Assignment 1

1. Why are risers not as useful in die casting as they are in sand casting?

2. Describe the drawbacks to having a riser that is (a) too large and (b) too small.

3. Why does die casting produce the smallest cast parts?

4. Why is the investment-casting process capable of producing fine surface detail

on casting?

5. Would you recommend preheating molds used in permanent-mold casting? Would you
remove the casting soon after it has solidified? Explain your reason.

6. Explain why squeeze casting produces parts with better mechanical properties,
dimensional accuracy, surface finish than do expendable-mold process.

7. Porosity that has developed in the boss of a casting is illustrated in Fig. P11.60. Show
that the porosity can be eliminated simply by repositioning the parting line of this casting.

Figure P11.60

8. If you need only a few castings of the same design, which three processes would be the
most expensive per piece cast?

9. The part in Figure P12.28 is to be cast of 10% Sn bronze, at the rate of 100 parts per
month. To find an appropriate casting process, consider all casting processes, then reject
those that are (a) technically inadmissible, (b) technically feasible but too expensive for
the purpose, and (c) identify the most economical one. Write a rationale using common-
sense assumptions about cost.
 Figure 12.28

10. For the cast metal wheel illustrated in Fig. P12.35, show how (a) riser placement, (b) core
placement, (c) padding, and (d) chills may be used to help feed molten metal and
eliminate porosity in the isolated hub boss.

Figure 12.35