KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY

(AUTONOMOUS)
NAMAKKAL- TRICHY MAIN ROAD, THOTTIAM, TRICHY
DEPARTMENT MECHANICAL ENGINEERING
24ME303-MANUFACTURING PROCESS

ASSIGNMENT – I
Academic Year:2026-2027
YEAR/SEM: II/III (B Section) Given Date: 14.07.2026 Submission Date: 25.07.2026
CO Blooms
[Link]. Register No. Student Name Assignment Topics / Questions
Mapping Level
Select a suitable moulding sand for a cylinder head application by applying its Ap
CO1
properties and justify your choice.
Choose an appropriate moulding method for different casting components and apply Ap
CO1
621325114064 MADHANKUMAR K the selected method to produce the mould, giving reasons for your selection.
1
Determine whether plastic welding or fusion welding is more suitable for a given Ap
CO2
manufacturing application by applying their characteristics and justify your choice.
Apply the principles of plastic welding and fusion welding to recommend suitable
CO2 Ap
industrial applications for each process based on material and service requirements.
Use the principles of investment casting to develop a suitable casting process for an
CO1 Ap
automotive engineering.
Analyze the relationship between casting defects and the appropriate non-destructive
CO1 A
and destructive inspection methods used to evaluate casting quality.
MADHESH S An automobile manufacturing company produces car bodies, exhaust systems, and
2 621325114065
heavy-duty chassis. The production engineer must select suitable welding processes
CO2 Ap
for different components to ensure high productivity, strength, and quality.
Recommend a suitable welding process for each component with justification.
Apply your knowledge of plastic welding and fusion welding to solve a joining
CO2 Ap
problem involving metallic and non-metallic materials.
Select suitable pattern making allowances for different casting applications and
CO1 Ap
621325114066 MAHESHWARAN N demonstrate their use in pattern preparation.
3
Apply the centrifugal casting process to manufacture a hollow cylindrical component
CO1 Ap
and explain the sequence of operations.
 Analyze the relationship between flame characteristics and the selection of suitable
CO2 A
welding conditions for various engineering applications.
A fabrication workshop has received orders to manufacture steel pipelines, thin sheet
metal components, and repair cracked cast-iron parts. The welding engineer must
select suitable gas welding processes for each job to ensure good weld quality, cost- CO2 Ap
effectiveness, and productivity. Identify the most suitable type of gas welding process
for each application and justify your choice.
Use the shell moulding process to produce a specified casting and justify its selection
CO1 Ap
over conventional sand moulding.
Apply the ceramic moulding process to manufacture a complex engineering
CO1 Ap
621325114067 MANIKANDAN V component and justify its suitability by considering its advantages and limitations.
4
Select and arrange the components of an industrial arc welding setup to fabricate a
CO2 Ap
steel structure and explain the role of each component.
Analyze the factors affecting the selection of gas welding for different industrial
CO2 A
applications.
Apply the factors affecting pattern material selection to choose a suitable material for
CO1 Ap
manufacturing an aluminium engine block pattern.
A machine manufacturer needs to produce a 2.5 m diameter flywheel in small
quantities. Manufacturing a full-size pattern is expensive and difficult to handle.
CO1 Ap
Select an appropriate pattern type for manufacturing the flywheel and explain how it
621325114068 MIDHUN SABARISH S minimizes cost and improves ease of mould preparation.
5
A fabrication shop needs to weld both aluminium and mild steel components. Choose
the appropriate welding current (AC or DC) for each case and justify your CO2 Ap
recommendations.
Examine how the use of Direct Current Electrode Positive (DCEP) polarity
CO2 A
influences heat distribution and weld characteristics during arc welding.
A foundry is assigned to manufacture a pump casing with complex internal cavities.
Choose an appropriate pattern with core arrangement and explain how it facilitates CO1 Ap
the production of the casting.
621325114069 MOHAMED AHSIN S Examine the factors influencing the selection of different types of patterns for casting
6 CO1 A
operations, and support your analysis with sketches of any three patterns.
A fabrication shop needs to weld a thick steel plate requiring deeper weld penetration.
Construct the appropriate DCEN polarity welding setup with a neat sketch and justify CO2 Ap
its suitability.
 Examine how different welding polarities influence the quality and efficiency of the
CO2 A
arc welding process.
A valve body requires accurate internal flow passages. Design a suitable core-making
procedure and explain how the core contributes to obtaining the required cavity CO1 Ap
dimensions
A foundry experiences low melting efficiency and excessive fuel consumption in its
cupola furnace. Analyze how the construction and operation of the cupola furnace CO1 Ap
621325114070 MOHAMED ARSHATH S could contribute to these problems, and support your answer with a neat diagram.
7
Analyze the relationship between welding polarity and weld characteristics by
CO2 A
comparing straight and reverse polarity under different welding conditions.
A manufacturer needs to weld titanium components used in aerospace applications
with deep penetration and a narrow heat-affected zone. Apply the Electron Beam CO2 Ap
Welding process and explain why it is the most suitable choice.
A foundry needs to manufacture a pattern for a large casting in low production
quantity. Select the most appropriate pattern material and justify your CO1 Ap
recommendation by considering its merits and demerits.
Examine the properties of core sand and analyze how they differ from moulding sand
in terms of composition, performance, and applications. CO1 A
621325114071 MOHAMED IRFAN I
8 A welded pressure vessel develops cracks after fabrication. Apply your
understanding of weld defects to identify the probable causes and recommend CO2 Ap
remedies.
An automotive company is deciding between Friction Stir Welding and Gas Metal
Arc Welding for joining aluminium body panels. Analyze the advantages and CO2 A
limitations of both processes and justify the most suitable choice.
A foundry needs to melt cast iron for mass production of machine components.
Recommend the appropriate furnace and explain its construction and operation with CO1 Ap
a neat sketch.
621325114072 MOHAMED WASEEM A Examine the green sand mould preparation process with a cope and drag pattern and
9 CO1 A
analyze how each stage influences the quality of the final casting.
A fabrication industry needs to weld structural steel exposed to atmospheric
conditions. Select a suitable flux-coated electrode and explain how the flux coating CO2 Ap
contributes to weld quality and protection.
 A welder experiences poor arc stability and excessive spatter while welding. Apply
your knowledge of welding electrodes to identify the probable cause and recommend CO2 Ap
a suitable electrode.
Evaluate the sequence of operations in the cold-chamber die casting process and
analyze how improper process parameters can lead to casting defects, supported by CO1 A
a neat sketch.
Examine the centrifugal casting process and analyze its suitability for manufacturing
CO1 A
hollow cylindrical components.
A welder experiences porosity and oxidation while joining stainless steel plates.
621325114073 MOUNIDHARAN P
10 Apply your knowledge of flux functions to recommend a suitable flux and explain CO2 Ap
how it improves weld quality.
A fabrication company is constructing a steel bridge using manual arc welding.
During inspection, engineers observe excessive spatter, poor penetration, and slag
inclusions in several weld joints. Analyze the possible causes of these welding defects CO2 Ap
during the manual arc welding process and recommend suitable corrective measures
to improve weld quality.
Recommend a suitable moulding sand for manufacturing a cast iron engine block by
applying the properties of different moulding sands, and justify your CO1 Ap
recommendation.
A foundry has received a bulk order to manufacture cast iron automotive brake
drums. Select a suitable cupola furnace for this application and justify your choice CO1 Ap
621325114074 MUTHUKRISHNAN P by explaining its construction and operation with a neat sketch.
11
Select an appropriate electrode size for welding an agricultural trailer chassis made
of mild steel and justify your selection based on the material thickness and welding CO2 Ap
requirements.
Analyze how beam focusing and energy density influence weld penetration, heat-
CO2 A
affected zone, and weld quality in Electron Beam Welding.
A manufacturer plans to produce aluminium alloy automotive gearbox housings in
large quantities with high dimensional accuracy. Analyze the suitability of the
CO1 A
pressure die casting process for this application and justify your recommendation
621325114075 NARESHKUMAR V with a neat sketch.
12
Select a suitable induction furnace for melting steel used in manufacturing
CO1 Ap
automotive gears and justify your choice based on its applications and advantages.
Apply the working principle of Electroslag Welding to develop a welding procedure
CO2 Ap
for manufacturing heavy machine frames and explain why the process is suitable.
 Apply the principles of arc welding to set up a suitable welding process for joining
Ap
mild steel plates in the fabrication of a pressure vessel and illustrate it with a neat CO2
sketch.
A quality engineer observes frequent casting rejections in an automotive foundry.
Analyze the possible casting defects and determine the most suitable inspection CO1 A
techniques to ensure product quality.
Compare jolt, squeeze, and jolt-squeeze moulding machines by analyzing their
CO1 A
operating principles, advantages, and limitations.
621325114076 NAVEEN KUMAR L
13 Determine suitable TIG welding process variables for welding aerospace aluminium
components and justify your recommendations based on the advantages of the CO2 Ap
process.
Analyze the influence of process parameters on the quality of joints produced by
Friction Welding and Friction Stir Welding, and compare their performance with neat CO2 A
sketches.
A foundry is producing cast steel gear housings with surface cracks after
solidification. Apply your knowledge of casting defects to identify the likely causes CO1 Ap
and recommend suitable preventive measures.
Analyze the working principle of pressure die casting and explain why it is preferred
621325114077 NAVEEN KUMAR M CO1 A
14 over other casting processes for mass production.
Analyze the suitability of TIG welding for joining thin sections of stainless steel and
CO2 A
aluminium alloys.
A manufacturer is fabricating aluminium aircraft components using TIG welding.
CO2 Ap
Select a suitable inert gas for this application and justify your recommendation.
Analyze the factors influencing the selection of pattern allowances and justify their
CO1 A
importance in producing accurate castings.
A foundry is producing cast iron engine blocks. Apply your knowledge of different
moulding sands to select the most suitable sand and explain the reasons for your CO1 Ap
621325114078 NITHISH KUMAR K selection.
15
Examine the Shielded Metal Arc Welding process and analyze how its process
CO2 A
parameters influence weld quality and application suitability, with a suitable diagram.
Apply the characteristics of different electrode materials to select a suitable electrode
CO2 Ap
for joining mild steel and aluminium components in an industrial application.
621325114079 PARNIKA P Analyze how properties such as permeability, strength, refractoriness, and
16 CO1 A
collapsibility influence the selection of moulding sand in casting processes.
 Recommend a suitable moulding method for producing precision castings with good
surface finish and dimensional accuracy by applying the principles of moulding CO1 Ap
processes.
Analyze the influence of electrode type, shielding gas, and welding parameters on
CO2 A
the performance of MIG and TIG welding processes.
Analyze the influence of accelerating voltage, beam current, and welding speed on
CO2 A
the performance of Electron Beam Welding.
Apply the principles of investment casting to select a suitable manufacturing process
CO1 Ap
for producing complex-shaped precision components and justify your choice.
Examine the relationship between casting defects and their detection techniques, and
CO1 A
analyze the effectiveness of various inspection methods.
621325114080 PERINBANATHAN B
17 Apply the principles of Submerged Arc Welding to develop a suitable welding
procedure for manufacturing pressure vessels and explain the reason for selecting this CO2 Ap
process.
Analyze the relationship between electrical resistance, heat generation, and weld
CO2 A
formation in resistance welding.
Apply the knowledge of shrinkage, machining, draft, and distortion allowances to
CO1 Ap
prepare a pattern for a given casting application.
Examine the centrifugal casting process and analyze how process parameters such as
CO1 A
rotational speed and pouring rate influence the quality of cast components.
621325114081 PRABHAKARAN R
18 An automobile company plans to join aluminium panels with steel reinforcement
parts to reduce vehicle weight. Choose an appropriate welding technique for welding CO2 Ap
these dissimilar metals and explain the reasons for your selection.
Analyze the effect of welding direction on heat input, weld bead formation, and
CO2 A
productivity in forward and reverse welding techniques.
Analyze the sequence of operations in shell moulding and evaluate how each stage
CO1 A
contributes to the production of defect-free castings.
Apply the principles of ceramic moulding to select a suitable casting process for
CO1 Ap
621325114082 PRAGADEESWARAN S manufacturing high-temperature alloy components and justify your choice.
19
Compare percussion welding with other resistance welding processes and analyze
CO2 A
their suitability for different industrial applications.
Analyze how the electroslag welding mechanism reduces welding time and improves
CO2 A
productivity compared with conventional welding methods.
 Apply the characteristics of pattern materials to select the most appropriate material
CO1 Ap
for a high-volume production casting process.
Analyze how the integration of gating and runner systems with match plate patterns
CO1 A
improves casting productivity and reduces defects.
621325114083 PRASANNA N
20 A manufacturer needs to join copper pipes in a refrigeration system. Apply the
characteristics of soldering and brazing to select the appropriate process and justify CO2 Ap
your recommendation
Analyze the relationship between electrical resistance, heat generation, and nugget
CO2 A
formation in the spot welding process.
Develop a suitable green sand moulding process for manufacturing a cast iron engine
block and justify the selection of moulding materials, pattern, and process parameters CO1 Ap
based on the casting requirements.
Apply the features of loose-piece, split, match plate, and skeleton patterns to select
suitable patterns for different casting applications and represent them with neat CO1 Ap
621325114084 PRASANTH D sketches.
21
Examine the Electron Beam Welding process and analyze how beam current,
accelerating voltage, and welding speed affect the characteristics of the welded joint CO2 A
with a suitable sketch.
Compare different types of welding defects and analyze their causes, effects, and
CO2 A
methods of prevention.
Apply the knowledge of core properties to develop a suitable core for manufacturing
CO1 Ap
complex-shaped castings and explain the preparation procedure.
A steel manufacturing industry plans to recycle scrap steel and produce high-quality
alloy steel components. Select a suitable furnace for this application and justify the CO1 Ap
621325114085 PRAVEEN KUMAR R use of an Electric Arc Furnace based on its working principle and advantages.
22
Analyze the working mechanism of resistance welding and justify its suitability for
CO2 A
high-volume production of sheet metal components.
Apply the principles of seam welding to select suitable process parameters for joining
CO2 Ap
thin sheets and achieving defect-free welds.
Apply the working principles of cupola, induction, and electric arc furnaces to select
CO1 Ap
PRAVEENKHAN P the most suitable furnace for a specified cast iron casting application.
23
621325114086 Analyze the factors influencing the selection of core sand and moulding sand and
CO1 A
evaluate their impact on the accuracy and quality of cast components.
 A manufacturer needs to weld thin stainless steel components with high accuracy and
minimum distortion. Apply the concept of Plasma Arc Welding and justify its CO2 Ap
suitability for the application.
Apply the working principle of friction welding to develop a suitable welding process
CO2 Ap
for joining cylindrical components and explain the reason for its selection.
Select an appropriate furnace for melting aluminium alloy components in a foundry
and justify your choice based on melting capacity, efficiency, and quality CO1 Ap
requirements.
A foundry plans to produce cast iron machine components using a cope and drag
621325114087 PRIYAN S pattern. Apply the green sand mould preparation steps and justify the selection of this CO1 Ap
24
moulding method.
Analyze the role of spot welding in industries such as automotive, aerospace, and
CO2 A
sheet metal fabrication by evaluating its process advantages and limitations.
Select an appropriate welding process for joining thin stainless steel sheets used in
CO2 Ap
food processing equipment by applying the characteristics of seam welding.
Compare cold-chamber and hot-chamber die casting processes and analyze their
CO1 A
suitability for different alloy casting requirements.
A foundry needs to manufacture large-diameter pipes with uniform wall thickness.
Apply the centrifugal casting process and justify its suitability for this application CO1 Ap
621325114088 PUGALENTHI C with a sketch.
25
Examine spot welding and seam welding processes and analyze their advantages,
CO2 A
limitations, and industrial applications.
Analyze the factors influencing the selection of special welding processes for joining
CO2 A
difficult-to-weld materials.
Analyze the suitability of different types of moulding sands for producing a engine
CO1 A
block casting and justify the most appropriate choice based on their properties.
Select pressure die casting for manufacturing an automobile wheel hub and explain
CO1 Ap
621325114089 RAHUL D the process with the help of a neat sketch.
26
Analyze the reasons for selecting Electron Beam Welding over conventional fusion
CO2 A
welding processes for high-precision engineering components.
Apply the Plasma Arc Welding process to manufacture a thin-walled stainless steel
CO2 Ap
component and justify its suitability for the application.
Analyze the working principle of an induction furnace and examine how
621325114090 RAMAKRISHNAN M
27 electromagnetic induction, frequency, and coil design influence melting efficiency CO1 A
and metal quality.
 Examine the relationship between casting defects and inspection methods, and
analyze the suitability of visual inspection, radiographic testing, ultrasonic testing, CO1 A
and dye penetrant testing for defect detection.
Select suitable forge welding conditions for joining metal parts in a blacksmithing
CO2 Ap
application and justify the choice of heating temperature, flux, and forging technique.
Choose an appropriate plastic welding method for fabricating a plastic storage tank
using flat sheets and explain how the selected technique ensures joint strength and CO2 Ap
leak prevention.
An engineering firm is planning the mass production of automotive engine covers.
The selected manufacturing process must ensure close dimensional tolerances, thin
sections, and rapid production. Analyze the given manufacturing requirements and CO1 A
explain how the pressure die casting process can meet these needs. Support your
answer with a neat sketch and discuss its advantages and disadvantages.
621325114092 RAMESHWARAN P Select a suitable core making process for manufacturing the core of a pump casing
28 CO1 Ap
and explain the process with a neat sketch, justifying your selection.
Analyze the advantages and limitations of friction welding and friction stir welding
CO2 A
in joining similar and dissimilar materials.
Choose the most suitable type of Plasma Arc Welding for welding a stainless steel
pressure vessel and justify your selection by explaining the process with a suitable CO2 Ap
block diagram.
A foundry produces castings with blowholes, shrinkage cavities, and misruns.
Analyze the causes of these defects with suitable sketches and recommend CO1 A
appropriate preventive measures.
Develop a sand mould for producing a valve body by applying the steps involved in
621325114093 RENGARAJ V CO1 Ap
29 the sand moulding process, with a neat sketch.
Develop a friction welding procedure for joining a steel shaft to a flange and explain
CO2 Ap
the process with a neat sketch.
Investigate the research scope in welding processes and analyze its role in the
CO2 A
development of advanced welding technologies.
Analyze the sequence of operations in the hot chamber die casting process using a
CO1 A
neat sketch, and determine how the process parameters affect the final casting quality.
621325114094 RITHISH P Apply the gravity die casting process to manufacture an aluminium housing
30 CO1 Ap
component and explain its industrial applications.
Choose a recent development in arc welding and explain how it can be applied in the
CO2 Ap
fabrication of automotive or aerospace components.
 Using the principles of Friction Stir Welding (FSW), develop a suitable welding
CO2 Ap
procedure for joining a given non-ferrous material.
Examine five common casting defects and analyze the relationship between their
CO1 A
causes and the appropriate remedial measures.
Demonstrate how investment casting can be applied to produce a complex-shaped
CO1 Ap
621325114095 ROHITH B component and explain the complete process in detail.
31
Apply the GTAW process for welding an aluminium alloy component and justify the
CO2 Ap
selection of equipment and operating procedure.
Investigate the properties of consumable and non-consumable electrodes and analyze
CO2 A
how they influence the welding process and the quality of the welded joint.
Compare and analyze green sand and dry sand based on their composition,
CO1 A
characteristics, and industrial applications.
Demonstrate the application of the cold chamber die casting process for
CO1 Ap
manufacturing an automotive component and explain the process with a neat sketch.
621325114096 ROHITH E A pressure vessel manufacturer needs to weld 20 mm thick steel plates in a butt joint
32
configuration. The weld must withstand high internal pressure and comply with
CO2 Ap
quality standards. Select the most suitable welding process and explain why it is
preferred over other welding techniques.
Analyze the key specifications of a welding machine with a neat sketch and justify
CO2 A
their importance in achieving efficient and defect-free welding.
Examine the mould-making process using a two-piece pattern and analyze how each
CO1 A
stage affects the quality and accuracy of the final casting.
Using the principles of a cupola furnace, develop a suitable melting procedure for
producing cast iron components and explain why this furnace is preferred for the CO1 Ap
621325114097 ROHITH G chosen application.
33
Analyze the methods used to repair cracks in railway tracks and justify the selection
CO2 A
of the most suitable welding process.
Demonstrate the setup and use of oxy-acetylene gas welding equipment for welding
CO2 Ap
a mild steel plate and explain the role of each equipment.
Analyze the differences between a pattern and a casting, and examine the significance
CO1 A
of the pattern colour coding system in foundry practice.
621325114098 SABDHAGIRI S S Compare and analyze the different pattern allowances using a schematic diagram,
34 CO1 A
and evaluate their effects on the quality of the final casting.
Examine the use of flux in the Submerged Arc Welding process and analyze its effect
CO2 A
on arc stability, weld penetration, and slag formation.
 Apply the principles of Electroslag Welding to fabricate a thick-section engineering
CO2 Ap
component and explain the process with a neat sketch.
Investigate the sand preparation process before mould making and analyze the role
CO1 A
of each operation in achieving the required mould characteristics.
Construct a gating system for an engineering casting by applying standard design
CO1 Ap
principles, and label all its components in a neat sketch.
621325114099 SACHIN T An automotive company is manufacturing fuel injectors and transmission
35
components that require accurate and repeatable welding. Recommend a suitable
CO2 Ap
welding process and explain how Plasma Arc Welding meets the production
requirements. Discuss its industrial applications.
Examine the requirements for welding in a vacuum space and analyze why Electron
CO2 A
Beam Welding is the most suitable process.
Apply the functions of a riser to design a feeding system for a valve body casting and
CO1 Ap
justify the riser location.
Investigate the various stages of the lost wax process with suitable sketches, and
CO1 A
621325114100 SANJAY S analyze the factors affecting the quality of the final casting.
36
Examine the principles of Friction Welding and Friction Stir Processing, and analyze
CO2 A
their suitability for different engineering applications.
Using the Friction Stir Welding (FSW) process, develop a suitable welding procedure
CO2 Ap
for joining a given non-ferrous material and explain the sequence of operations.
Investigate the properties of pattern materials and analyze their impact on pattern life,
CO1 A
dimensional accuracy, and casting quality.
Demonstrate the application of moulding sand properties in designing a mould for an
CO1 Ap
automotive component and explain how each property contributes to casting quality.
621325114101 SANJAY YATHRA M
37 Analyze the characteristics of the different modes of metal transfer in arc welding
and determine the most suitable mode for various welding positions with CO2 A
justification.
Using the forces influencing metal transfer in arc welding, determine the suitable
CO2 Ap
welding parameters for producing a defect-free weld.
A foundry is assigned to produce hollow cylindrical components such as pipes and
cylinder liners for industrial applications. The customer demands excellent internal
CO1 Ap
621325114102 SANTHI S soundness and minimal machining. Recommend a suitable casting process and
38
explain how centrifugal casting meets these requirements.
Investigate the steps involved in the sand-casting process and analyze the role of each
CO1 A
operation in minimizing casting defects.
 Examine the role of shielding gases in GTAW and analyze how their properties affect
CO2 A
the shape and quality of the weld bead.
Demonstrate the use of MIG welding for manufacturing an automotive component
CO2 Ap
and explain the advantages that make it suitable for this application.
Using the contents of moulding sand, prepare a suitable moulding sand composition
CO1 Ap
for a cast iron engine block and justify the function of each constituent.
Investigate the different stages of a cupola furnace with the aid of a neat sketch and
CO1 A
analyze their influence on melting efficiency and metal quality.
621325114103 SANTHOSH D Demonstrate the application of GTAW variants in an industrial welding operation
39 CO2 Ap
and explain how Hot Wire GTAW improves productivity and weld quality.
An automotive company is manufacturing aluminium fuel tanks and exhaust
components requiring precise, distortion-free welds. As the welding engineer,
CO2 Ap
recommend TIG welding, identify the suitable metals for the process, and explain its
applications in automotive manufacturing.
Examine any four sand testing methods and analyze how each test contributes to
CO1 A
achieving dimensional accuracy, surface finish, and defect-free castings.
Apply the knowledge of pattern allowances to prepare a pattern for a cast iron pump
CO1 Ap
621325114104 SANTHOSH G casing and explain the need for any four allowances.
40
Analyze the Electron Beam Welding process with a neat sketch and determine its
CO2 A
suitability for precision welding applications.
Apply the TIG welding process to join a stainless steel plate by drawing a neat setup
CO2 Ap
diagram and explaining the welding procedure.
A foundry is planning to produce large steel castings for heavy machinery and small
precision aluminium castings for aerospace applications. As a foundry engineer,
CO1 Ap
recommend appropriate pattern materials for each case and explain their merits and
demerits.
621325114105 SARATH S Apply the ceramic moulding process to manufacture a valve body and justify its
41 CO1 Ap
suitability by discussing its merits and demerits.
Investigate the Submerged Arc Welding process and analyze the relationship
CO2 A
between welding parameters, flux characteristics, and weld quality.
Analyze the working mechanism of Plasma Arc Welding and evaluate its
CO2 A
effectiveness compared with conventional arc welding processes.
Using the CO₂ moulding process, develop a suitable moulding procedure for a cast
621325114106 SARVESHWARAN N
42 iron component and explain the process parameters, advantages, limitations, and CO1 Ap
application.
 Evaluate the factors responsible for shrinkage and casting defects, and analyze the
CO1 A
effectiveness of different defect elimination techniques.
A precision engineering industry is producing gear assemblies and turbine
components that require narrow welds, high accuracy, and minimal heat-affected
CO2 Ap
zones. Analyze the welding requirements and justify the selection of Electron Beam
Welding by explaining its process, equipment, and application.
Investigate the oxy-acetylene welding setup with a labelled sketch and analyze how
CO2 A
the selection and operation of equipment influence weld quality.
Investigate different pattern materials and analyze how their properties affect pattern
CO1 A
performance, casting quality, and manufacturing efficiency.
Using the principles of core selection, recommend a suitable core type for producing
CO1 Ap
an engine block casting and justify your selection.
621325114107 SATHEESH V
43 Compare the requirements of different cutting applications and analyze the suitability
of oxy-fuel gas cutting with reference to torch design, process capability, and CO2 A
applications.
Examine the construction and operation of percussion welding with a neat sketch,
CO2 A
and analyze the relationship between process parameters and weld characteristics.
Using the principles of gating system design, prepare a suitable gating arrangement
CO1 Ap
for a cast component and explain the role of each element.
Compare and analyze different casting defects, their root causes, and suitable
CO1 A
corrective actions for producing defect-free castings.
An automobile industry plans to join thin aluminium alloy components for
44 621325114108 SATHISH K
lightweight vehicle structures. The company requires better arc stability and
improved weld quality compared with conventional welding methods. Select a CO2 Ap
suitable welding process and explain how Plasma Arc Welding satisfies the
requirement.
Examine the purposes of electrode coatings and analyze how each function
CO2 A
contributes to arc stability, weld protection, and mechanical properties of the joint.
Demonstrate the application of moulding test methods in a foundry environment and
CO1 Ap
explain how the test results help in improving casting quality.
621325114109 SINTHESH S T Compare and analyze different casting defects and evaluate the effectiveness of
45 CO1 A
various methods used to eliminate them in foundry operations.
Apply the working principle of oxy-acetylene welding to fabricate a mild steel
CO2 Ap
component and illustrate the welding arrangement with a neat sketch.
 A welding engineer is assigned to join dissimilar metals such as stainless steel and
nickel alloys in a critical component. Analyze the requirement and justify the use of CO2 Ap
GTAW by explaining its equipment, process operation, and advantages.
Investigate the properties of moulding sand and analyze the relationship between
CO1 A
sand characteristics and the occurrence of casting defects.
Demonstrate the application of a suitable moulding method for producing an engine
CO1 Ap
621325114110 SIVARAJ V block casting and explain the mould preparation steps.
46
Investigate the key process variables in TIG welding and analyze their role in
CO2 A
achieving defect-free welds for different applications.
Analyze the relationship between SAW process parameters and weld quality, and
CO2 A
evaluate their role in achieving defect-free welds.
Apply the principles of casting to produce a defect-free component and explain the
CO1 Ap
stages involved in the casting process.
Analyze the formation mechanisms of casting defects and determine the critical
CO1 A
factors responsible for reducing defects in foundry operations.
Analyze the relationship between welding power source characteristics and welding
621325114111 SRI GOKUL S CO2 A
47 performance, including arc stability, current control, and weld penetration.
A fabrication industry is manufacturing large structural components for bridges and
heavy machinery. The company requires a welding process capable of producing
deep penetration welds with high productivity. Analyze the requirement and justify CO2 Ap
the selection of Electroslag Welding by explaining its process and industrial
applications.
Investigate the types of allowances provided on patterns and analyze the factors
CO1 A
influencing the selection of suitable allowances for automotive casting applications.
An automobile company wants to manufacture engine cylinder liners with high
density, good surface finish, and improved wear resistance. Evaluate the suitability
CO1 Ap
621325114112 SRIDHARSHINI P of centrifugal casting for this application and explain the process along with its
48
advantages.
Analyze the occurrence of weld defects by illustrating them with sketches and
CO2 A
evaluating the factors affecting weld quality.
Compare and analyze different methods of welding current regulation in transformers
CO2 A
and determine their importance in achieving stable welding conditions.
621325114113 SRITHAR S Demonstrate the application of shell moulding for producing an automotive
49 CO1 Ap
component and explain its working principle with suitable process steps.
 Analyze the factors affecting the moulding process and evaluate how its advantages
CO1 A
and limitations influence the selection of a suitable casting method.
Demonstrate the application of Submerged Arc Welding in heavy fabrication
CO2 Ap
industries and explain the equipment arrangement and working process.
Using the friction welding process, develop a suitable joining method for an
CO2 A
industrial component and explain the process steps with a neat sketch.
Analyze the features of match plate patterns and evaluate their importance in
CO1 A
improving casting productivity, accuracy, and cost effectiveness.
Apply the concept of pattern classification to choose suitable patterns for mass
CO1 Ap
production and prototype casting requirements, supported by neat sketches.
621325114114 SUDHARSAN S
A manufacturer of heavy machinery frames and large structural components requires
50
a welding process with deep penetration and high deposition rate. Recommend
CO2 Ap
Electroslag Welding and analyze how its process characteristics satisfy the
manufacturing requirements. Explain with a neat sketch.
Investigate the working mechanism of ultrasonic welding with a suitable diagram and
CO2 A
analyze how ultrasonic vibrations produce a strong joint between materials.
Apply the knowledge of pattern material properties to select a suitable material
CO1 Ap
for mass production casting and explain its suitability.
Analyze the core-making process by evaluating the materials, steps, and factors
CO1 A
responsible for producing defect-free cores.
An aerospace component manufacturer needs to join thin titanium alloy sheets used
621325114115 SUJIBALA I
51 in aircraft structures. The weld should have high precision, minimum distortion, and
excellent strength. As a welding engineer, recommend a suitable welding process and CO2 Ap
explain how Plasma Arc Welding can be applied, including its process steps and
advantages.
Investigate the working principle of resistance welding and analyze the suitability of
CO2 A
seam welding for different industrial applications.
An automobile casting industry requires a reliable melting system for producing cast
iron engine blocks and housings. Analyze the production requirement and justify the
CO1 Ap
selection of a Cupola furnace by evaluating its construction, operating principles, and
621325114116 SUKUMAR S performance with a neat diagram.
52
Investigate the selection of pattern materials and analyze how their merits and
CO1 A
demerits affect the quality and efficiency of casting production.
Investigate the principle of resistance welding and analyze the factors controlling
CO2 A
heat generation and joint formation during the welding process.
 Demonstrate the application of different spot welding cycle variants for joining sheet
CO2 Ap
metal components and explain their sequence with a suitable sketch.
Evaluate the preparation of a green sand mould using a cope and drag pattern by
CO1 A
analysing the role of each process step in preventing casting defects.
Apply the principles of the cold-chamber die casting process to manufacture an
aluminium alloy component. Illustrate the process with a neat sketch and explain the CO1 Ap
621325114117 SUMAN S sequence of operations.
53
Analyse the working principles of seam welding and projection welding with the help
CO2 A
of neat sketches, and compare their suitability for different engineering applications.
Demonstrate the flash butt welding process for joining railway tracks or rods using a
CO2 Ap
neat sketch, and explain each stage of the welding operation.
Examine the properties of different moulding sands and analyse how these properties
CO1 A
affect the performance of the mould during the casting process.
Demonstrate the use of a cupola furnace for producing cast iron components by
CO1 Ap
explaining its construction and operation with a neat diagram.
Using a neat sketch, demonstrate how upset butt welding is performed for joining
CO2 Ap
621325114118 SUPRIYA N two components in an engineering application.
54
A fabrication workshop uses Submerged Arc Welding (SAW) to weld thick steel
plates but faces problems such as excessive welding time and multiple welding
passes. The workshop plans to replace SAW with Electroslag Welding. Analyse the
CO2 A
advantages and limitations of Electroslag Welding compared with Submerged Arc
Welding for the given application. Support your answer with a neat sketch of the
ESW process.
Using a suitable engineering application, demonstrate the operation of an induction
CO1 Ap
furnace and discuss its advantages in modern foundry practice.
A foundry produces castings with defects such as blowholes, shrinkage cavities, and
misruns. Analyse the possible causes of these defects and determine the most CO1 Ap
621325114119 THIRAJ V appropriate inspection methods to evaluate the quality of the castings.
55
Examine the brazing process and analyse the role of joint preparation, filler metal
CO2 A
selection, heating, and cooling in achieving a defect-free brazed joint.
Compare soft soldering and hard soldering by analysing their process characteristics,
CO2 A
joint strength, and industrial applications.
621325114120 THUKILAN S Classify the casting processes and demonstrate the operation of pressure die casting
56 CO1 Ap
for producing a high-volume engineering component using a neat sketch.
 Differentiate the various pattern allowances by analysing their purpose, method of
CO1 A
application, and effect on the final casting.
A refrigeration workshop is required to join copper tubes and electrical terminals
during the assembly of an air-conditioning unit. Different soldering techniques are
available, but the engineer must choose the most appropriate ones for each joint. List CO2 Ap
the different soldering methods and analyse their suitability for the given
applications. Explain in detail any two methods and justify why they are preferred.
Examine the functions of flux in soldering and analyse how the selection of an
CO2 A
appropriate flux influences joint quality and reliability.
Analyze the sequence of operations in the investment casting process and explain
how each stage influences the dimensional accuracy and surface finish of the final CO1 A
casting.
Apply the shell moulding process to manufacture a thin-walled cast iron valve body
with good surface finish and dimensional accuracy. Explain each step of the shell
CO1 Ap
621325114121 UMAPATHI M moulding procedure in detail and justify the purpose of every stage in producing a
57
defect-free casting.
Examine how surface preparation affects the metallurgical bonding in the soldering
CO2 A
process.
Apply the GTAW process to join two dissimilar metals for a chemical processing
application. Explain the precautions and welding procedure required to ensure joint CO2 Ap
integrity.
Analyze the different types of moulding sand and compare their properties,
CO1 A
composition, and suitability for various casting applications.
A foundry receives an order for 10,000 identical aluminium castings. Apply your
knowledge of pattern types to recommend the most suitable pattern and explain how CO1 Ap
it would enhance productivity, alignment, and consistency of the castings.
621325114122 VISHAL M
58 A manufacturer observes inconsistent penetration and excessive porosity in electron
beam welded joints. Analyze the constructional features of the EBW setup to identify CO2 A
the possible component-related causes and recommend suitable corrective measures.
Choose an appropriate resistance welding process (spot, seam, projection, or butt
welding) for manufacturing fuel tanks, wire joints, and railway track joints, and CO2 Ap
explain the reasons for your selection.
Examine the relationship between moisture content and green compressive strength
621325114123 VISHNUKUMAR D
59 of moulding sand, and analyze how variations in these properties affect mould CO1 A
stability and casting quality.
 Compare the causes and characteristics of gas-related defects and solidification-
CO1 A
related defects in castings, and analyze the preventive measures for each.
A manufacturer needs a deep and narrow weld in a titanium component. Apply your
knowledge of laser beam welding process variables to achieve the required weld CO2 Ap
characteristics and explain the role of each selected variable.
Inspect a welded joint and identify the type of weld defect present using a neat sketch,
CO2 Ap
and explain how the defect could have occurred during welding.
Apply your knowledge of the cupola furnace to explain how each zone contributes
CO1 Ap
to the melting of cast iron and the production of quality molten metal.
Analyze the causes of any two casting defects from the categories (i) metallic
projections and (ii) cavities, and examine the effectiveness of suitable remedial CO1 A
621325114124 YOGESH T measures to prevent each defect.
60
Demonstrate the application of brazing and soldering equipment in the fabrication of
electrical, automotive, and plumbing components, and explain the procedure CO2 Ap
followed in each case.
Compare different welded joint designs and analyze their susceptibility to residual
CO2 A
stresses and distortion under various loading and fabrication conditions.
Select a suitable ceramic moulding process for producing a precision casting with
intricate details and justify your choice based on the merits and demerits of the CO1 Ap
process.
Examine the working principle of investment casting and analyze the role of wax
pattern preparation, ceramic shell formation, dewaxing, and metal pouring in CO1 A
621325114125 YUVA KRISHNA M producing precision cast components.
61
Analyze how improper electrode selection, welding current, travel speed, and heat
input contribute to different welding defects, and assess the most effective remedies CO2 A
to improve weld integrity.
Use the plasma arc welding process to prepare a welding procedure for joining high-
temperature alloy components, and justify the choice of plasma gas, current, and CO2 Ap
travel speed.
Demonstrate the application of the casting process by preparing a complete casting
CO1 Ap
procedure for a component with internal cavities and explain the role of each stage.
621325114126 YUVARAJ S Examine the relationship between casting process parameters and the occurrence of
62 CO1 A
defects such as blowholes, shrinkage cavities, misruns, cold shuts, and hot tears.
Analyze the characteristics of an ideal welding power source and determine their
CO2 A
effect on arc initiation, metal transfer, and weld penetration.
 A transformer in an industrial welding power supply shows poor voltage regulation
and excessive heating. Analyze the transformer characteristics that may be CO2 A
responsible for these problems and recommend suitable corrective measures.
Using the CO₂ moulding process, develop a suitable moulding procedure for a cast
iron component and explain the process parameters, advantages, limitations, and CO1 Ap
application.
Compare and analyze different casting defects and evaluate the effectiveness of
CO1 A
2026LME07 NITHYA PAVITHRAN S various methods used to eliminate them in foundry operations.
63
Select an appropriate electrode size for welding an agricultural trailer chassis made
of mild steel and justify your selection based on the material thickness and welding CO2 Ap
requirements.
Examine how process variables such as reaction temperature, mould alignment, and
CO2 A
pouring time affect the quality and reliability of thermit welded joints.
Use a sand slinger moulding machine to prepare a mould for a large casting and
CO1 Ap
explain the sequence of operations involved.
Choose a suitable die material and hot chamber die casting setup for manufacturing
a small zinc alloy gear, and explain how your selection improves production CO1 Ap
2026LME08 RAHIGARAN S efficiency.
64
Analyze the MIG welding process and explain how welding current, voltage, wire
CO2 A
feed rate, and travel speed influence weld quality and penetration.
Analyze the suitability of percussion welding for joining fine wires, electrical
contacts, and dissimilar metal components, and explain the factors that govern CO2 A
process selection.
Compare positive and negative allowances in pattern design, and analyze the
CO1 A
conditions under which each type is applied in foundry practice.
Demonstrate the procedure for producing a non-ferrous alloy cylinder liner using the
CO1 Ap
2026LME09 RANJITH K centrifugal casting process and explain the sequence of operations involved.
65
Demonstrate the sequence of operations involved in manual metal arc welding for
CO2 Ap
preparing and welding a butt joint with proper penetration and fusion.
Analyze the electroslag welding process and explain how the molten slag bath
CO2 A
influences heat generation, metal transfer, and weld formation.
2026LME10 SANJAY S M Analyze the factors governing the selection of pattern materials and explain how they
66 CO1 A
influence pattern life, dimensional accuracy, and production cost.
 Demonstrate the sequence of operations involved in preparing a shell mould for a
complex engineering component and explain how each step contributes to casting CO1 Ap
quality.
Apply the leftward (forehand) welding technique to fabricate a thin sheet metal
CO2 Ap
component and explain why it is suitable for the given application.
Select suitable friction stir welding parameters for joining dissimilar aluminium
CO2 Ap
alloys and explain how the chosen parameters influence joint quality and strength.
Analyze the different types of patterns used in casting and explain how pattern
selection influences mould preparation, dimensional accuracy, and production CO1 A
efficiency.
Demonstrate the sequence of operations involved in pressure die casting for
2026LME11 SARVIK K CO1 Ap
67 manufacturing a precision zinc alloy component with good surface finish.
Analyze the characteristics of neutral, carburizing, and oxidizing flames and explain
CO2 A
how each flame influences weld quality and metallurgical properties.
Apply electron beam welding techniques to join reactive metals such as titanium and
CO2 Ap
zirconium, and explain how the vacuum environment improves weld quality.
Analyze the construction and working principle of an electric arc furnace and explain
CO1 A
how its components contribute to efficient melting and refining of metals.
Demonstrate the sequence of operations involved in the lost wax process for
CO1 Ap
2026LME12 VIJAY S producing a precision casting and explain the importance of each step.
68
Select suitable TIG welding conditions for welding stainless steel sheets and explain
CO2 Ap
how current, welding speed, and shielding gas affect weld quality.
Analyze the working principle of electron beam welding and explain how electron
CO2 Ap
beam characteristics influence heat generation, penetration depth, and weld quality.
Blooms Level:
R- Remembering U- Understanding, Ap- Applying, A- Analyzing, E- Evaluating, C- Creating

FACULTY INCHARGE COORDINATOR HOD