GURU NANAK INSTITUTIONS TECHNICAL CAMPUS(AUTONOMOUS)

Ibrahimpatnam, R.R. District, - 501 506

[Link] II Year Supplementary Examinations, October/ Nov – 2020
(For the Academic year 2019-20)
Subject: Production Technology (18PC0ME04) - Key

1 a). Ans:

The first step of this process is to create a wax pattern; it is typically done by injecting wax into a metal tool or die. Due
to the evolution of additive patterns manufacturing, it can also be printed. In art world, artist carve out pieces of pattern
from wax block. Finally, in a situation where multiple casting is needed, a silicon tool is made from artist’s sculpture and
wax is poured and injected to the resulting cavity.

Second step is the assembling of wax in a tree form; it is typically uneconomical to produce small parts one at a time.
Assembling is carryout by attaching wax pattern to a part called “wax sprue”. Sprue provides a mounting surface to
assemble patterns into a single mold. It also provides a flow path for molten alloy into the void created by wax pattern.
The wax between the pattern and sprue is called “gates”. Because it throttles the direction and flow of alloy into voids
created by pattern.

Third step is building of shell. It is achieved by dipping wax tree into a ceramic shell. It eventually become the mold in
which alloy will be poured into. After dipping the wax tree into a ceramic bath or slurry, fine sand or stucco is applied to
the wet surface. This process is carried out twice or until a layer of ceramic mold is formed on the wax pattern. The layer
must be capable of undergoing stresses of the casting process. Next stage is performed after the mold dries.

The next step is known as dewaxing or burnout. It is carried out before pouring the molten metal into the mold. helping
in removing the wax pattern leaving the shape in the ceramic shell. It is typically achieved by using a stream-dewax
autoclave to melt out the wax. Autoclave is a large industrial pressure cooker.

The final step is pouring the liquid metal. This is done after the ceramic mold or shell is preheated to a specific
temperature. it helps to prevent the alloy from solidifying before the entire mold is filled. (2 MARKS )

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Advantages of investment casting:

 • Parts of great complexity and intricacy can be cast
• Close dimensional control and good surface finish
• Wax can usually be recovered for reuse
• Additional machining is not normally required - this is a net shape process
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Limitations:
• Many processing steps are required
• Relatively expensive process
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Applications: Jet propulsion for military and civilian aircrafts gave investment casting the foremost status in the casting
industry. From heavy casting of 300Kg to small casting of 30 kg, this casting method is used for as wide for hi-tech
industrial applications.
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1 b). Ans
The following allowances are provided on the pattern :
a. Shrinkage or contraction allowance:
Almost all the metals used in the casting work shrink or contract during cooling from pouring temperature to room
temperature.
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b. Machining allowance:
The finish and accuracy achieved in sand casting are generally poor and therefore when the casting is functionally
required to be of good surface finish or dimensionally accurate, it is generally achieved by subsequent machining.
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c. Draft allowance:
Draft allowance or taper allowance is given to all vertical faces of a pattern for their easy removal from sand without
damaging the mould. This slight taper inward or outward on the vertical faces is known as draft. It can be expressed
either in degrees or in mm/meter.
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.d. Distortion allowance (Camber allowance):
Sometimes castings get distorted, during solidification, due to their typical shape.
For example, if the casting has the form of the letter U, V, T, or L etc. it will tend to contract at the closed end
causing the vertical legs to look slightly inclined.
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e. Rapping or Shake allowance:
When a pattern is to be taken out from the mould, it is first rapped or shaken by striking it with a wooden piece from
side to side. This is done so that the pattern surface becomes free from adjoining sand of the mould. Due to this,
there is little increase in the size of the mould cavity.
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2 a) Ans:

.
 A) Welding spool, B) Shielding gas cylinder, C) welding torch, D) base plate, E) welding powersource, and F)
consumable electrode.

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MIG or "metal inert gas” welding This process is based on the principle of developing weld by melting faying surfaces
of the base metal using heat produced by a welding arc established between base metal and a consumable electrode.
Welding arc and weld pool are well protected by a jet of shielding inactive gas coming out of the nozzle and forming a
shroud around the arc and weld.

The current from the welding machine is changed by the rate of feeding of the electrode wire. Normally DC arc welding
machines are used for GMAW with electrode positive (DCRP).The DCRP increases the metal deposition rate and also
provides for a stable arc and smooth electrode metal [Link] DCSP, the arc becomes highly unstable and also results
in a large spatter. But special electrodes having calcium and titanium oxide mixtures as coatings are found to be good for
welding steel with DCSP.

MIG or "metal inert gas” welding is ideal in a shop setting for high production with low down time. It's main downside
is that it’s less portable than a SMAW welding machine. Because it is a wire feeding system there is a limit to how far
the wire can be pushed through the whip to the welding nozzle, even with push-pull systems. Unless using a flux cored
wire the process also requires a shielding gas such as argon to protect the weld puddle, but this gas can be blown away
causing porosity outdoors. Some weld flaws to look out for are cold lap and lack of fusion. The process is great for
deposition rates, and the finished weld requires little if any cleaning.

MAW or “Metal arc welding” really doesn't have many downsides other than the amount of time it takes. Welding rods
are only so long and finished welds need to be cleaned. Extra care needs to be takes at the beginning of a weld to avoid
cold starts. Otherwise they make rods for all position, extra deposition, stainless, nickel, shallow penetration, deep
penetration.
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2 B) Ans

DC Welding
DC currents have the electrons flowing in a steady single direction. It has constant polarity, which can be either positive
or negative. DC is often used in low voltage devices, such as cell phone batteries and remote controls.
DC polarity is used in most welding applications. It produces a smoother welding output compared to AC. It creates a
more stable arc, easier welding and less spatter.
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Advantages of DC Welding:
It’s used in most stick welding applications.
Overhead and vertical welding.
Stainless steel TIG welding.
When welding thinner metals.
Single carbon brazing.
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Disadvantages of DC Welding:
Can’t fix arc blow.
DC currents usually require an internal transformer for switching the current, which makes DC welders more expensive.
It’s doesn’t work well for welding aluminum as it can’t produce the necessary high-intensity heat.
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AC Welding
In AC, the flow of electrons keeps switching directions, going back and forth. It can change its polarity 120 times per
second. Every time the polarity goes from DC negative to DC positive, the output for a split second has zero amperage.
This no output moment results in that the arc tends to wander or extinguish. To overcome this problem, look for electrodes
specifically designed for AC welding. They have special coating that keeps the arc ignited.
AC is usually a secondary choice in welding. However, there are a few instances where AC would be preferred. First of
all, you can use it if it’s the only power supply available. For example, low cost, entry-level machines sometimes offer
only AC power.
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Advantages of AC Welding:
TIG welding aluminum since AC supports welding at a higher temperature. Aluminum also has a tenacious oxide film
on the surface and when AC switches to electrode positive, it helps to remove the oxide and clean the surface.
In shipbuilding when you need deeper penetration of plate metals.
When welding materials that have a magnetized field.
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Disadvantages of AC Welding:
The quality of the weld is usually not as smooth as with DC welding.
It also creates more spatter.
The arc is more difficult to handle and it’s not as reliable as when DC welding.
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3 A) Ans

During metal cutting or metal welding, the metal absorbs the generated heat. This heat transmits away from the cutting
edge through the metal body, as metal is a good heat conductor.

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A zone is formed between the melted metal and the unaffected base metal called the heat affected zone (HAZ). In this
zone, the metal is not melted but the heat has led to changes in the metal’s micro-structure. These changes in structure
can reduce the metal’s strength.
The heat affected zone leads to structural changes in the metal that weaken the part in this area. A metal’s mechanical
properties such as fatigue resistance, distortion, and surface cracking are affected.
Metals’ molecular structures expand when heated. If the heat applied changes over the cross-section of the metal, it leads
to uneven expansion and subsequent contraction of the metal body. Deformities such as distortion can occur during the
cooling process
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3 B) Ans:

Weld Crack
The most serious type of welding defect is a weld crack and
it’s not accepted almost by all standards in the industry. It can
appear on the surface, in the weld metal or the area affected by
the intense heat.
Causes of cracks:

 Use of hydrogen when welding ferrous metals.

 Residual stress caused by the solidification shrinkage.
 Base metal contamination.
 High welding speed but low current.
 No preheat before starting welding.
 Poor joint design.
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Remedies:
 Preheat the metal as required.
  Provide proper cooling of the weld area.
 Use proper joint design.
 Remove impurities.
 Use appropriate metal.

Porosity
Porosity occurs as a result of weld metal contamination. The trapped gases create a bubble-filled weld that becomes
weak and can with time collapse.

Causes of porosity:
 Inadequate electrode deoxidant.
 Using a longer arc.
 The presence of moisture.
 Improper gas shield.
 Incorrect surface treatment.
 Use of too high gas flow.
 Contaminated surface.

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Remedies:
 Clean the materials before you begin welding.
 Use dry electrodes and materials.
 Use correct arc distance.
 Reduce arc travel speed, which will allow the gases to escape.

Undercut
This welding imperfection is the groove formation at the weld toe, reducing the cross-sectional thickness of the base
metal. The result is the weakened weld and workpiece.

Causes:
 Too high weld current.
 Too fast weld speed.
 The electrode is too large.
 Incorrect usage of gas shielding.
 Incorrect filler metal.
 Poor weld technique.

Remedies:
 Use proper electrode angle.
 Reduce the arc length.
 Reduce the electrode’s travel speed, but it also shouldn’t
be too slow.
 Use of proper electrode angle, with more heat directed towards thicker components.
Incomplete Fusion
This type of welding defect occurs when there’s a lack of proper fusion between the base metal and the weld metal. It
can also appear between adjoining weld beads. This creates a gap in the joint that is not filled with molten metal.
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Causes:
  Low heat input.
 Surface contamination.
 Electrode angle is incorrect.
 Travel speed is too fast.

Remedies:
 Use a sufficiently high welding current with the
appropriate arc voltage.
 Before you begin welding, clean the metal.
 Avoid molten pool from flooding the arc.
 Use correct electrode diameter and angle.
 Reduce deposition rate.
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4 B) Ans:
5 A) Ans
Types of Forging process
1. According to the working temperature
a. Hot forging
- Most of the forging operations are performed above the recrystallization temperature but below the melting point of the
metals.
- During the process there is deformation of the metal which reduces the strength and increases the ductility of metal.
b. Cold forging
- For certain products like bolts, rivets, screws, pins, nails, etc. cold forging is also very common.
- It increases the strength which results from the strain hardening of the component.
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2. According to the method of applying the blows
a. Impact forging
- In this method of forging, a machine that applies impact load on the workpiece is called as forging hammer.
b. Gradual pressure forging
- In this method of forging, a machine that applies gradual pressure on the workpiece called as forging press.
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3. According to the degree to which the flow of workpiece is constrained by the dies
a. Open-die forging
- In this method of forging, the workpiece is compressed between two flat dies which allows the metal to flow without
constraint in a lateral direction relative to the die surfaces.
b. Closed-die or impression-die forging
- In this method, the die surfaces contain an impression or shape which is applied to the workpiece during the compression.
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Types of forging operations

- During the operation, some portion of the workpiece flows beyond the die impression to form a flash. (Flash is excess
metal which is trimmed off at the end).

c. Flash less forging

- In this method, the workpiece is completely constrained within the die and no flash is produced.
- The volume of the initial workpiece must be controlled closely so that it matches with the volume of the die cavity.
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5 B) Ans

1) Incomplete forging penetration: Dendritic ingot structure at the interior of forging is not broken. Actual forging takes
place only at the surface.
Cause- Use of light rapid hammer blows
Remedy- To use forging press for full penetration.

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2) Surface cracking:
Cause- Excessive working on the surface and too low temperature.
Remedy- To increase the work temperature
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3) Cracking at the flash:
This crack penetrates into the interior after flash is trimmed off.
Cause- Very thin flash
Remedy- Increasing flash thickness, relocating the flash to a less critical region of the forging, hot trimming and stress
relieving.
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4) Cold shut (Fold): Two surfaces of metal fold against each other without welding completely.
Cause- Sharp corner (less fillet), excessive chilling, high friction
Remedy- Increase fillet radius on the die.

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5) Unfilled Section (Unfilling/Underfilling): Some section of die cavity not completely filled by the flowing metal.
Cause- Improper design of the forging die or using forging techniques, less raw material, poor heating.
Remedy- Proper die design, Proper raw material and Proper heating. Figure 6- Shows the fish-bone diagram for root-
cause analysis of underfilling defect.

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6) Die shift (Mismatch): Misalignment of forging at flash line.

Cause- Misalignment of the die halves.
Remedy- Proper alignment of die halves. Make mistake proofing for proper alignment for eg. provide half notch on upper
and lower die so that at the time of alignment notch will match each other.

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6 A) Ans

Type of Riser :
1. Top Riser,
2. Blind Riser
3. Side Riser,
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Top Riser
on castings where hot-spots are
cessible from the top directly…
to mould, easy to fettle & act efficiently by gravitational force…
uld gases &indicate the filling
They are always default chosen.
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Blind Riser
 ots which are below parting line and not accessible for top or side risers
ngs have profile with different heights… ex. Valves and intricate castings
lind risers help in reducing the excessive feed material compared to top risers.
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Side Riser
Side risers are provided on casting having hot-spots not accessible for direct top risers.
They help in reducing excess metal of padding and reduce fettling cost
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6 B) Ans:
Property of Moulding Sand
Moulding sand is used to produce sound castings. Hence, it should possess following desirable properties:

[Link]
Adhesiveness is a property of molding sand to get the stick or adhere to foreign material such sticking of molding sand
with the inner wall of molding box
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[Link]
Cohesiveness is property of molding sand by virtue which the sand grain particles interact and attract each other within
the molding sand. Thus, the binding capability of the molding sand gets enhanced to increase the green, dry and hot
strength property of molding and core sand
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[Link]
Collapsibility is that property of the molding sand which determines the readiness with which the molding sand or mold,
automatically gets collapsed after the casting solidifies, and breaks down in knock out and cleaning operations.
If the mold or core does not collapse, it may restrict free contraction of the solidifying metal and cause the same to tear
or crack.
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[Link] strength:
It is the strength of the moulding sand in the dry state.
A sand must have sufficient dry strength to withstand erosion of the mould wall sand enlargement of mould cavity during
the flow of molten metal.
It is related to grain size, binder and water content.
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[Link] ability or plasticity:
It is the ability of the moulding sand to get compacted to a uniform density.
It assists moulding sand to flow and pack all-around the pattern and take up the desire shape. It increases with the amount
of clay and water.
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[Link] strength:
It is the strength of the sand in the green or moist condition. A mould which has adequate green strength will retains its
shape and does not distort or collapse, even after the pattern has been removed from the moulding box.
It helps in making and handling the moulds. If the mould is hardened in contact with the pattern surface with adequate
green strength, then high degree of dimensional accuracy and stability can be obtained.
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[Link] or porosity:
Molten metal always contain some amount of dissolved gases which are evolved when the metal solidifies. Also, when
the molten metal comes in contact with moist sand, it generates steam or water vapour.
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[Link]:
It is the ability of moulding sand to withstand high temperatures without fusion, cracking and buckling, hence facilitating
a clean casting. The amount of this property depends upon the metal which is to be cast. If sand lacks this property, then
it slags on the surface of the mould and smooth casting surface can be obtained.
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7 A)Ans:
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7B) Ans:

Arc Welding Forge Welding

1 Faying surfaces of the base metals are fused to No such melting takes place in solid state
form coalescence during welding. Filler metal, if welding. However, the base metals may be
used, is also fused. heated to an elevated temperature without
melting.
2 Application of heat during welding is necessary. No such heat source is usually required, but
Heat can be applied by various means such as pressure may be applied externally for welding.
electric arc, fuel-gas flame, resistance heating,
laser beam, etc.
3 Filler material can be applied easily. Usually no filler is applied.
4 Because of excessive heating, noticeable heat HAZ is usually not noticeable. A narrow HAZ
affected zone (HAZ) exists surrounding the weld may exist in certain cases.
bead.
5 Mechanical and metallurgical properties of the Mechanical properties usually remain unaltered
parent materials are severely affected during in solid state welding. Sometimes minor changes
fusion welding because of intense heating. may occur.
6 Dissimilar metal joining by fusion welding is a Joining of dissimilar metal is comparatively
challenging task, especially if the duo have easier by solid state welding processes as
substantially different melting points and melting and solidification are not involved here.
coefficients of thermal expansion.
7 Level of distortion is very high in fusion welding Solid state welding produces minimal distortion.
owing to excessive heat input per unit area.
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8 A) Ans:

Inert Gas Welding:

Shielding gases are inert or semi-inert gases that are commonly used in several welding processes, most notably gas
metal arc welding and gas tungsten arc welding (GMAW and GTAW, more popularly known as MIG (Metal Inert Gas)
and TIG (Tungsten Inert Gas), respectively). Their purpose is to protect the weld area from oxygen, and water vapour.
 Depending on the materials being welded, these atmospheric gases can reduce the quality of the weld or make the
welding more difficult.
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Gas Tungsten Arc Welding (TIG Welding)
Tungsten inert gas welding is a commonly used high quality welding process where precision is required. In tig welding
an arc is formed between a non-consumable tungsten electrode and the metal being welded. Fluxing of the joint is
achieved by the use of an inert gas shielded arc. Argon is used and it flows over the electrode preventing oxygen in the
air contacting the weld joint. A high frequency generator provides a path for the welding current through the shielding
gas. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between
the electrode and the work. A filler metal is added manually to the front end of the weld pool as it is required.
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Metal inert gas arc welding (MIG)
Metal inert gas arc welding (MIG) or more appropriately called as gas metal arc welding (GMAW) utilizes a consumable
electrode and hence, the term metal appears in the title. There are other gas shielded arc welding processes utilizing the
consumable electrodes, such as flux cored arc welding (FCAW) all of which can be termed under MIG.
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8 B) Ans
Induction welding was first discovered by Michael [Link] basics of induction welding explain that the magnetic
field's direction is dependent on the direction of current flow and the field's direction will change at the same rate as the
current's frequency.
For example, a 120 Hz AC current will cause the field to change directions 120 times a [Link] concept is known as
Faraday's Law

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Induction welding is a form of welding that uses electromagnetic induction to heat the workpiece. The welding apparatus
contains an induction coil that is energized with a radio-frequency electric current. This generates a high-
frequency electromagnetic field that acts on either an electrically conductive or a ferromagnetic workpiece. In an
electrically conductive workpiece, the main heating effect is resistive heating, which is due to induced currents called eddy
currents. In a ferromagnetic workpiece, the heating is caused mainly by hysteresis, as the electromagnetic field repeatedly
distorts the magnetic domains of the ferromagnetic material. In practice, most materials undergo a combination of these
two effects. Nonmagnetic materials and electrical insulators such as plastics can be induction-welded by implanting them
with metallic or ferromagnetic compounds, called susceptors, that absorb the electromagnetic energy from the induction
coil, become hot, and lose their heat to the surrounding material by thermal [Link] can also be induction
welded by embedding the plastic with electrically conductive fibers like metals or carbon fiber. Induced eddy currents
resistively heat the embedded fibers which lose their heat to the surrounding plastic by [Link] welding of
carbon fiber reinforced plastics is commonly used in the aerospace industry

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