polymer
(b) Branched polymer
(c) Cross-linked polymer
(d) Network polymer
87 Polyesters can be defined as the condensation products of.
(a) Dicarboxylic acids with dihydroxy alcohals
(b) Biphenol-A and epichloro-hydrin
(c) Phenol and formaldehyde
(d) Benzene and toluene
88 The coordination number for FCC crystal structure is
(a) 4 (b) 8 (c) 12 (d) 16
89 Match list - I (Crystal structure) with list - II (Example) and select the correct answer using the codes
given below the lists:
List - I List - II
A. Simple cubic 1. Zinc
B. Body -centered cubic 2. Copper
C. Face - centered cubic 3. Alpha iron at room temperature
D. Hexagonal close packed 4. Manganese
Codes:
ABCD
(a) 4 3 1 2
(b) 4 3 2 1
(c) 3 4 2 1
(d) 3 4 1 2
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MECHANICAL ENGINEERING
90 Which one of the following pairs is not correctly matched?
(a) Point defect in crystal lattice: Self interstitial
(b) Linear defect in crystal lattice : Grain boundary
(c) Planar defect in crystal lattice: External surface
(d) Volume defect in crystal lattice: other phases
91 A screw dislocation
1. Lies parallel to its Burger’s vector
2. Lies perpendicular to its Burger’s vector
3. Moves in a perpendicular direction to the Burger’s vector
4. Moves in an inclined direction to the Burger’s vector
Select th e correct answer using the codes given below:
(a) 1 and 4 (b) 1 and 3 (c) 2 and 3 (d) 2 and 4
92 According to Gibb’s phase rule, the number of degrees of freedom of an eutectic point in a
binary system is
(a) 1 (b) 2 (c) 0 (d) 3
93 Assertion (A) : Unlike in the case of ionic bonds, the coordination numbers for covalently
bonded atoms are not controlled by the radii ratio.
Reason (R) : A covalent bond has a specific direction of bonding in space.
94 Assertion (A) : The machinability of steels improves by adding sulphur to obtain so called
Free Machining Steels’
Reason (R) : Sulphur in steel forms manganese sulphide inclusion which helps to produce thin
ribbon like continous chip.
(a) Both Aand R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
95 Match list - I (Name of treatment) with list - II (Media used) and select the correct answer using
the codes given below the lists:
List - I List - II
A. Pack carburizing 1.Ammonia gas
B. Gas carburizing 2. Sodium cyanide
C. Cyaniding 3. Carburising compound
D. Nitriding 4. Ethane
Codes:
ABCD
(a) 3 4 2 1
(b) 2 1 3 4
(c) 3 1 2 4
(d) 2 4 3 1
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PRODUCTION
96 Consider the following pairs
Heat Treatment Effects on medium carbon steel
1. Normalising : Grain refinement
2. Full annealing : Uniform grain structure
3. Martempering : Decreased ductility
4. Spheroidizing : Maximum softness
Which of the pairs given above are correctly matched?
(a) 1 and 2 (b) 2 and 3 (c) 3 and 4 (d) 1, 2, 3 and 4
97 Match list - I (Material) with list - II (Typical use) and select the correct answer using the codes
given below the lists:
list - I list - II
A. Branched polyethylene 1. Bottles
B. Polyester 2. Textiles fibres
C. Polyvinylchloride 3. Films for packaging
D. Linear Polyethylene 4. Transparent film
Codes:
ABCD
(a) 3 2 1 4
(b) 2 3 4 1
(c) 2 3 1 4
(d) 3 2 4 1
98 Match list - I (Steel type) with list - II (Product) and select the correct answer using the codes
given below the lists:
list - I list - II
A. Mild steel 1. Screws
B. Tool steel 2. Commercial beams
C. Medium carbon steel 3. Crane hooks
D. High carbon steel 4. Blanking dies
Codes :
ABCD
(a) 2 4 1 3
(b) 3 1 4 2
(c) 2 1 4 3
(d) 3 4 1 2
99 Match list - I (Alloy) with list - II (Application) and select the correct answer using the codes
given below the lists:
List - I List - II
A. Silicon steel 1. Marine bearings
B. High carbon steel 2. Cutting tools
C. High speed steel 3. Springs
D. Monel metal 4. Transformer laminations
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MECHANICAL ENGINEERING
Codes:
ABCD
(a) 1 2 3 4
(b) 4 3 2 1
(c) 4 2 3 1
(d) 1 3 2 4
100 Match list - I (Alloying Element) with list - II (Effect on steel) and select the correct answer
using the codes given below the lists:
list - I list - II
A. Vanadium 1. Increases endurance strength
B. Molybdenum 2. Improves creep properties
C. Silicon 3. Increases hardness
D. Chromium 4. Increases resistance to high temperature oxidation
Codes:
ABCD
(a) 2 1 3 4
(b) 1 3 2 4
(c) 2 1 4 3
(d) 1 2 4 3
101 A 60 C-plain carbon steel has, approximately,
(a) 75% of pearlite and 25% of ferrite (b) 25% of pearlite and 75% of ferrite
(c) 75% of cementite and 25% of ferrite (d) 75% of pearlite and 25% of cementite
102 Austempering is employed to obtain
(a) 100% martensitic structure
(b) 100% baintic structure
(c) 50% martensitic and 50% bainitic structure
(d) 100% pearlitic structure
103 Match list - I (steel) with list - II (Application) and select the correct answer using the codes
given below the lists:
list - I list - II
A. Mild steel 1. Ball bearing
B. Tool steel 2. Cold chisels
C. High carbon steel 3. Shaft and axles
D. Medium carbon steel 4. Rolled steel sections
Codes:
ABCD
(a) 2 1 4 3
(b) 4 3 2 1
(c) 2 3 4 1
(d) 4 1 2 3
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PRODUCTION
104 Increase of ferrite phase in steel increases
(a) Strength (b) Hardness (c) Ductility (d) Brittleness
105 Consider the following statements about FCC and HCP crystal structure;
1. Both have same coordination number and atomic packing fraction.
2. Both represent closely packed crystal structures.
3. Both structures are generated by stacking of close packed planes on top of one another, but
only the stacking sequence is different.
Which of the statements given above are correct?
(a) 1 and 2 (b) 2 and 3 (c) 1, 2 and 3 (d) 1 and 3
106 The eutectoid of carbon in iron. above lower critical temperature, when cooled, results in.
(a) Ferrite and austenite(b) Ferrite and cementite
(c) Cementite & austenite (d) Ferrite,cementite, austenite
107 Consider the following statements about medium carbon steel:
1. It can be quench-hardened but not case hardened
2. It cannot be quench -hardened but case hardening can be done.
3. It exhibits distinct yield point under tension test.
Which of the statements given above are correct?
(a) 1 and 2 (b) 2 and 3 (c) 1 and 3 (d) 1, 2 and 3
108 Match list - I (Alloy) with list - II (Major constiuent) and select the correct answer using the
codes given below the lists:
list - I list - II
A. Babbit 1. Nickel
B. Invar 2. Tin and lead
C. Gun metal 3.Aluminium
D. Duralumin 4. Copper
Codes:
ABCD
(a) 2 4 1 3
(b) 3 1 4 2
(c) 2 1 4 3
(d) 3 4 1 2
109 Which of the following materials is used in the manufacture of extrusion nozzles?
(a) Grey cast iron (b) Malleable cast iron
(c) White cast iron (d) Nodular cast iron
110 Consider the following statements:
1. Cast iron has poor ability to damp vibrations.
2. Cast iron has higher compressive strength compared to that of steel.
3. Cast iron parts are suitable where permanent deformation is preferred over fracture.
Which of the statements given above is / are correct?
(a) 1, 2 and 3 (b) 1 and 3 (c) 3 only (d) 2 only
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MECHANICAL ENGINEERING
111 Assertion (A) :Carburizing is done on nonferrous alloys to increase the surface hardness.
Reason (R) : Precipitation hardening of nonferrous
alloys involves solution heat treatment followed by precipitation heat treatment.
112 Match list - I (Composition) with list - II (Application) and select the correct answer using the
codes given below the lists:
List - I List - II
A. Commercial bronze (10% Zn) 1. Radiator
B. Red brass (15% Zn) 2. Spring metal
C.Aluminium brass (22% Zn, 2%Al) 3. Forging and stamping
D.P-bronze (11% tin, small - 4. Power plant chemical amount of P) equipment
Codes :
ABCD
(a) 2 4 1 3
(b) 3 1 4 2
(c) 2 1 4 3
(d) 3 4 1 2
113 Phenol formaldehyde is a/an
(a) thermoplastic polymer (b) thermoset polymer
(c) elastomer (d) rubber
114 The pattern known as Widmanstatten structure is encountered in .
(a) tempering (b) normalizing
(c) spheroidizing (d) annealing
115 Assertion (A) : In Addition Polymerization method, polymer is produced by adding a second
monomer to the first, then a third monomer to this dimer and so on.
Reason (R) : There must exist at least one double bond in the monomer for Addition
polymerization reaction .
(a) Both Aand R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
116 In case of power screws, what is the combination of
materials used for the screw and the nut ?
(a) cast iron screw and mild steel nut
(b) carbon steel screw and phosphor bronze nut
(c) cast iron screw and cast iron nut
(d)Aluminium screw and alloy steel nut.
117 In zinc Blende structure each atom is surrounded by fouratoms of the opposite kind which are
located at the corners of which one of the following ?
(a) Tetrahedron (b) Hexahedron
(c) Cube (d) Orthorhombic
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PRODUCTION
118 Match list - I (Fe-Fe3 C phase Diagram characteristic) with list - II (phase) and select the
correct the answer using the codes given below the lists:
List - I List - II
A.Alpha () iron 1. iron
B. Iron carbide having crystal 2. Eutectic with 3 iron and lattice 1 carbon atom
C. BCC pure allotrope of iron is 3. Ferrite stable between 13880C and its melting point at 15350C.
4. Cementite
Codes:
ABC
(a) 4 2 3
(b) 3 4 1
(c) 4 2 1
(d) 3 1 2
119 Which one of the following pairs is not correctly matched Space lattice Relation between
Atomic Radius r and Edge Element a a2 = 4r2
(a) Simple cubic structure: 3a2 = 16r2
(b) Body centred cubic structure: 2a2 = 3r2
(c) Triclinic a2 = 8r2
(d) Face centred cubic structure:
120 What is the planar density of (100) plane in FCC (face - centred cubic) crystal with unit cell side
a equal to? (b) 2 / a2 (c) 1 / a2 (d) √2 / a2
(a) 1.484 / a2
121 Match list - I (Element) with list - II (Crystal structure) and select the correct answer using the
codes given below the lists:
List - I List - II
A.Alpha iron - 1. Hexagonal closed packed
B. Copper - 2. Body-centred cubic
C. Zinc - 3. Amorphous
D. Glass - 4. Face - centred cubic
Codes:
ABCD
(a) 2 3 1 4
(b) 1 4 2 3
(c) 2 4 1 3
(d) 1 3 2 4
122 Which one of the following factors is more relevant to represent complete solubility of two
metals in each other?
(a) Chemical affinity (b) Valency factor
(c) Crystal structure factor (d) Relative size factor
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MECHANICAL ENGINEERING
123 Match list - I (Effect of cooling) with list - II (Cooling medium) and select the correct answer
using the codes given below the lists:
List - I List - II
A. Martensite 1. Water quenched
B. Very fine pearlite 2. Air cooled
C. Fine pearlite 3. Furnace cooled
D. Coarse pearlite 4. Oil quenched
Codes:
ABCD
(a) 1 4 2 3
(b) 2 3 1 4
(c) 2 3 4 1
(d) 1 2 3 4
124 Which one of the following is the process to refine the grains of metal after it has been distorted
by hammering or cold working?
(a)Annealing (b) Softening (c) Recrystallizing (d) Normalizing
125 Tempering is a process of annealing
(a) martensite at low temperatures (b) martensite at higher temperatures
(c) bainite at low temperatures (d) bainite at higher temperatures
126 What is apporximate strain energy expression for a dislocation of unit length , irrespectively of
its edge or screw character?
(a) G2 b / 2 (b) G b2 / 2 (c) G2 b / 4 (d) G b2 / 4
127 What is the movement of block of atoms along certain crystallographic plane and directions,
termed as ?
(a) Glide (b) Twinning (c) Slip (d) Jog
128 Which one of the following is the correct statement?
Pearlite in iron-carbon system is a
(a) Phase consisting of ferrite and cerement at room temperature.
(b) mechanical mixture of ferrite and cementite at room temperature.
(c) eutectic mixture of ferrite and cementite at room temperature.
(d) all the above the three are correct.
129 Match list - I (Name of the invariant reaction) with list - II (Critical load reaction during
cooling) and select the correct answer using the code given below the lists:
List - I List - II
A. Monotectic
B. Eutectic 1. Liquid→ Solid1 + Solid2 .
C.Eutectoid 2. Liquid1→ Liquid2 + Solid .
D.Peritectic 3. Solid → Solid1 + Solid2 .
4. Liquid + Solid1→ Solid2 .
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PRODUCTION
Codes :
ABCD
(a) 3 1 2 4
(b) 2 4 3 1
(c) 3 4 2 1
(d) 2 1 3 4
130 Which of the following factors influence hardness in a plain carbon steel?
1. Percentage carbon
2. Quenching media
3. Work size
Select the correct answer using the code given below:
(a) 1 and 2 only (b) 2 and 3 only (c) 1 and 3 only (d) 1 , 2 and 3
131 Match list - I (Material) with list - II (Application) and select the correct answer using the code
given below the lists:
List - I List - II
A. Fibre reinforced plastics 1.Automobile tyres
B.Acrylics 2. Aircraft
C. Phenolics 3. Lenses
D. Butadiene rubber 4. Electric cover
Codes:
ABCD
(a) 1 4 3 2
(b) 2 3 4 1
(c) 1 3 4 2
(d) 2 4 3 1
132 Which one among the following is the most effective strengthening mechanism of non-ferrous
metal?
(a) Solid solution hardening
(b) Strain hardening
(c) Grain size refinement
(d) Precipitation hardening
133 Wood is a natural composite consisting of which of the following?
(a) lignin fibres in collagen matrix
(b) lignin fibres in apatite matrix
(c ) Cellulose fibres in apatite matrix
(d) Cellulose fibres in lignin matrix
134 Which one of the following is not a ceramic?
(a)Alumina (b) Porcelain (c) Whisker (d) Pyrosil
135 Which one of the following elements /alloys exhibits season cracking?
(a) Iron (b) Brass (c)Aluminium (d) Steel
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MECHANICAL ENGINEERING
136 Which one of the following is the correct ascending order of packing density for the given
crystal structures of metals.
(a) Simple cubic - Face central cubic-Body centered cubic
(b) Body centered cubic- Simple cubic-Face centered cubic
(c) Simple cubic - Body centered cubic - Face centred cubic
(d) Body centered cubic-Face centered cubic- Simple cubic
137 Vibration damping in machinery is best achieved by means of base structures made of which
one of the following material?
(a) Low carbon steel (b) Nodular iron
(b) Grey cast iron (d) White cast iron
138 For a Rhombohedral space lattice, which one of the
following is correct?
(a) α = β = γ = 900 (b) α = β = γ ≠ 900
(a) α = γ = 900 ≠ β (a) α ≠ β ≠ γ ≠ 900
139 Match list - I (Component) with list - II (Required property) and select the correct answer using
the code given below the lists:
List - I List - II
A. Blades of bulldozer - 1.High wear resistance and high toughness.
B. Gas turbine blades - 2. Low Young’s modulus and high fatigue strength.
C. Drill bit - 3. High wear and abrasion resistance.
D. Spring of automobiles - 4. High creep strength and good corrosion resistance.
Codes:
ABCD
(a) 3 2 1 4
(b) 1 4 3 2
(c) 3 4 1 2
(d) 1 2 3 4
140 Structure of a polymer is :
(a) Long chain (b) Rhombic
(c) Cubic (d) Closed pack hexagonal
141 In the atomic hard - sphere model of the crystal structure of Copper, what is the edge length of
unit cell? (b) (4 / √3) x Atomic radius
(a) 2 x Atomic radius
(c) (2 / √2) x Atomic radius (d) √2 x Atomic radius
142 Which one of the following is correct?
When “devitrification” of inorganic glasses done,
(a) glass transforms from crystalline to noncrystalline
(b) glass transforms into a fully transparent material
(c) glass transforms from monocrystalline state to polycrystalline state.
(d) glass is relieved of internal stresses
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PRODUCTION
143 What is a surface imperfection, which separates crystals of different orientations a
polycrystalline aggregate, called?
(a) Edge dislocation (b) Stacking fault
(c) Grain boundary (d) Screw dislocation
144 Which one of the following statements is correct in the case of screw dislocations?
(b = Burger’s Vector; t = Imaginary Vector)
(a) b is perpendicular to t
(b) b is parallel to t
(c) b is inclined to t
(d) b and t are non -coplanar and non- intersecting
145 Which one of the following is correct?
Malleability is the property by which a metal or alloy can be plastically deformed by applying?
(a) tensile stress
(b) bending stress
(c) shear stress
(d) compressive stress
146 Which of the following elements given below determine(s) the maximum attainable, hardness
in steel?
1. Chromium 2. Manganese 3. Carbon 4. Molybdenum
147 Coefficient of Expansion is practically nil in a particularalloy. What is this alloy?
(a) Hadfield Manganese Steel (b) Invar
(c) Vitallium (d) Stellite
148 Consider the following statements relating to mechanical properties of ceramics:
1. Tensile strength is theoretically high but is practice quite low.
2. Compressive strength is many times lower than tensile strength.
3. Shear strength is high
4. Transverse strength is easy to ascertain
Which of the statements given above are correct?
(a) 1 and 3 (b) 1 and 4 (c) 2 and 3 (d) 2 and 4
149 Consider the following statements in respect of austenditicstainless steels:
1. Austenitic stainless steels are hardened and strengthened by cold working.
2. Austenitic stainless steels cannot be quenched and tempered.
Which of the statements given above is / are correct?
(a) 1 only (b) 2 only (c) Both 1 and 2 (d) Neither 1 nor 2
150 Assertion (A): Lever Rule can be applied to determine relative amounts of phases present at
any temperature.
Reason (R) : Lever Rule is restricted to estimate relative phases, only if they are solid phases.
151 Assertion (A) : Elements are classified into metals and nonmetals on the basis of their atomic
weights.
Reason (R) : The valence electron structures contribute to the primary bonding between the
atoms to form aggregates.
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MECHANICAL ENGINEERING
152 Which one of the following is correct?
Babbits are used for
(a) gears (b) bearings (c) bolts (d) clutch liners
153 What is the process by which two or more chemically different monomers are polymerized to
form a cross link polymer together with a by product such as water or ammonia known as ?
(a)Addition polymerization (b) Co-polymerization
(c) Linear polymerization (d) Condensation polymerization.
154 Which material is used for bushes in the bushed pin type of flexible coupling?
(a) Gun metal (b) Plastic (c) Rubber (d)Aluminium
****************************
“Where the willingness is great, the difficulties
cannot be great”
UNIT I : MATERIAL SCIENCE (ANS.)
1- c, 2-b, 3-a, 4-b, 5-a, 6-b, 7-d, 8-c, 9-b, 10-b, 11-d, 12-c, 13-b, 14-c, 15-b, 16-d, 17-c, 18-c, 19-d,
20-d, 21-b, 22-c, 23-c, 24-c , 25-a, 26-b, 27-b , 28-d , 29-b , 30-b, 31-a, 32-c , 33-a, 34-c, 35-b, 36-
c, 37-a , 38-c, 39-c, 40-d, 41-a, 42-* , 43-d , 44-b, 45-d, 46-d, 47-b, 48-d, 49-a, 50-d, 51-b, 52-d, 53-
b, 54-c, 55-a, 56-c, 57-d, 58-a, 59-a, 60-c, 61-b, 62-c, 63-a, 64-d, 65-c, 66-d, 67-d, 68-c, 69-a, 70-
a, 71-d, 72-d, 73-d, 74-a, 75-c, 76-b, 77-b, 78-c, 79-b, 80-d, 81-d, 82-c, 83-a, 84-a, 85-b, 86-c, 87-
a, 88-c, 89-b, 90-b, 91-b, 92-c, 93-c, 94-d, 95-a, 96-d, 97-a, 98-d, 99-c, 100-d, 101-a, 102-b, 103-d,
104-c, 105-d, 106-b, 107-b, 108-c, 109-c, 110-d, 111-d, 112-b, 113-b, 114-a, 115-a, 116-b, 117-a,
118-b, 119-c, 120-b, 121-c, 122-c, 123-a, 124-c, 125-a, 126-b, 127-c, 128-b, 129-d, 130-a, 131-b,
132-d, 133-d, 134-d, 135-b, 136-c, 137-c, 138-b, 139-c, 140-c, 141-c, 142-c, 143-c, 144-b, 145-d,
146-d, 147-b, 148-a, 149-c, 150-c, 151-d, 152-b, 153-d, 154-c.
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PRODUCTION
2 CASTING
CLASS ROOM OBJECTIVE
1. Riser is designed so as to [ME-GATE-87]
a) Freeze after the casting freezes b) Freezing before the casting freezes
c) Freeze at the same as the casting d) Minimize the time of pouring
2. The pressure at the in-gate will be maximum with the gating system [ME-GATE-90]
a) 4:8:3 b) 1:3:3 c) 1:2:4 d) 1:2:1
3. Converging passage is used for feeding the liquid molten metal into the mold to [ME-GATE-91]
a) Increase the rate of feeding
b) Quickly break off the protruding portion of the casting
c) Decrease wastage of cast metal
d) avoid aspiration of air
4. The primary purpose of spure in casting mold is to [ME-GATE-02]
a) Feed the casting at rate consistent with the rate of solidification
b)Act as a reservoir for molten metal
c) Feed molten metal from the pouring basin to the gate
d) Help feed the casting until all solidification takes place
5. The optimum pouring time for a casting depends on several factors. One important factor among them
is [PI-GATE-91]
a) location of riser b) porosity of sand mold
c) fluidity of casting d) area of the pouring basin
6. The primary function of a riser is to [PI-GATE-92]
a) feed molten metal to casting as it solidifies
b) prevent atmospheric air from contaminating the metal in the mold
c) allow gases to easily escape from mold cavity
d) allow molten metal to rise above the mold cavity
7. Chaplets are placed between mold in order to [PI-GATE-92]
a) promote directional solidification b) help alloying the metal
c) facilitate easy removal of core from casting d) prevent core movement due to buoyancy
8. Chills are used in molds to [ME-GATE-89]
a)Achieve directional solidification b) reduce possibility of blow holes
c) reduce the freezing time d) smoothen the metal for reducing spatter
9. The contraction allowance provided on the pattern and core boxes compensates for the following
type of contraction. [ME-GATE-88]
a) Liquid contraction b) Solidification contraction
c) Solid contraction d) all the above three types of contractions
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MECHANICAL ENGINEERING
10. When there is no room temp change, the total shrinkage allowance on a pattern is IDENPENDENT
OF [ME-GATE-91]
a) pouring temp of the liquid metal
b) freezing temp of the liquid metal
c) the component size
d) coefficient of thermal contraction of solidified metal
11. Which of the following materials requires the largest shrinkage allowance, while making a pattern for
casting [ME-GATE-99]
a)Aluminum b) Brass
c) Cast iron d) Plain carbon steel
12. Shrinkage allowance on pattern is provided to compensate for shrinkage when [ME-GATE-01]
a) the temp of liquid metal drops from pouring to freezing temp
b) the metal change from liquid to solid state at freezing temp
c) the temp of solid phase drops from freezing to room temp
d) the temp of metal drops from pouring to room temp
13. Negative allowance is provided on the pattern to take care of [PI-GATE-89]
a) The distortion allowance b) The draft allowance
c) The machining allowance d) The shake allowance
14. Increase in water content in molding sand causes [ME-GATE-89]
a) Flowability to go through a maxima b) permeability to go through a maxima
c) Compressive strength to go through a maxima d) strength to go through a maxima
15. In a green sand molding process, uniform ramming leads to [ME-GATE-92]
a) Less chance of gas porosity
b) Uniform flow of molten metal into the mold cavity
c) greater dimensional stability of the casting
d) leas and expansion type of casting defect
16. Hardness of green sand mould increase with [ME-GATE-03]
a) increase in moisture content beyond 6 percent
b) increase in permeability
c) decrease in permeability
d) increase in both moisture content and permeability
17. Green sand mould indicates that [ME-GATE-11]
a) Polymeric mould has been cured b) mould has been totally dried
c) mould is green in colour d) mould contains moisture
18. Which of the following is NOT a property of a sand mold ? [PI-GATE-03]
a) permeability b) Collapsibility
c) Strength d) Fluidity
19. Wood flour is added to core sand to improve [PI-GATE-04]
a) Collapsibility of core b) Dry strength of core
c) Shear strength of core d) Tolerance on casting
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PRODUCTION
20. An expandable pattern is used in [ME-GATE-06]
a) slush casting b) squeeze casting
c) centrifugal casting d) investment casting
21. In centrifugal casting, the lighter impurities are [ME-GATE-02]
a) uniformly distributed
b) forced towards the outer surface
c) trapped near the mean radius of the casting
d) collected at the center of the casting
22. Light impurities in the molten metal are prevented from reaching the mold cavity by providing
[ME-GATE-96]
a) Strainer b) Button well c) Skim bob d)All of the above
23. Green strength is powder metallurgy refers to the strength of [PI-GATE-89]
a) original material in the bulk form
b) the powder before compaction
c) the powder after compaction
d) the powder after sintering and cooling
24. An expandable pattern is used in [PI-GATE-05]
a) slush casting b) squeeze casting c) centrifugal casting d) investment casting
25. Cold shut is a defect in casting due to [PI-GATE-06]
a) sand sliding from the cope surface
b) internal voidsor surface depression due to excessive gas trapped
c) discontinuity resulting from hindered contraction
d) two streams of material that are too cold to fuse properly
26. In sand casting fluidity of the molten metal increases with [PI-GATE-11]
a) Increase in degree of superheat b) Decrease in pouring rate
c) Increase in theermal conductivity of the mold d) Increase in sand grain size
27. Casting Process Product [ME-GATE-92]
A. Slush casting 1. Turbine blade
B. Shell molding 2. Machine tool bed
C. Dry sand molding 3. Cylindrical block
D. Centrifugal casting 4. Hollow castings like lamp shades
5. Rain water pipes
6. Cast iron shoe brake
28. Only 4 pairs can be matched [ME-GATE-94]
Casting Process Products
A. Investment casting 1. Turbine rotors
B. Die casting 2. Turbine blades
C. Centrifugal casting 3. Connecting rods
D. Drop forging 4. Galvanized iron pipes
E. Extrusion 5. Cast iron pipes
F. Shell molding 6. Carburetor body
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MECHANICAL ENGINEERING
29. Match the following [ME-GATE-98]
A. Sand casting 1. Symmetrical and circular shapes only
B. Plaster mold casting 2. Parts have hardened skin and soft interior
C. Shell mold casting 3. Minimum post casting process
D. Investment casting 4. Parts have soft skin and hard interior
5. Parts a have tendency to warp
6. Suitable only for non ferrous metals
30. With a solidification factor of 0.97 x 106 s/m2, the solidification time (in seconds) for a spherical casting
of 200 mm diameter is [ME-GATE-03]
a) 539 b) 1078 c) 4311 d) None
31. Gray cast iron blocks 200 x 100 x 10 mm are to be cast in sand moulds. Shrinkage allowance for
pattern making is 1%. The ratio of the volume of pattern to that of the casting will be [ME-GATE-04]
a) 0.97 b) 0.99 c) 1.01 d) 1.03
32. A mould has a down sprue whose length is 20 cm and the cross sectional area at the base of the down
sprue is 1 cm2. The down sprue feeds a horizontal runner leading into the mould cavity of 1000 cm3.
The time required to fill the mould cavity will be [ME-GATE-05]
a) 4.05 s b) 5.05 s c) 6.05 s d) 7.25 s
33. Match the following [ME-GATE-09]
Part used in casting Purpose
P. Metallic chills 1. Support for the core
Q. Metallic chaplets 2. Reservoir of the molten metal
R. Riser 3. Control cooling of critical sections
S. Exothermicpadding 4. Progressive solidification
a) P-1, Q-3, R-2, S-4 b) P-1, Q-4, R-2, S-3 c) P-3, Q-4, R-2, S-1d) P-4, Q-1, R-2, S-3
34. In a gating system, the ratio 1:2:4 represents [ME-GATE-10]
a) Sprue base area : Runner area : in-gate area
b) Pouring basin area : in-gate area : Runner area
c) Sprue base area : in-gate area : casting area :
d) Runner area : in-gate area : Casting area
35. A cubic casting of 50 mm side undergoes volumetric solidification shrinkage and volumetric solid
contraction of 4% and 6% respectively. No riser is used.Assume uniform cooling in all directions. The
side of cube after solidification and contraction is [ME-GATE-10]
a) 48.32 mm b) 49.90 mm
c) 49.49 mm d) 49.96 mm
36. When there is no room temp change, the total shrinkage allowance on a pattern is INDEPENDENT
OF [PI-GATE-90]
a) pouring temp of the liquid metal
b) heezing temp of liquid metal
c) the component size
d) cofficient of thermal contraction of solidified metal
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PRODUCTION
37. Manufacturing process Property [PI-GATE-93]
A. Hot tears 1. Mould restraint
B. Porosity 2. Inadequate reserving
C. Sand inclusions 3. High pouring temp
D. Shrinkage cavity 4. Loosely rammed sand mold
5. Gas entrapment
38. Application Type of pattern [PI-GATE-92]
A. Undercut in components 1. Cope and drag
B. Large bells 2.. Follow board
C. Mass production of casting by Machine molding 3. Gated
D. Components with irregular parting lines 4. Loose piece
5. Sweep
39. Proper gating design in metal casting [PI-GATE-02]
P. Influences the freezing range of the melt
Q. Compensates the loss of fluidity of the melt
R. Facilitates top feeding of the melt
S.Avoids misrum
a) P, R b) Q, S c) R, S d) P, S
40. A 10 mm thick steel bar is to be horizontally cast with two correctly spaced top risers of adequate
feeding capacity.Assuming end effect without chill, what should be the theoretical length of the bar ?
[PI-GATE-02]
a) 96 mm b) 132 mm
c) 192 mm d) 156 mm
41. Process Mold making technique [PI-GATE-02]
P. Green sand molding 1. Pouring
Q. Sheel molding 2. Dipping
R. Investment molding 3. Compaction
S. Ceramic molding 4. Resin bonding
P QRS
a) 2 1 3 4
b) 1 3 4 2
c) 4 2 2 3
d) 3 4 1 1
42. Chaplets are placed between mould and core surface in order to [PI-GATE-03]
a) Reduce directional solidification
b) Help local alloying of molten metal
c) Help easy removal of core from casting
d) Prevent core movement due to buoyancy
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MECHANICAL ENGINEERING
43. Match the items of List I (Equipment) with the items of List II (Process) and select the correct answer
using the given codes. [PI-GATE-04]
List - I (Equipment) List - II (Process)
P. Hot Chamber Machine 1. Cleaning
Q. Muller 2. Core making
R. Dielectric Baker 3. Die Casting
S. Sand Blaster 4.Annealing
5. Sand mixing
P QRS
a) 2 1 4 5
b) 4 2 3 5
c) 4 5 1 2
d) 3 5 2 1
44. The shape factor for a casting in the form of an annular cylinder of outside diameter 30 cm inside
diameter 20 cm and height 30 cm (correction factor k = 1.0) will be [PI-GATE-05]
a) 21.77 b) 6.28 c) 4.92 d) 12.28
45. Match the following [PI-GATE-07]
Group - I Group - II
P. Sand casting 1. Turbine blades
Q. Centrifugal casting 2. LC engines
R. Investment casting 3. Large bells
S. Die casting 4. Pulleys
P QRS
a) 4 1 3 2
b) 2 4 3 1
c) 3 4 1 2
d) 3 2 1 4
Statement for Linked Answer Question 46 & 47
In a sand process, a spure of 10 mm base diameter and 250 mm height leads to a runner which fills a
cubical mold cavity of 100 mm size. [PI-GATE-07]
46. The volume flow rate (in mm3/s) is
a) 0.8 x 105 b) 1.1 x 105 c) 1.7 x 105 d) 2.3 x 105
47. The mold filling time in second is [PI-GATE-07]
a) 2.8 b) 5.78 c) 7.54 d) 8.41
***********************
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PRODUCTION
Practice Questions :
1. Centrifugally casted products have [ME-GATE-93]
a) Large grain structure with high porosity
b) Fine grain strucutre with high density
c) Fine grain strucutre with low porosity
d) Segregation of slug towards the outer skin of the casting
2. Disposable patterns are made of [ME-GATE-2000]
a) wood b) rubber c) metal d) Polystyrene
3. Misrum is a casting defect which occurs due to [ME-GATE-04]
a) very high pouring temperature of the metal b) insufficient fluidity of the molten metal
c) absorption of gases by the liquid metal d) improper alignment of the mould flasks
4. Which of the following engineering materials is the most suitable candidate for hot chamber die casting
a) Low carbon steel b) titanium c) Copper d) tin [ME-GATE-07]
5. Two streams of liquid metal which are not hot enough to fuse properly result into a casting defect known as
a) cold shut b) Swell c) blow hole d) Scar [ME-GATE-09]
6. The process by which shell like castings (like toys) are made is [PI-GATE-89]
a) Shell molding b) centrifugal casting c) slush casting d) die casting
7. Poor collapsibility of the mold lead\s to ................... type of casting defect in aluminum casting. [PI-GATE-89]
8. For casting of turbine blades made of high temp and high strength alloys, the most suitable process is
[PI-GATE-90]
a) Die casting b) Investment casting c) Centrifugal casting d) Slush casting
9. For the same material, powder metallurgy process is superior to casting for [PI-GATE-89]
a) making large products
b) better control over the density of product
c) better strength of the finish product
d) making parts with wide variations of thickness at different section
10. The problem of shrinkage cavity is more likely to occur while casting ............ A ............. B .......... a chill block.
A. metal / plastick B. wiht / without [PI-GATE-90]
11. Assertion : Converging passage is used for feeding liquid metal into a mould
Reason : Inhalation of air promotes blow holes in casting [PI-GATE-90]
12. Ceramic slurry is used in making the molds for [PI-GATE-9]
a) investment casting b) die casting
c) shell mold d) centrifugal casting
13. Low permeability molds and low pouring temp of the molten metal causes ................. defect in casting.
[PI-GATE-91]
14. Pressure die casting deals with casting metals of relatively .......... A ......... melting point and provides ........ B .....
production rate. [PI-GATE-91]
A. higher / lower B. higher / lower
15. Increase in carbon content in plain carbon steels raise its [PI-GATE-92]
a) Ductility and UTS b) Tensile strength and malleability
c) Tensile strength and hardness d) Ductility and melting temperature
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MECHANICAL ENGINEERING
16. Investment casting uses ........ A ............ as pattern material and is preferred for small parts with ........ B ........ designs.
A. wax / resin coated sand B. simple / intricate [PI-GATE-92]
17. Investment casting uses .......... (wax / resin coated sand) as pattern material and is preferred for small parts with
.......... (simple/intricate) designs. [PI-GATE-92]
18. Bentonite is commonly used bonding material for dry sand cores. (T/F/) [PI-GATE-94]
19. Shell molding is an investment casting process (True/Fasle) [PI-GATE-95]
20. In hallow cylindrical parts made by centrifugal casting, the density of the part is [PI-GATE-08]
a) Maximum at the outer region
b) maximum at the inner region
c) Maximum at the mid point between outer and inner surfaces
d) Uniform throughout
21. Hot chamber die casting is NOT suited for [PI-GATE-09]
a) Lead and its alloys b) zinc and its alloys c) Tin and it’s alloys d) Aluminum and its alloy
22. Solidification time of a metallic alloy casting is [PI-GATE-10]
a) Directly proportional to its surface are
b) Inversely proportional to the specific heat of the cast meterial
c) Inversely proportional to the thermal diffusivity of the mould material
d) Inversely proportional to the pouring temp
23. Which of the following casting processes uses expandable pattern and expandable mold [PI-GATE-11]
a) Shell mod casting b) Investment casting c) Pressure die casting d) centrifugal casting
24. Two cubical castings of the same metal and sizes of 2 cm side and 4 cm side are moulded in green sand. If the smaller
casting solidifies in 2 mins, the expected time of solidification of larger casting will be [ME-GATE-89]
a) 16 min b) 2√8 min c) 8 min d) 4 min
25. Match list - I (products) with List - II (casting process) and select the correct answer using the codes given below
the lists [ME-GATE-05]
List - I List - II
A. Hollow statues 1. Centrifugal casting
B. Dentures 2. investment casting
C. Aluminum alloy pistons 3. Slush casting
D. Rocker arm 4. Shell moulding
5. Gravity die casting
a)A-3, B-2, C-4, D-5 b)A-1, B-3, C-4, D-5
c)A-1, B-2, C-3, D-4 d)A-3, B-2, C-5, D-4
26. In a sand casting operation, the total liquid head is maintained constant such that it is equal to the mould height.
The time taken to fill the mold with a top gate is tA. If the same mold is field with a bottom gate, then the time taken
is tB. ignore the time required to fill runner and frictional effects. Assume atmospheeric pressure at the top molten
metal surfaces. The relation between the tA and tB is [ME-GATE-06]
d) tB = 2. √2.tA
a) tB = √2.tA b) tB = 2.tA c) tB = tA /√2
27. If a particular Fe-C alloy contains less than 0.83% carbon, it is called [ME-GATE-07]
a) High speed steel b) Hypo-eutectoid steel
c) Hyper eutectoid steel d) Cast irons
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PRODUCTION
28. Volume of a cube of a side “1” and volume of sphere of radius ‘r’ are equal. Both the cube and the shere are solid and
same material. They are being cast. The ratio of the solidification time of the cube to the same of the sphere is
[ME-GATE-07]
a) (4II/6)3. (r/l)6 b) (4II/6). (r/l)2 c) (4II/6)2. (r/l)3 d) (4II/6)3. (r/l)4
29. A 200 mm long down sprue has an area of cross section of 650 mm2 where the pouring basin meets the down sprue
( i.e. at the begining of the down sprue). A constant head of molten metal is maintaining by the pouring basin. The
molten metal flow rate is 6.5 x 105 mm3/s. considering the end of down sprue to be open to atmosphere and and
acceleration due to gravity of 104mm/s2, the area of the down sprue in mm2 at its end (avoiding aspiration effect)
should be [ME-GATE-07]
a) 650 111111222222333333444444555555666666777777888888999999000000111111 Pouring
b) 350 Basin
c) 290.7
d) 190.0 650 mm2 111112222233333444445555566666 200 mm
Area of
down sprue
at its edns
30. While cooling, a cubical casting of side 40 mm undergoes 3%, 4% and 5% volume shrinkage during the liquid state,
phase transition and solid state respectively. The volume of metal compensated from the riser is [ME-GATE-08]
a) 2% b) 7% c) 8% d) 9%
31. For the case of molding, it is decided to replace a spherical riser of diameter 100 mm by a cyliondrical riser. Determine
size of the cylindrical riser that will have the identical solidification time. Assume blind risering & ratio of height to
radius of cylinder is 2. [ME-GATE-10]
a) 10 cm b) 100 cm c) 50 cm d) 5 cm
32. Shrinkage allowance on pattern is provided to compensate for shrinkage when [PI-GATE-89]
a) the temp of liquid metal drops from pouring to freezing temp
b) the metal changes from liquid to solid state at freezing temp
c) the temp of solid phase drops from freezing to room temp
d) the temp of metal drops from poruing to room temp
33. What is the velocity of the steel at the buttom of the sprue if the sprue height is 30 cm ? assume the frictional and
other losses to be 20%. [PI-GATE-89]
34. According to Chvorinove’s rule, the solidification time of a casting is proportional to [Volume/Surface area]n, where
‘n’ equal to [PI-GATE-94]
a) 0.5 b) 1 c) 2 d) 4
35. Casting Defect Most Appropriate Cause [PI-GATE-95]
A. Hot tears 1. Mold restraint
B. Porosity 2. Inadequate resering
C. Sand inclusions 3. High pouring temp
D. Shrinkage cavity 4. Loosely rammed sand mold
5. Gas entrapment
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MECHANICAL ENGINEERING
36. The height of the down spure is 175 mm and its CS area at the base is 200mm2. The CS area of the horizontal runner
is also 200 mm2. Assuming no losses, indicate the correct choice for the time (seconds) required to fill a mold cavity
of volume 106 mm3. (use g = 10 m/s2) [PI-GATE-02]
a) 2.67 b) 8.45 c) 26.72 d) 84.50
37. The permeability of molding sand was determined using a standard AFS sample by passing 2000cc of air at a gage
pressure of 10g/cm2. If the time taken for the air to escape was 1 min, the permeability number is : [PI-GATE-02]
a) 112.4 b) 100.2 c) 75.3 d) 50.1
38. Grating ratio of 1 : 2 : 4 is used to design the gating system for magnesium alloy casting. This gatting ratio refers to
the cross section area of the various gating elements as given below [PI-GATE-03]
1. Down sprue 2. Runner 3. Ingates
The sequence of the above elemets in the ratio 1 : 2 : 4 is
a) 1, 2 & 3 b) 1, 3 & 2 c) 2, 3 &1 d) 3, 1 & 2
39. A cassting of size 100 mm x 100 mm x 50 mm is required. Assume volume shrinkage of casting as 2.6%. If the height
of the riser is 80 mm and riser volume desired is 4 times the shrinkage in casting, what is the apporpirate riser
diameter in mm ? [PI-GATE-03]
a) 14.38 b) 20.34 c) 28.76 d) 57.52
40. A cast steel slab of dimension 30 x 20 x 5 cm is poured horizontally using a sider riser. The riser is cylindrical in shape
with diameter and height, both equal to D. the freezing ratio of the mould is [PI-GATE-05]
a) 8D/75 b) 4D/75 c) 75/8D d) 75/4D
41. A casting of size 400 mm x 200 mm x 140 mm solidifies in 20 min, the solidification time for a casting 400 mm x 200 mm
3 35 mm under similar condition is [PI-GATE-06]
a) 2 min b) 3.3 min c) 4 min d) 8.1 min
42. In sand casting of hallow part of lead, a cylindrical core of diameter 120 mm and height 180 mm is placed inside the
mould cavity. The densities of core material and lead are 1600 Kg/m3 and 11300 Kg/m3 respectively. The net force
(in N) that tends to lift the core during pouring of molten metal will be [PI-GATE-08]
43. A solid cylinder of diameter D and height equal to D, and a solid cube of side L are being sand cast by using the
same material. Assuming there is no superheat in both the cases, the ratio of solidification times of the cylinder to
the solidification time of the cube is [PI-GATE-09]
a) (L/D/)2 b) (2L/D)2 c) (2D/L)2 d) (D/L)3
44. During the filling process of a given sand mould cavity by molten metal through a horizontal runner of circular C.S.,
the frictional head loss of the moltern metal in the runner will increase with the [PI-GATE-10]
a) Increase in runner diameter b) Decrease internal surface roughness of the runner
c) Decrease in length of runner d) Increase in average velocity of molten metal
45. In a sand casting process, a sphere and a cylinder of equal volumes are separately cast from the same molten metal
under identical conditoins. The height and diameter of the cylinder are equal. The ratio of the solidification time of
the sphere to that of the cylinder is [PI-GATE-11]
a) 1.14 b) 0.87 c) 1.31 d) 0.76
46. A mold having dimensions 100 mm x 90 mm x 20 mm is filled with molten metal through a gate with height ‘h’ and C.S.
area A, the mould filling time is t1. The height is now quadrupled and the cross sectional area is halved. The
corresponding filling time is t2. The ration t2/t1 is [PI-GATE-12]
d) 2
a) 1/√2 b) 1 c) √2
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PRODUCTION
47. Consider the following statements:
Assertion (A) :- Aluminium alloys are cast in hot chamber die casting machine.
Reason (R) :- Aluminium alloys require high melting when compared to zinc alloys.
(a) Both A and R are indiividually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not thecorrect explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
48. Match List-I (Product) with List-II (Process of manufacture) and select the correct answer using the codes given
below the lists:
List-I (Product)
A. Automobile piston in aluminium alloy .
B. Engine crankshaft in spheroidal graphite iron.
C. Carburettor housing in aluminium alloy.
D. Cast titanium blades.
List-II (Process of Manufacture)
1. Pressure die-casting.
2. Gravity die-casting.
3. Sand casting.
4. Precision investment casting.
5. Shell moulding.
Codes:
ABCD
(a) 2 3 1 5
(b) 3 2 1 5
(c) 2 1 3 4
(d) 4 1 2 3
49. Directional solidification in castings can be improved by using :
(a) chills and chaplets
(b) chills and padding
(c) chaplets and padding
(d) chills,chaplets and padding
50. Which of the following methods are used for obtaining directional solidification for riser design ?
1. Suitable placement of chills.
2. Suitable placement of chaplets.
3. Employing padding.
Select the correct answer:
(a) 1 and 2 (b) 1 and 3
(c) 2 and 3 (d) 1, 2, and 3
51. Misrun is a casting defect which occurs due to:
(a) very high pouring temperature of the metal. (b) insufficient fludity of the molten metal.
(c) absorption of gases by the liquid metal. (d) improper alignment of the mould flasks.
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MECHANICAL ENGINEERING
52. Which one of the following pairs is not correctly matched?
(a) Aluminium alloy piston - Pressure die casting
(b) Jewellry - Lost wax process
(c) Large pipes - Centrifugal casting
(d) Large bells - Loam moulding
53. Consider the following statements:
Assertion (A): Steel can be melted in hot blast cupola.
Reason (R) : In hot blast cupola, the flue gases are used to preheat the air blast to the cupola so that
the temperature in the furnace is consider ably higher than that in a conventional cupola.
(a) Both A and R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
54. A sand casting mould assembly is shown in the given fig. The elements marked A and B are respectively:
(a) Sprue and riser (b) Ingate and riser
(c) Drag and runner (d) Riser and runner.
55. Which of the following are the requirements of an ideal gating system?
1. The molten metal should enter the mould cavity with as high a velocity as possible.
2. It should facilitate complete filling of the mouldcavity.
3.It should be able to prevent the absorption of air or gases from the surroundings on the molten metal while
flowing through it.
Select the correct answer using the codes given below:
(a) 1, 2 and 3 (b) 1 and 2
(c) 2 and 3 (d) 1 and 3
56. In solidification of metal during casting, compensation for solid contraction is:
(a) Provided by the oversize pattern
(b) Achieved by properly placed risers.
(c) Obtained by promoting direction solidification
(d) Made by providing chills.
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PRODUCTION
57. Match List-I (Type of casting) with List-II (Working principles) and select the correct answer using the codes
given below the lists:
List-I List-II
A. Die casting - 1. Molten metal is forced into the die under pressure.
B. Centrifugal casting - 2. Axis of rotation does not coincide with axis of mould.
C. Centrifuging - 3. Metal solidifies when mould is rotating.
D. Continuous casting - 4. Continously pouring molten metal into mould.
Codes:
ABCD
(a) 1 3 2 4
(b) 4 3 2 1
(c) 1 2 3 4
(d) 4 2 3 1
58. Match List-I (Components of a table fan) with List-II (Manufacturing processes) and select the correct answer
using the codes given below the lists:
List-I List-II
A. Base with stand 1. Stamping and pressing
B. Blade 2. Wire drawing
C. Armature coil wire 3. Turning
D. Armature shaft 4. Casting
Codes:
ABCD
(a) 4 3 2 1
(b) 2 1 4 3
(c) 2 3 4 1
(d) 4 1 2 3
59. Match List-I (Process) with List-II (Products/Materials) and select the correct answer using the codes given
below the lists:
List-I List-II
A. Die casting 1. Phenol formaldehyde
B. Shell molding 2. C.I. Pipes
C. CO2 molding 3. Non-ferrous alloys
D. Centrifugal casting 4. Sodium silicate
Codes:-
ABCD
(a) 1 3 4 2
(b) 3 1 4 2
(c) 3 1 2 4
(d) 1 3 2 4
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MECHANICAL ENGINEERING
60. Match List-I (Components) with List-II (Manufacturing processes) and select the correct answer using the
codes given below the lists:
List-I List-II
A. Car body (metal) 1. Machining
B. Clutch lining 2. Casting
C. Gears 3. Sheet metal pressing
D. Engine block 4. Powder metallurgy
Codes:-
ABCD
(a) 3 4 2 1
(b) 4 3 1 2
(c) 4 3 2 1
(d) 3 4 1 2
61. Scrab is a:
(a) sand casting defect. (b) machining defect
(c) welding defect (d) forging defect
62. The main purpose of chaplets is:
(a) to ensure directional solidification (b) to provide efficient venting
(c) for aligning the mould boxes. (d) to support the cores
63. Consider the following statements:
Assertion (A): In CO2 casting process, the mould or core attains maximum strength.
Reason (R) : The optimum gassing time of CO2 through the mould of core forms silica gel which imparts
sufficient strength to the mould or core.
(a) Both A and R are individually true and R is the correct explanation of A.
(b) Both A and R are individually true but R is not the correct explanation of A.
(c) A is true but R is false.
(d) A is false but R is true.
64. Match List-I (Products) with List-II (Casting Process) and select the correct answer using the codes given
below the lists:
List-I List-II
A. Hollow state 1. Centrifugal casting
B. Dentures 2. Investment casting
C. Aluminum alloy pistons 3. Slush casting
D. Rocker arms 4. Shell moulding
5. Gravity die casting
Codes:
ABCD
(a) 3 2 4 5
(b) 1 3 4 5
(c) 1 2 3 4
(d) 3 2 5 4
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PRODUCTION
65. A gating ratio of 1 : 2 : 4 is used to design the gating system for magnesium alloy casting. this gating ratio refers
to the cross-section areas of the various gating elements as given below:
(1) Down sprue (2) Runner bar (3) Ingates
The correct sequence of the above elements in the ratio 1 : 2 : 4 is.
(a) 1, 2 and 3 (b) 1, 3 and 2 (c) 2, 3 and 1 (d) 3, 1 and 2
66. The centrifugal casting method is used for casting articles of.
(a) Symmetrical shape about vertical axis.
(b) Symmetrical shape about horizontal axis.
(c) Irregular shape
(d) Non-ferrous metal only
67. Which one of the following processes produces a casting when pressure forces the molten metal into the mould
cavity?
(a) Shell moulding (b) Investment casting
(c) Die casting (d) Continous casting
68. Which of the following materials are used for making patterns in investment casting method?
1. Wax 2. Rubber 3. Wood 4. Plastic
Select the correct answer using the codes given below:
(a) Only 1 and 3 (b) Only 2 and 3 (c) Only 1, 2 and 4 (d) Only 2, 3 and 4
*********************
CONVENTIONAL
1. A down sprue of 180 mm length has diameter of 20 mm at its top end. The liquid metal in the pouring cup is
maintained upto 60 mm height. What should be the theoretical diameter of down sprue at its lower end to ensure
that there is no aspiration effect. [ME-GATE-87] [4M]
2. A flask consisting of a cope and drag has the following dimentions : length 300 mm, width 200 mm and total depth
200 mm (cope height 50 mm). A 150 mm x 100 mm x 50 mm cast iron block is to be cast. If the specific weight of cast
iron is 78 KN/m3 and [ME-GATE-91] [6M]
3. Calculate the ratio of the solidification times of two steel cylindrical risers of sizes 30 cm diameter by 60 cm in height
and 60 cm diameter by 30 cm in height subjected to identical conditions of cooling.[ME-GATE-92] [4M]
4. An aluminum cube of 10 cm side has to be cast along with a cylindrical riser of height equal to its diameter. The riser
is not insulated on any surface. If the volume shrinkage of aluminum during solidification is 6%, calculate shrinkage
volume of cube on solidification and minimum size of the riser so that it can provide the shrinkage volume.
[ME-GATE-93] [5M]
5. The pouring basin in a sand mold is 200 mm diameter 100 mm height. The mold cavity is a cube of 125 mm side and
must be filled in 25 seconds. The maximum velocity must ensure laminar flow into the mold cavity and in the gates
of circular cross section. Assume (a) constant temperature, (b) no loss in the velocity head and (c) diameter of gate
= 8 times diameter at the sprue base. Properties of the molten metal are γ = 0.9 mm2 per second, ρ = 700 kg/m3 &
CP = 33.6 j/mol-K. The diameter of spure to avoid aspiration effect. [ME-GATE-96] [5M]
6. Two castings of the same metal have the same surface area one casting is in the form of a sphere and the other is a
acube. What is the ratio of the solidification time for the sphere to that of cube. [ME-GATE-98] [4M]
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MECHANICAL ENGINEERING
7. In a particular mold design, the down sprue has an area of Cross section of 6.45 cm2 where the pouring basin leads
into the sprue. The sprue is 20 cm long. The required metal flow rate at the top section of the sprue is 820 cm3/s.
Determine the pouring height necessary above the sprue top. Also determine the area of C.S. of the sprue at its
bottom to avaoid the aspiration of liquid nolten metal. [ME-GATE-99] [5M]
8. Two castings, a cube and a slab of the same material solidify under indentical conditons. The volumes of the
castings are equal but the slab dimentions are in the ratio of 1:2:4 find the ratio of the solidification times of the cube
to that of the slab. [ME-GATE-00] [4M]
9. Molten aluminum was spoured in a sand mold and the thickness of solid skin formed after 20 seconds and
50 seconds were found to be 3 mm and 4.5 mm respectively. What would be the thickness of the solid skin at the end
of 100 seconds after pouring ? [PI-GATE-89]
a) 5.5 mm b) 6.19 mm c) 7.1 mm d) none
10. A steel plate 40 cm x 30 cm x 0.3 cm is to be cast. The volume shrinkage of steel during solidification is 3%. A
cylindrical side riser with diameter 4 cm and height 4cm is used. The riser volume should at least be 3 times that the
dictated by shrinkage consideration. Is the riser volume sufficient if not what is the riser size ? [PI-GATE-90] [6M]
11. A rectangular block of steel C.S. 100 x 150 mm and 250 mm height is to be cast with out any riser. The block is
moulded entirely in the drag of a green sand flask & is top gated. The cope of the the flask is 200 mm height & the
height of the metal during pouring is 100 mm above the cope level. A tapered sprue is employed & the gating ratio
is 1:4:2 assume no energy losses in the system. The time taken (in seconds) to fill the casting cavity, if the tapered
sprues with 500 sq. mm exit area is used. [PI-GATE-91] [6M]
12. If the freezing ratio equal to (casting area / casting volume) / (riser area / riser volume) & the volumetric ratio equal
to riser volume / casting volume, for a disc casting of 20 cm diameter and 10 cm thick are 1.4 and 0.8 respectively. The
corresponding values for a square disc of 20 cm side and 10 cm thick if the same cylindrical riser with a height to
diameter ratio of unity is used in both cases. [PI-GATE-92] [5M]
a) 1.4 & 0.68 b) 1.4 & 0.8 c) 1.2 & 0.8 d) 1.2 & 0.68
13. A casting of 200 x 100 x 70 mm size solidifies in ten minutes. Estimate solidification time for a 200 x 100 x 10 mm
casting under similar conditions ? [PI-GATE-93] [5M]
14. A cylinder of 150 mm dia & 200 mm height is to be cast with any riser. The cylinder is moulded entirely in the drag
of a green and flask & is top gated. The cope of the flask is 200 mm height & the height of the metal during pouring
is 50 mm above the cop. A tapered sprue is employed & the gating ratio is 1:1:5:2. The time taken (in seconds) to fill
the casting cavity neglecting energy losses, if the in-gate area is 400 sq. mm. [PI-GATE-94] [5M]
15. Three castings are of the same material, volume and cast under similar conditions. One is a sphere, another is a cube
and the thirs is cylinder with its length being equal to its diameter. [PI-GATE-95] [6M]
i) The ratio of solidification times of sphere to the cube is
a) 1.54 b) 0.65 c) 0.848 d) 1.3
ii) The solidification time of the sphere to the cylinder
a) 0.767 b) 1.3 c) 1.18 d) none
16. For true centrifugal casting process with the axis of rotation in horizontal direction, an acceleration of 75g, where g
is the acceleration due to gravity, is requried for sound casting, the relation between dia ‘D’ (in mm) and the
rotational speed N (1 rev/s) for this casting is N2D = constant, determine the constant. Aslo calculate the mold
speed (in rev/se(c) for casting CI pipes of 5m long with outside and inside diameters of 0.52 m and 0.5 m
respectively. [PI-GATE-01] [5M]
**********************
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PRODUCTION
UNIT - II : CASTING
1-a, 2-c, 3-d, 4-c, 5-c, 6-a, 7-d, 8-a, 9-c, 10-a, 11-b, 12-c, 13-d, 14-a, 15-c, 16-c, 17-d, 18-d, 19-a, 20-d, 21-d, 22-c, 23-c, 24-d,
25-c, 26-a, 27-sol, 28-sol, 29-sol, 30-b, 31-a, 32-d, 33-d, 34-a, 35-a, 36-a, 37-sol, 38-sol, 39-b, 40-b, 41-c, 42-d, 43-d, 44-a,
45-c, 46-c, 47-b
Practice Questions :
1-b, 2-d, 3-b, 4-d, 5-a, 6-c, 7-sol, 8-b, 9-b, 10-sol, 11-sol, 12-c, 13-sol, 14-sol, 15-c, 16-sol, 17-sol, 18-T, 19-F, 20-a, 21-d, 22-c,
23-b, 24-c, 25-d, 26-b, 27-b, 28-d, 29-c, 30-b, 31-a, 32-c, 33-sol, 34-c, 35-sol, 36-a, 37-d, 38-a, 39-d, 40-a, 41-b, 42-c, 43-d, 44-
d, 45-c, 46-b, 47-d, 48-a, 49-b, 50-b, 51-b, 52-a, 53-a, 54-a, 55-c, 56-a, 57-a, 58-d, 59-b, 60-d, 61-a, 62-d, 63-a, 64-d, 65-a, 66-b,
67-c, 68-c.
Conventional :
1-14.14 mm, 2-10.5N, 3-0.64, 4-10 cm, 5-55.3 mm, 6-1.91, 7-2.11 mm, 8-1.36, 9-6.206 mm, 10-4 cm, 11-3.09 sec, 12-0.628, 13-0.65
min, 14-8 sec, 15-1.306, 16-8.55 rps
“You don’t pay the price for success. You enjoy the price
for success”
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MECHANICAL ENGINEERING
3. WELDING
1. In DC welding, the straight polarity (electrode negative) results in [ME-GATE-93]
a) Lower penetration b) Lower desposition rate
c) Less heating of work piece d) Smaller weldd pool
2. The electrodes used in are welding are coated. This is not expected to [ME-GATE-94]
a) Provide protective asmoshere to weld b) Stabilize the arc
c) Add alloying elements d) Prevent electrode from contamination
3. The ratio of acetylene to oxygen is approximately ........... for neutral flame used in gas welding. [ME-GATE-94]
4. Preheating before welding is done to [ME-GATE-96]
a) Make the steel softer b) Burn away oil, grease etc from the plate surface
c) Prevent cold cracks d) Prevent plate distortion
5. The temp of a carburizing flame in gas welding ................. that of a neutal or an oxidizing flame. [ME-GATE-02]
a) Lower than b) Higher than c) Equal to d) Unrelated to
6. Which of the following are welding processes does not use consumable electrode. [ME-GATE-02]
a) GMAW b) GTAW c) SAW d) none
7. In oxyacetylene gas welding, temperature at the inner come of the flame is around [GATE-ME-03]
a) 35000C b) 32000C c) 29000C d) 25500C
8. Which of the following is a solid state welding process. [ME-GATE-07]
a) GTAW b) Resistance spot welding c) Friction welding d) SAW
9. In welding brass with oxy-acetylene flame, the type of flame used is .......... [ME-GATE-89]
10. Welding Process Heat Source [ME-GATE-90]
A. Thermit welding 1. Electric arc
B. Projection welding 2. Mechanical work
C. MIG welding 3. Exothermic chemical reaction
D. Friction welding 4. Ohmic resistance
11. With increasing joint thickness, the tensile strenght of a brazed joint [ME-GATE-90]
a) Continuously decreases b) First decreases and then increases
c) Continously increases d) First increase and then decreases
12. High alloy steel components are preheated before welding for reducing [PI-GATE-90]
a) Heat affected zone b) Total energy consumption
c) Total time of welding d) Welding stresses
13. Continuous rails for Indian railways are welded by ........... welding process. [PI-GATE-91]
14. The joint configuration best suited for adhesive bonding is [PI-GATE-92]
a) butt b) fillet c) lap d) spot
15. The composition of an oxy-acetylene flame for cutting of steel contain more oxygen.[PI-GATE-94]
(True / False)
16. Which of the following powders should be fed for effective oxy-fuel cutting of stainless steeel [PI-GATE-01]
a) Steel b) Aluminum c) Copper d) Ceramic
17. In resistance welding, heat is generated due to the resistance between [PI-GATE-03]
a) electrode and wokr piece b) asperities between touching plates
c) two dissimilar metals being in contact d) inter-atomic forces
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PRODUCTION
18. In resistance seam welding, the electrode is in the form of a [PI-GATE-11]
a) cylinder b) flat plate c) coil of wire d) circular disc
19. The metal powder used in Themit welding of steel is [PI-GATE-04]
a) Al b) Cu c) Pb d) W
20. Which of the following welding process results in the smallest heat affected zone [PI-GATE-11]
a) Shielded metal arc welding b) Gas welding
c) Laser beam welding d) Thermit welding
21. 1. Welding process Heat source [ME-GATE-91]
A. Themit welding 1. Chemical reaction
B. Seam welding 2. Exothermic chemical reaction
C. MIG wedling 3. Electric spark
d. Friction welding 4. Ohmic resistance
5. Mechanical work
6. Electric arc
22. List - I List - II [ME-GATE-96]
A. Welding of aluminum alloy 1. Submerged arc welding
B. Ship building 2. Electron beam welding
C. Joining of HSS dril bit to shank 3. TIG welding
D. Deep penetration precision welds 4. Firction welding
5. Gas welding
23. Match the following [ME-GATE-03]
Work material Type of joining
P. Aluminum 1. Submerged Arc Welding
Q. Die steel 2. Soldering
R. Copper wire 3. Thermit Welding
S. Titanium sheet 4. Atomic Hydrogen Welding
5. Gas Tungsten Arc Welding
6. Laser Beam Welding
P QRS
a) 2 5 1 3
b) 6 3 4 4
c) 4 4 6 2
d) 5 4 2 6
24. Two 1 mm thick steel sheets are to be spot welded at a current of 5000 A. Assuming effective resistance to be 200
micro-ohms and current flow time of 0.2 second, heat generated during the process will be [ME-GATE-04]
a) 0.2 Joule b) 1 Joule c) 5 Joule d) 1000 Joules
25. In arc welding process, the voltage and current are 25V and 300A respectively. The arc heat transfer efficiency is
0.85 and welding speed is 8mm/sec. The net heat input (in J/mm) is [ME-GATE-06]
a) 64 b) 797 c) 1103 d) 79700
26. In are welding of butt joint, the welding speed is to be selected such that highest cooling rate is achieved. Melting
efficiency and heat transfer efficiency are 0.5 and 0.7, respectively. The area of the weld cross section is 5mm2 and
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MECHANICAL ENGINEERING
the unit energy required to melt the metal is 10J/mm3, if the welding power is 2KW, the welding speed in mm/s is
closet to [ME-GATE-08]
a) 4 b) 14 c) 24 d) 34
27. In welding a mild steel sheet using on oxy-acetylene flame, the total amount of acetylene consumed was 8.0 ltrs, the
oxygen consumption from the cylinder is [PI-GATE-89]
a) 8.0 ltrs b) 16 ltrs c) 20 ltrs d) 24 ltrs
28. Match the following [PI-GATE-89]
List - I List - II
A. Cellulose coating 1. Alloying agent
B. Rutile coating 2. Absorb gasses
C. Iron powder coating 3. Forming slag
D. Basic coating 4. Shielding gasses
29. In welding process, penetration is increased by [PI-GATE-91]
a) increasing current and decreasing speed b) decreasing both current and speed
c) increasing both are voltage and speed d) increasing are voltage and decreasing
30. Welding Application Process [PI-GATE-92]
A. Heighly reactive metals 1. Ultrasonic
B. long straight butt join in thick sections 2. Thermit
C. site weld of rails 3. Electron beam
d. MS rods to plate like components 4. Submerged arc
5. Stud
31. Which of the following process can be used for welding of Aluminum alloys [PI-GATE-03]
P. Submerged are welding
Q. Gas metal are welding
R. Electroslag welding
S. Gas tungsten are welding
a) P,Q b) Q,S c) Q,R d) R,S
32. Group I Group II
P. Arc welding 1. Difussion
Q. Friction welding 2. Polarity
R. Sold state welding 3. Focusing
S. Laser welding 4. Kinetic energy
P QRS
a) 4 1 3 2
b) 3 2 4 3
c) 1 2 4 3
d) 2 4 1 3
33. A 900 mm long steel plate is welded by manual metal arc welding process using welding current of 150 A, arc voltage
of 20 V and welding speed of 300 mm/min. if the process efficiency of is 0.8 and surface is 36 micro-ohm, the heat
input will be [PI-GATE-03]
a) 600 J/mm b) 480 j/min c) 146 kJ d) 116 kJ
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PRODUCTION
34. Spot welding of two 1 mm thick sheets of steel (density = 8000 kg/m3) is carried out sucessfully by passing a certain
amount of current for 0.1 second through the electrodes. The resultant weld nugget formed is 5 min in diameter and
1.5 mm thick. If the latent heat of fusion of steel is 1400 kJ/kg and the effective resistance in the welding operation
is 200 µΩ, the current passing through the electrodes is approximately. [ME-GATE-05]
a) 1480 A b) 3300A c) 4060A d) 9400 A
35. A Dc welding machine with a linear power source characteristic provides open circuit voltage of 80V and short
circuit current of 800A. during welding with the machine, the measured are current is 500 A corresponsding to an arc
length of 5.0 mm and the measured arc current I 460 A corresponding to an arc length of 7.0 mm. the linear voltage
(E) - arc length (L) characteristic of the welding arc can be given as (where E is in Volts and L is in mm)
[PI-GATE-07]
a) E = 20 + 2L b) E = 20 + 8L c) E = 80 + 2L d) E = 80 + 8L
36. Two 8mm thick steel plates are placed 5mm apart and welded by a butt joint. Welding is carried out
at 20 V and speed of 5mm/sec. Heat transfer efficiency is 0.80. If the heat required to melt steel is 10
J/mm3 and melt-ing efficiency is 0.625. the weld current (inAmp.) will be.
(a) 100 (b) 200 (c) 300 (d) 400
37. Two steel bars each of diameter 10 mm are coaxially friction welded end to end at an axial pressure of 200 MPa and
ata rotational speed of 400 rpm. The coefficient of friction between the mating faces of the rotating bars is 0.50. the
torque is assumed to act at the 3/4th radius of the rotating bar. The power (in KW) consumed at the interface fro
welding is [ME-GATE-10]
a) 12.33 b) 16.44 c) 18.50 d) 24.66
38. Two plates with symmetrical V Joint penetration of V angle 600 are to be arc welded in a single pass. The power
P(KW)-arc length L(mm) characteristic is given by P = 4+0.8L-0.1L2. Assuming that the top surface of the weld is flat
& flush with the plate top surface, & the energy losses are 20%. The density of filter material is 8gm/cc and the
energy required to melt 1 gm is 1400 joules. The plate dimensions are 1000 mm length & 5mm thickness . The
maximum welding speed is...........................
39. The voltage - arc length characteristics of a power source is V=20+40L, where V=operating voltage in volts and
L= arc length in cm. The open circuit voltage and short circuit current for arc lengths ranging from 3 to 5mm and
current from 400 to 500 amps during welding operation are...................................
40. Two sheets of low carbon steel 1.5mm thick each are spot welded by passing a current 10000amps for 5 cycles in
50 Hz main supply.
(i)The heat generated due to the supply of power if effective resistance has 200 micro ohms, is ...................
(ii) The maximum indentation is 10% of sheet thickness and density of the spot weld nugget 8 gm/cc. If 1380 joules
are required to melt 1 gm of steel, The heat required for welding operation if D=6 SQRT(t) to deter mine nugget
diameter D and assume the nugget size to be equal to metal between the two electrodes is..............................
41. A resistance welder is rated at 50KVA, at 50% duty cycle. Secondary voltage is always constant at 25 volts. if a job
requires 1500 Amps current, the maximum welding time in a total cycle time of 30 secs is...........................
42. A 20 mm thick plate with single V-edge preparation as shown in fig. is subjected to multipass submerged are
welding from one side only, 15% extra weld metal is deposited as weld crown. If the V-groove is filled in 5 equal
passes, the welding speed in mm/min when other welding parameters are.
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MECHANICAL ENGINEERING
43. Two different pairs of sheets of same material are welded by resistance -spot welding. In one pair, the average
radius (r) of each spherical bridge is 0.2mm and the number of bridges per cm2 (n) is 25. In another pair, the number
of bridges per cm2 is 50 with the same ‘r’ of bridge. The contact resistance (Rc) per unit area is given by Rc = 0.85
(ρ/ nπr) where ‘ρ’ is the resistivity of metal. If the voltage applied is 5 volts and the resistivity of metal is 2 x 10-5
ohm-cm. The rate of heat generated per cm2 in each case is ............................
Q. 44 & 45 Linked Questions
A weld is made using MIG welding process with the following welding parameters: Current:200A; Voltage:
25V; Welding speed : 18cm/min; wire diameter: 1.2 mm; Wire feed rate: 4m/min; Thermal efficiency of the process :
65%
44. The heat input per unit length of the weld in kJ/cm is:
(a) 0.18 (b) 0.28 (c) 10.83 (d) 16.66
45. The area of cross section of weld bead in mm2 is:
(a) 16.3 (b) 25.1 (c) 30.3 (d) 38.6
46. Two 1 mm thick steel sheets are to be spot welded at a current of 5000A .Assuming effective resistance to be
200micro-ohms and current flow time of 0.2 second, heat generated during the process will be.
(a) 0.2 joule (b) 1 joule (c) 5 joule (d) 1000 joules
47. The current in amperes used in resistance spot welding of plain carbon steel sheets (1 to 3 mm thick) lies with in the
range:
(a) 10-50 (b) 50-500 (c) 500-5000 (d) 5000-50000
48. Spot welding of two 1mm thick sheets of steel (density = 8000 kg/m3) is carried out successfully by passing a certain
amount of current for 0.1 second through the electrodes. The resultant weld nugget formed is 5mm in diameter and
1.5mm thick. If the latent heat of fusion of steel is 1400 kJ/kg and the effective resistance in the welding operation
is 200nano ohm the current passing through the electrodes is apporximately
(a) 1480 A (b) 3300A (c) 4060 A (d) 9400 A
********
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PRODUCTION
3. WELDING
PRACTICE QUESTIONS :
1. Penetration is increase by [ME-GATE-90]
a) Increasing welding current and welding speed
b) Increasing welding current and decreasing welding speed
c) Decreasing welding current and welding speed
d) Decreasing welding current and increasing welding speed
2. At small variations of arc length at operating conditions, the manual metal arc welding transformer provides nearly
a) Constant power b) Constant power factor [ME-GATE-90]
c) Constant voltage d) constant current
3. For gas welding a particular job using a neutral oxy-acetylene flame the acetylene consumption was 10 ltrs. The
oxygen consumption from the cylinder in liters will be [ME-GATE-91]
a) 5 b) 10 c) 15 d) 20
4. For resistance spot welding of 1.5 mm thick steel sheets, the current required is of the order [ME-GATE-92]
a) 10 Amp b) 100 Amp c) 1000Amp d) 10,000Amp
5. In an explosive welding process, the ................. (maximum/minimum) velocity of impact is fixed by the velocity of
sound in the ..................... (flyer / target) plate material. [ME-GATE-92]
6. Generally cylindrical parts produced by power metallurgy should not have non-uniform cross section and length to
diameter ratio exceeding ...................... [ME-GATE-94]
7. Two plates of the same metal having equal thickness are to be butt welded with electric arc. When the plate
thickness changes, welding is achieved by [ME-GATE-01]
a) Adjusting the current b) Adjusting the duration of the current
c) Changing the electrode size d) Changing the electrodee coating
8. The strength of a brazed joint [ME-GATE-05]
a) Decrease with increase in gap between the two joining surfaces
b) Increases with increase in gap between the two joining surfaces
c) Decrease up to certain gap between the two joining surfaces beyond which it increases
d) Increase up to certain gap between the two joining surfaces beyond which it decrease
9. Which one among the following welding processes uses non-consumable electrode ? [ME-GATE-11]
a) Gas metal arc welding b) Submerged are welding
c) Gas tungsten arc welding d) Flux coated arc welding
10. The mode of metal transfer in CO2-MIG welding at low temperature is [PI-GATE-90]
a) Spray transfer b) Short circuiting type of transfer
c) Globular transfer d) Droplet transfer
11. In TIG welding a ............ A ........... and ......... B ............ electrode is uded. [PI-GATE-90]
a) non-consumable / consumable b. coated / bare
12. In spot welding of aluminum sheets, the welding current should be ................A ........... and weld time should be kept
.......... B ............ than for MS sheet of same thickness. [PI-GATE-91]
a) higher / lower b) higher / lower
13. ............... is the non-fusion method of joining dissimilar metals with metals whose melting temp is greater than 400C.
[PI-GATE-91]
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MECHANICAL ENGINEERING
14. The type of coated electrode most widely used for welding low carbon steel is [PI-GATE-92]
a) cellulose b) acidic c) futile d) oxide
15. Filler material is ............. A .................... in resistance welding and the heat generated in the process is dirrectly
proportional to ................. B ............... [PI-GATE-92]
a) used / not used b. square of the current / cube of the current
16. The consumption of an xoy-acetylene flame for cutting of steel contains more oxygen . [PI-GATE-95]
(True / Flase)
17. High speed electron beam welding is focussed on the weld spot using [PI-GATE-03]
a) vacccum lens b) inert gas lens c) optical lens d) magnetic lens
18. The current in Amperes used in resistance spot welding of plain carbon steel sheets (1 to 3 mm thick) lies within the
range : [PI-GATE-04]
a) 10-50 b) 50-500 c) 500-5000 d) 5000-50000
19. Resistance spot welding is performed on two plates of 1.5 mm thickness with 6 mm dia electrode, using 15000A
current for a time duration of 0.25 sec. assuming the interface resistance to be 0.0001Ω-, the heat generated to form
the weld is [PI-GATE-01]
a) 5625 W-sec b) 8437 W-sec c) 22500 W-sec d) 33750 W-sec
20. During gas welding of copper sheets a neutral flame was used consuming 8 ltrs of acetylene. But the weld was
found to be defective. So it was re-welded using an oxidizing flame. The likely consumption of oxygen in litres
will be. [PI-GATE-93]
a) 6 b) 8 c) 10 d) 16
21. In spot pulsed laser welding of alunimum (density = 2700 kg/m3, specific heat = 896j/kg, melting temp = 933K, latent
heat of melting = 398 KJ/kg) at a temp of 30C, pulse with energy of 0.5J is focused onto an area of 0.05 mm2, if the
entire energy is coupled into the material, what will be the depth of weld assuming the CS area of the weld is circular
and is uniform throughout its depth and only heat conduction in the direction of penetration. [PI-GATE-02]
a) 5.34 mm b) 2.15 mm c) 4.23 mm d) 3.85 mm
22. The cold cracking susceptibility of the heat affected zone in an are weld is influenced by [PI-GATE-03]
P. entraped hydrogen
Q. residual stresses
R. marternsitic transformation
S. Slag inclusion
a) P,S b) P,Q,S c) P,Q,R d) R,S
23. Match list - I (welding defects) with list - II (causes) and the correct answer using the codes given below the lists
List- I List - II [PI-GATE-03]
A. spatter 1. Damp electrodes
B. Distortion 2. Arc blow
C. slag inclusion 3. Improper cleaning in multi pass welding
D. Porosity 4. Poor joint selection
a)A-4, B-2, C-3, D-1
b)A-4, B-2, C-1, D-3
c)A-2, B-4, C-1, D-3
d)A-2, B-4, C-3, D-1
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