Casting, Forming and Joining Processes GATE Questions

12/21/2019 Casting, Forming and Joining Processes | Materials, Manufacturing and Industrial Engineering | ME | GATE Syllabus, Paper Solution,
| GATE Syllabus, Paper Solution, Question Answer
Casting, Forming and Joining Processes 77 Question(s)

Di"erent Types of Castings (Metal-Casting-Forming-Joining-Processes/Di"erent-Types-Castings) , Design of Patterns, Moulds and Cores (Metal-
Casting-Forming-Joining-Processes/Design-Patterns-Moulds-Cores) , Solidification and Cooling (Metal-Casting-Forming-Joining-
Processes/Solidification-Cooling) , Riser and Gating Design (Metal-Casting-Forming-Joining-Processes/Riser-Gating-Design) , Plastic Deformation and
Yield Criteria (Metal-Casting-Forming-Joining-Processes/Plastic-Deformation-Yield-Criteria) , Fundamentals of Hot and Cold Working Processes
(Metal-Casting-Forming-Joining-Processes/Fundamentals-Hot-Cold-Working-Processes) , Load Estimation for Bulk (Forging, Rolling, Extrusion,
Drawing) (Metal-Casting-Forming-Joining-Processes/Load-Estimation-Forging-Rolling-Extrusion-Drawing) , Sheet (Shearing, Deep Drawing, Bending)
Metal Forming Processes (Metal-Casting-Forming-Joining-Processes/Sheet-Shearing-Deep-Drawing-Bending-Metal-Forming-Processes) , Principles of
Powder Metallurgy (Metal-Casting-Forming-Joining-Processes/Principles-Powder-Metallurgy) , Principles of Welding, Brazing, Soldering and Adhesive
Bonding (Metal-Casting-Forming-Joining-Processes/Principles-of-Welding-Brazing-Soldering-and-Adhesive%20Bonding)
GATE - 2018 (../../../GATE2018) 01

Question No. 22 (../../Mechanical-GATE-2018-Question-22)
The type of weld represented by the shaded region in the figure is
gate-exam.in/ME/Syllabus/Materials-Manufacturing-Industrial-Engineering/Metal-Casting-Forming-Joining-Processes 1/44
12/21/2019 Casting, Forming and Joining Processes | Materials, Manufacturing and Industrial Engineering | ME | GATE Syllabus, Paper Solution, Question Answer
(A) groove (B) spot (C) fillet (D) plug
Show Answer
Answer : (C) fillet

Subject : Casting, Forming and Joining Processes Topic : Principles of Welding, Brazing, Soldering and Adhesive Bonding
GATE - 2018 (../../../GATE2018) 02

The maximum reduction in cross-sectional area per pass ( R ) of a cold wire drawing process is
R =1− e−(n+1) ,
where n represents the strain hardening coe cient. For the case of a perfectly plastic material, R is
(A) 0.865 (B) 0.826 (C) 0.777 (D) 0.632
Show Answer
Answer : (D) 0.632

Subject : Casting, Forming and Joining Processes Topic : Load Estimation for Bulk (Forging, Rolling, Extrusion, Drawing)
Question No. 46 (../../Mechanical-GATE-2018-Question-46) GATE - 2018 (../../../GATE2018) 02
The percentage scrap in a sheet metal blanking operation of a continuous strip of sheet metal as shown in the figure is (correct to two decimal
places).
Enter Your Answer Here
Show Answer
Answer : 52.00 to 54.00

Match the following products with the suitable manufacturing process
Product Manufacturing Process

P Toothpaste tube 1 Centrifugal casting
Q Metallic pipes 2 Blow moulding
R Plastic bottles 3 Rolling

S Threaded bolts 4 Impact extrusion
(A) P-4, Q-3, R-1, S-2 (B) P-2, Q-1, R-3, S-4 (C) P-4, Q-1, R-2, S-3 (D) P-1, Q-3, R-4, S-2
Show Answer
Answer : (C) P-4, Q-1, R-2, S-3

∘
A steel wire is drawn from an initial diameter (di ) of 10 mm to a final diameter (df ) of 7.5 mm. The half cone angle (α) of the die is 5 and the
coe cient of friction (μ) between the die and the wire is 0.1. The average of the initial and final yield stress [(σ ) ] is 350 MPa. The equation for
Y avg
drawing stress σf , (in MPa) is given as:
σf= (σ )Y avg {1 + 1
μ cotα
} [1 − ( ) df
di
2μ cotα
]
The drawing stress (in MPa) required to carry out this operation is (correct to two decimal places).
Show Answer
Answer : 315.00 to 317.00
GATE - 2018 (../../../GATE2018) 02

For sand-casting a steel rectangular plate with dimensions 80 mm × 120 mm × 20 mm, a cylindrical riser has to be designed. The height of the riser is
equal to its diameter. The total solidification time for the casting is 2 minutes. In Chvorinov’s law for the estimation of the total solidification time,
exponent is to be taken as 2. For a solidification time of 3 minutes in the riser, the diameter (in mm) of the riser is (correct to two decimal
places).
Show Answer
Answer : 42.00 to 52.00

Subject : Casting, Forming and Joining Processes Topic : Solidification and Cooling
GATE - 2018 (../../../GATE2018) 02

A welding operation is being performed with voltage = 30 V and current = 100 A. The cross-sectional area of the weld bead is 20 mm2 . The work-piece
and filler are of titanium for which the specific energy of melting is 14 J/mm3 . Assuming a thermal e ciency of the welding process 70%, the welding
speed (in mm/s) is (correct to two decimal places).
Show Answer
Answer : 7.49 to 7.51

GATE - 2017 (../../../GATE2017) 01

In a metal forming operation when the material has just started yielding, the principal stresses are σ1 = +180 MPa, σ2 = −100 MPa, σ3 = 0.
Following von Mises' criterion, the yield stress is MPa.
Show Answer
Answer : 245 to 246

Subject : Casting, Forming and Joining Processes Topic : Plastic Deformation and Yield Criteria
GATE - 2017 (../../../GATE2017) 01

In an arc welding process, welding speed is doubled. Assuming all other process parameters to be constant, the cross sectional area of the weld bead will
(A) increase by 25% (B) increase by 50% (C) reduce by 25% (D) reduce by 50%
Show Answer
Answer : (D) reduce by 50%

GATE - 2017 (../../../GATE2017) 02

A 10 mm deep cylindrical cup with diameter of 15 mm is drawn from a circular blank. Neglecting the variation in the sheet thickness, the diameter (upto 2
decimal points accuracy) of the blank is mm.
Show Answer
Answer : 28.71 to 28.73

GATE - 2017 (../../../GATE2017) 02

A sprue in a sand mould has top diameter of 20 mm and height of 200 mm. The velocity of the molten metal at the entry of the sprue is 0.5 m/s. Assume
acceleration due to gravity as 9.8 m/s2 and neglect all losses. If the mould is well ventilated, the velocity (upto 3 decimal points accuracy) of the molten
metal at the bottom of the sprue is m/s
Show Answer
Answer : 2.04 to 2.07

Subject : Casting, Forming and Joining Processes Topic : Design of Patterns, Moulds and Cores
GATE - 2017 (../../../GATE2017) 01

It is desired to make a product having T-shaped cross-section from a rectangular aluminium block. Which one of the following process is expected to
provide the highest strength of the product?
(A) Welding (B) Casting (C) Metal forming (D) Machining
Show Answer
Answer : (C) Metal forming

GATE - 2017 (../../../GATE2017) 02

A rod of length 20 mm is stretched to make a rod of length 40 mm. Subsequently, it is compressed to make a rod of final length 10 mm. Consider the
longitudinal tensile strain as positive and compressive strain as negative. The total true longitudinal strain in the rod is
(A) -0.5 (B) -0.69 (C) -0.75 (D) -1.0
Show Answer
Answer : (B) -0..69

GATE - 2017 (../../../GATE2017) 02

A strip of 120 mm width and 8 mm thickness is rolled between two 300 mm-diameter rolls to get a strip of 120 mm width and 7.2 mm thickness. The
speed of the strip at the exit is 30 m/min. There is no front or back tension. Assuming uniform roll pressure of 200 MPa in the roll bite and 100%
mechanical e ciency, the minimum total power (in kW) required to drive the two rolls is
Show Answer
Answer : 9.4 to 9.8

Subject : Casting, Forming and Joining Processes Topic : Fundamentals of Hot and Cold Working Processes
GATE - 2016 (../../../GATE2016) 01

Under optimal conditions of the process the temperatures experienced by a copper work piece in fusion welding, brazing and soldering are such that
(A) Twelding > Tsoldering > Tbrazing (B) Tsoldering > Twelding > Tbrazing (C) Tbrazing > Twelding > Tsoldering
(D) Twelding > Tbrazing > Tsoldering
Show Answer
Answer : (D) Twelding > Tbrazing > Tsoldering
GATE - 2016 (../../../GATE2016) 01

The part of a gating system which regulates the rate of pouring of molten metal is
(A) pouring basin (B) runner (C) choke (D) ingate
Show Answer
Answer : (C) choke

Subject : Casting, Forming and Joining Processes Topic : Riser and Gating Design
GATE - 2016 (../../../GATE2016) 02

A cylindrical job with diameter of 200 mm and height of 100 mm is to be cast using modulus method of riser design. Assume that the bottom surface of
cylindrical riser does not contribute as cooling surface. If the diameter of the riser is equal to its height, then the height of the riser (in mm) is
(A) 150 (B) 200 (C) 100 (D) 125
Show Answer
Answer : (A) 150

GATE - 2016 (../../../GATE2016) 02

A 300 mm thick slab is being cold rolled using roll of 600 mm diameter. If the coe cient of friction is 0.08, the maximum possible reduction (in mm) is
Show Answer
Answer : 1.90 : 1.94

GATE - 2016 (../../../GATE2016) 01

The welding process which uses a blanket of fusible granular flux is
(A) tungsten inert gas welding (B) submerged arc welding (C) electroslag welding (D) thermit welding
Show Answer
Answer : (B) submerged arc welding

(../../../GATE2016) 02
Question No. 159 (../../Mechanical-GATE-2016-Question-159) GATE - 2016
Gray cast iron blocks of size 100 mm × 50 mm × 10 mm with a central spherical cavity of diameter 4 mm are sand cast. The shrinkage allowance for the
pattern is 3%. The ratio of volume of the pattern to volume of the casting is
Show Answer
Answer : 1.08 : 1.10

GATE - 2016 (../../../GATE2016) 02

The voltage-length characteristic of a direct current arc in an arc welding process is V = ( 100 + 40 l ), where l is the length of the arc in mm and V is arc
voltage in volts. During a welding operation, the arc length varies between 1 and 2 mm the welding current is in the range 200-250 A. Assuming a linear
power source, the short circuit current is A.
Show Answer
Answer : 423 : 428

GATE - 2016 (../../../GATE2016) 01

Equal amounts of a liquid metal at the same temperature are poured into three moulds made of steel, copper and aluminum. The shape of the cavity is a
cylinder with 15 mm diameter. The size of the moulds are such that the outside temperature of the moulds do not increase appreciably beyond the
atmospheric temperature during solidification. The sequence of solidification in the mould from the fastest to slowest is
(Thermal conductivities of steel, copper and aluminum are 60.5, 401 and 237 W/m-K, respectively. Specific heats of steel, copper and aluminum are 434,
385 and 903 J/kg-K, respectively. Densities of steel, copper and aluminum are 7854, 8933 and 2700 kg/m3, respectively.)
(A) Copper - Steel - Aluminum (B) Aluminum - Steel - Copper (C) Copper - Aluminum - Steel (D) Steel - Copper - Aluminum
Show Answer
Answer : (C) Copper - Aluminum - Steel

GATE - 2016 (../../../GATE2016) 02

Spot welding of two steel sheets each 2 mm thick is carried out successfully by passing 4 kA of current for 0.2 seconds through the electrodes. The
resulting weld nugget formed between the sheets is 5 mm in diameter. Assuming cylindrical shape for the nugget, the thickness of the nugget
is mm.
Latent heat of fusion for steel 1400 kJ/kg

E"ective resistance of the weld joint 200 μΩ
Density of steel 8000 kg/m3
Show Answer
Answer : 2.85 : 2.95

GATE - 2016 (../../../GATE2016) 02

In a sheet metal of 2 mm thickness a hole of 10 mm diameter needs to be punched. The yield strength in tension of the sheet material is 100 MPa and its
ultimate shear strength is 80 MPa. The force required to punch the hole (in kN) is
Show Answer
Answer : 4.9 : 5.1

Subject : Casting, Forming and Joining Processes Topic : Sheet (Shearing, Deep Drawing, Bending) Metal Forming Processes
GATE - 2015 (../../../GATE2015) 01

Match the following products with preferred manufacturing process:
Product Process
P Rails 1 Blow molding
Q Engine crankshaft 2 Extrusion
R Aluminium channels 3 Forging
S PET water bottles 4 Rolling
(A) P-4, Q-3,R-1,S-2 (B) P-4,Q-3,R-2,S-1 (C) P-2,Q-4,R-3,S-1 (D) P-3,Q-4,R-2,S-1
Show Answer
Answer : (B) P-4,Q-3,R-2,S-1
GATE - 2015 (../../../GATE2015) 01

In a linear arc welding process, the heat input per unit length is inversely proportional to
(A) welding current (B) welding voltage (C) welding speed (D) duty cycle of the power source
Show Answer
Answer : (C) welding speed

GATE - 2015 (../../../GATE2015) 02

A DC welding power source has a linear voltage-current (V-I) characteristic with open circuit voltage of 80 V and a short circuit current of 300 A. For
maximum arc power , the current (in Amperes) should be set as .
Show Answer
Answer : 149 to 151

GATE - 2015 (../../../GATE2015) 02

2
The solidification time of a casting is proportional to ()
A
V
,Where V is the volume of the casting and A is the total casting surface area losing heat. Two
cubes of same material and size are cast using sand casting process. The top face of one of the cubes is completely insulated. The ratio of the
solidification time for the cube with top face insulated to that of the other cube is
25 36
(A) 36
(B) 25
(C) 1 (D) 6
5
Show Answer
Answer : (B)25
36
In a slab rolling operation, the maximum thickness reduction (△hmax ) is given by △hmax = μ2 R, where R is the radius of the roll and μ is the
coe cient of friction between the roll and the sheet. If μ = 0.1 , the maximum angle subtended by the deformation zone at the centre of the roll (bit
angle in degrees) is .
Show Answer
Answer : 5.6 to 5.8

GATE - 2015 (../../../GATE2015) 02

A cube and a sphere made of cast iron (each volume 1000 cm3) were cast under identical conditions. The time taken for solidifying the cube was 4 s. The
solidification time ( in s) for the sphere is .
Show Answer
Answer : 6.0 to 6.3

In a two stage wire drawing operation, the fractional reduction (ratio of change in cross sectional area to initial cross sectional area) in the first stage is
0.4. The fractional reduction in the second stage is 0.3. The overall fractional reduction is
(A) 0.24 (B) 0.58 (C) 0.60 (D) 1.00
Show Answer
Answer : (B) 0.58

GATE - 2015 (../../../GATE2015) 02

The flow stress (in MPa) of a material is given by
σ = 500ε
0.1
,
Where ε is true strain. The Young’s modulus of elasticity of the material is 200 GPa. A block of thickness 100 mm made of this material is compressed to
95 mm thickness and then the load is removed. The final dimension of the block (in mm) is
Show Answer
Answer : 95.14 to 95.20

GATE - 2015 (../../../GATE2015) 02

During a TIG welding process, the arc current and arc voltage were 50 A and 60 V, respectively, when the welding speed was 150 mm/min. In another
process, the TIG welding is carried out at a welding speed of 120 mm/min at the same arc welding voltage and heat input to the material so that weld
quality remains the same. The welding current (in A) for this process is
(A) 40.00 (B) 44.72 (C) 55.90 (D) 62.25
Show Answer
Answer : (A) 40.00

GATE - 2015 (../../../GATE2015) 01

In full mould (cavity-less) casting process, the pattern is made of
(A) expanded polystyrene (B) wax (C) epoxy (D) plaster of Paris
Show Answer
Answer : (A) expanded polystyrene

Which two of the following joining processes are autogeneous?
(i) Di"usion welding

(ii) Electroslag welding
(iii)Tungsten inert gas welding
(iv)Friction weding
(A) (i) and (iv) (B) (ii) and (iii) (C) (ii) and (iv) (D) (i) and (iii)
Show Answer
Answer : (A) (i) and (iv)

GATE - 2015 (../../../GATE2015) 02

In a rolling operation using rolls of diameter 500 mm, if a 25 mm thick plate cannot be reduced to less than 20 mm in one pass, the coe cient of friction
between the roll and the plate is
Show Answer
Answer : 0.10 to 0.15

GATE - 2015 (../../../GATE2015) 02

Ratio of solidification time of a cylindrical casting (height=radius) to that of a cubic casting of side two times the height of cylindrical casting is
Show Answer
Answer : 0.5 to 0.6

GATE - 2015 (../../../GATE2015) 02

The dimensions of a cylindrical side riser (height = diameter) for a 25 cm × 15 cm × 5 cm steel casting are to be determined. For the tabulated shape factor
values given below, diameter of the riser (in cm) is .
Shape factor 2 4 6 8 10 12
Raiser volume/ Casting volume 1.0 0.70 0.55 0.50 0.40 0.35
Show Answer
Answer : 10.5 to 10.7

GATE - 2014 (../../../GATE2014) 01

The major di culty during welding of aluminium is due to its
(A) high tendency of oxidation (B) high thermal conductivity (C) low melting point (D) low density
Show Answer
Answer : (A) high tendency of oxidation

GATE - 2014 (../../../GATE2014) 01

In solid-state welding, the contamination layers between the surfaces to be welded are removed by
(A) alcohol (B) plastic deformation (C) water jet (D) sand blasting
Show Answer
Answer : (B) plastic deformation

An aluminium alloy (density 2600 kg/m3) casting is to be produced. A cylindrical hole of 100 mm diameter and 100 mm length is made in the casting using
sand core (density 1600 kg/m3). The net buoyancy force (in newton) acting on the core is
Show Answer
Answer : 7 to 8
GATE - 2014 (../../../GATE2014) 01

With respect to metal working, match Group A with Group B:
Group A Group B
P: Defect in extrusion I: alligatoring
Q: Defect in rolling II: scab
R: Product of skew rolling III: fish tail
S: Product of rolling through cluster
IV: seamless tube
mill
V: thin sheet with tight tolerance
VI: semi-finished balls of ball
bearing
(A) P-II, Q-III, R-VI, S-V (B) P-III, Q-I, R-VI, S-V (C) P-III, Q-I, R-IV, S-VI (D) P-I, Q-II, R-V, S-VI
Show Answer
Answer : (B) P-III, Q-I, R-VI, S-V
GATE - 2014 (../../../GATE2014) 02

A mild steel plate has to be rolled in one pass such that the final plate thickness is 2/3rd of the initial thickness, with the entrance speed of 10 m/min and
roll diameter of 500 mm. If the plate widens by 2% during rolling, the exit velocity (in m/min) is
Show Answer
Answer : 14.6 to 14.8

GATE - 2014 (../../../GATE2014) 02

A rectangular hole of size 100 mm × 50 mm is to be made on a 5 mm thick sheet of steel having ultimate tensile strength and shear strength of 500 MPa
and 300 MPa, respectively. The hole is made by punching process. Neglecting the e"ect of clearance, the punching force (in kN) is
(A) 300 (B) 450 (C) 600 (D) 750
Show Answer
Answer : (B) 450

GATE - 2014 (../../../GATE2014) 01

Match the casting defects (Group A) with the probable causes (Group B):
Group A Group B
P: Hot tears 1: Improper fusion of two streams of liquid metal
Q: Shrinkage 2: Low permeability of the sand mould
R: Blow holes 3: Volumetric contraction both in liquid and solid stage
S: Cold Shut 4: Di"erential cooling rate
Show Answer
Answer : (B) P-4, Q-3, R-2, S-1

GATE - 2014 (../../../GATE2014) 01

The hot tearing in a metal casting is due to
(A) high fluidity (B) high melt temperature (C) wide range of solidification temperature (D) low coe cient of thermal expansion
Show Answer
Answer : (C) wide range of solidification temperature

GATE - 2014 (../../../GATE2014) 02

A cylindrical blind riser with diameter d and height h, is placed on the top of the mold cavity of a closed type sand mold son as shown in the figure. If the
riser is of a constant Volume then the rate of solidification in the riser is the least when the ratio h:d is
(A) 1:2 (B) 2:1 (C) 1:4 (D) 4:1
Show Answer
Answer : (A) 1:2

(../../../GATE2014) 02
For spot welding of two steel sheets (base metal) each of 3 mm thickness, welding current of 10000 A is applied for 0.2 s. The heat dissipated to the base
metal is 1000 J. Assuming that the heat required for melting 1 mm3 volume of steel is 20 J and interfacial contact resistance between sheets is 0.0002 Ω,
the volume (in mm3) of weld nugget is
Show Answer
Answer : 140 to 160

GATE - 2014 (../../../GATE2014) 01

Within the Heat A"ected Zone (HAZ) in a fusion welding process, the work material undergoes
(A) microstructural changes but does not melt (B) neither melting nor microstructural changes
(C) both melting and microstructural changes after solidification (D) melting and retains the original microstructure after solidification
Show Answer
Answer : (A) microstructural changes but does not melt

(../../../GATE2014) 02
A cylindrical riser of 6 cm diameter and 6 cm height has to be designed for a sand casting mould for producing a steel rectangular plate casting of 7 cm ×
10 cm × 2 cm dimensions having the total solidification time of 1.36 minute. The total solidification time (in minute) of the riser is
Show Answer
Answer : 2.5 to 4.5

GATE - 2014 (../../../GATE2014) 02

A butt weld joint is developed on steel plates having yield and ultimate tensile strength of 500 MPa and 700 MPa, respectively. The thickness of the plates
is 8 mm and width is 20 mm. Improper selection of welding parameters caused an undercut of 3 mm depth along the weld. The maximum transverse
tensile load (in kN) carrying capacity of the developed weld joint is
Show Answer
Answer : 68 to 72
Question No. 11 (../../Mechanical-GATE-2013-Question-11) (../../../GATE2013) 01

GATE - 2013
Match the CORRECT pairs.
Processes Characteristics / Applications

P. Friction Welding 1. Non-consumable electrode
Q. Gas Metal Arc Welding 2. Joining of thick plates
R. Tungsten Inert Gas Welding 3. Consumable electrode wire
S. Electroslag Welding 4. Joining of cylindrical dissimilar materials
Show Answer
Answer : (A) P-4, Q-3, R-1, S-2

GATE - 2013 (../../../GATE2013) 01

A cube shaped casting solidifies in 5 min. The solidification time in min for a cube of the same material, which is 8 times heavier than the original casting,
will be
(A) 10 (B) 20 (C) 24 (D) 40
Show Answer
Answer : (MARKS TO ALL) MARKS TO ALL

GATE - 2012 (../../../GATE2012) 02

Calculate the punch size in mm, for a circular blanking operation for which details are given below.
Size of the blank 25 mm

Thickness of the sheet 2 mm
Radial clearance between punch and die0.06 mm
Die allowance 0.05 mm
(A) 24.83 (B) 24.89 (C) 25.01 (D) 25.17
Show Answer
Answer : (A) 24.83

GATE - 2012 (../../../GATE2012) 02

In a DC arc welding operation, the voltage-arc length characteristic was obtained as Varc = 20 + 5l where the arc length l was varied between 5 mm and 7
mm. Here Varc denotes the arc voltage in Volts. The arc current was varied from 400 A to 500 A. Assuming linear power source characteristic, the open
circuit voltage and the short circuit current for the welding operation are
(A) 45 V, 450 A (B) 75 V, 750 A (C) 95 V, 950 A (D) 150 V, 1500 A
Show Answer
Answer : (C) 95 V, 950 A
GATE - 2011 (../../../GATE2011) 01

The operation in which oil is permeated into the pores of a powder metallurgy product is known as
(A) mixing (B) sintering (C) impregnation (D) infiltration
Show Answer
Answer : (C) impregnation

Subject : Casting, Forming and Joining Processes Topic : Principles of Powder Metallurgy
GATE - 2011 (../../../GATE2011) 01

Green sand mould indicates that
(A) polymeric mould has been cured (B) mould has been totally dried (C) mould is green in colour (D) mould contains moisture
Show Answer
Answer : (D) mould contains moisture

Which one among the following welding processes uses non-consumable electrode?
(A) Gas metal arc welding (B) Submerged arc welding (C) Gas tungsten arc welding (D) Flux coated arc welding
Show Answer
Answer : (C) Gas tungsten arc welding

GATE - 2011 (../../../GATE2011) 02

The shear strength of a sheet metal is 300 MPa. The blanking force required to produce a blank of 100 mm diameter from a 1.5 mm thick sheet is close to
(A) 45 kN (B) 70 kN (C) 141 kN (D) 3500 kN
Show Answer
Answer : (C) 141 kN

GATE - 2011 (../../../GATE2011) 02

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 the cube after solidification and contraction is
(A) 48.32 mm (B) 49.90 mm (C) 49.94 mm (D) 49.96 mm
Show Answer
Answer : (A) 48.32 mm

GATE - 2010 (../../../GATE2010) 01

In a gating system, the ratio 1:2:4 represents
(A) sprue base area: runner area: ingate area (B) pouring basin area: ingate area: runner area (C) sprue base area: ingate area: casting area
(D) runner area: ingate area: casting area
Show Answer
Answer : (A) sprue base area: runner area: ingate area

GATE - 2010 (../../../GATE2010) 02

Two pipes of inner diameter 100mm and outer diameter 110mm each joined by flash butt welding using 30V power supply. At the interface, 1mm of
material melts from each pipe which has a resistance of 42.4Ω. If the unit melt energy is 64.4MJm-3, then time required for welding in seconds is
(A) 1 (B) 5 (C) 10 (D) 20
Show Answer
Answer : (C) 10
GATE - 2010 (../../../GATE2010) 02

In a shear cutting operation, a sheet of 5mm thickness is cut along a length of 200mm. The cutting blade is 400mm long and zero-shear (S=0) is provided
on the edge. The ultimate shear strength of the sheet is 100MPa and penetration to thickness ratio is 0.2. Neglect friction.
Assuming force vs displacement curve to be rectangular, the work done (in J) is
(A) 100 (B) 200 (C) 250 (D) 300
Show Answer
Answer : (B) 200

GATE - 2010 (../../../GATE2010) 02

In a shear cutting operation, a sheet of 5mm thickness is cut along a length of 200mm. The cutting blade is 400mm long and zero-shear (S=0) is provided
on the edge. The ultimate shear strength of the sheet is 100MPa and penetration to thickness ratio is 0.2. Neglect friction.
A shear of 20mm (S=20mm) is now provided on the blade. Assuming force vs displacement curve to be trapezoidal, the maximum force (in kN) exerted is
(A) 5 (B) 10 (C) 20 (D) 40
Show Answer
Answer : (B) 10
GATE - 2009 (../../../GATE2009) 01

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) sand wash (D) scab
Show Answer
Answer : (A) cold shut

GATE - 2009 (../../../GATE2009) 02

Match the items in Column I and Column II.
Column I Column II
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. Exothermic Padding 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-1 (D) P-4,Q-1,R-2,S-3
Show Answer
Answer : (D) P-4,Q-1,R-2,S-3

GATE - 2008 (../../../GATE2008) 02

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
(A) 2% (B) 7% (C) 8% (D) 9%
Show Answer
Answer : (B) 7%
GATE - 2008 (../../../GATE2008) 02

In arc welding of a butt joint, the welding speed is to be selected such that highest cooling rate is achieved. Melting e ciency and heat transfer e ciency
are 0.5 and 0.7, respectively. The area of the weld cross section is 5mm2 and the unit energy required to melt the metal is 10 J/mm3. If the welding power
is 2 kW, the welding speed in mm/s is closest to
(A) 4 (B) 14 (C) 24 (D) 34
Show Answer
Answer : (B) 14
GATE - 2008 (../../../GATE2008) 02

In the deep drawing of cups, blanks show a tendency to wrinkle up around the periphery (flange). The most likely cause and remedy of the phenomenon
are, respectively,
(A) Buckling due to circumferential compression; Increase blank holder pressure
(B) High blank holder pressure and high friction; Reduce blank holder pressure and apply lubricant
(C) High temperature causing increase in circumferential length; Apply coolant to blank
(D) Buckling due to circumferential compression; decrease blank holder pressure
Show Answer
Answer : ()
GATE - 2007 (../../../GATE2007) 01

Which one of the following is a solid state joining process?
(A) gas tungsten arc welding (B) resistance spot welding (C) friction welding (D) submerged arc welding
Show Answer
Answer : (C) friction welding

GATE - 2007 (../../../GATE2007) 01

Volume of a cube of side ‘l’ and volume of a sphere of radius ‘r’ are equal. Both the cube and the sphere are solid and of same material. They are being
cast. The ratio of the solidification time of the cube to the same of the sphere is
4π 3 r 6 4π r 2 4π 2 r 3 4π 2 r 4
(A) ( )( ) (B) ( )( ) (C) ( )( ) (D) ( )( )
6 l 6 l 6 l 6 l
Show Answer
Answer : (D) ( )( )
4π 2 r 4
6 l
A direct current welding machine with a linear power source characteristic provides open circuit voltage of 80 V and short circuit current of 800 A. During
welding with the machine, the measured arc current is 500 A corresponding to an arc length of 5.0 mm and the measured arc current is 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 Volt and L is
in mm)
(A) E = 20 + 2L (B) E = 20 + 8L (C) E = 80 + 2L (D) E = 80 + 8L
Show Answer
Answer : (A) E = 20 + 2L
Two metallic sheets, each of 2.0 mm thickness, are welded in a lap joint configuration by resistance spot welding at a welding current of 10 kA and
welding time of 10 millisecond. A spherical fusion zone extending up to the full thickness of each sheet is formed. The properties of the metallic sheets
are given as:
ambient temperature = 293 K

melting temperature = 1793 K density = 7000 kg/m3
latent heat of fusion = 300
specific heat = 800 J/kg K
kJ/kg
Assume : (i) contact resistance along sheet – sheet interface is 500 micro-ohm and along electrode – sheet interface is zero; (ii) no conductive heat loss
through the bulk sheet materials; and (iii) the complete weld fusion zone is at the melting temperature.
The melting e ciency (in %) of the process is
(A) 50.37 (B) 60.37 (C) 70.37 (D) 80.37
Show Answer
Answer : (C) 70.37

GATE - 2007 (../../../GATE2007) 02

The thickness of a metallic sheet is reduced from an initial value of 16 mm to a final value of 10 mm in one single pass rolling with a pair of cylindrical
rollers each of diameter of 400 mm. The bite angle in degree will be
(A) 5.936 (B) 7.936 (C) 8.936 (D) 9.936
Show Answer
Answer : (D) 9.936
GATE - 2007 (../../../GATE2007) 02

Match the correct combination for following metal working processes.
Processes Associated state of stress

P. Blanking 1. Tension
Q. Stretch Forming 2. Compression
R. Coining 3. Shear
S. Deep Drawing 4. Tension and Compression
5. Tension and Shear
Show Answer
Answer : (D) P-3, Q-1, R-2, S-4

GATE - 2007 (../../../GATE2007) 02

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 beginning of the down
sprue). A constant head of molten metal is maintained by the pouring basin. The molten metal flow rate is 6.5 × 105 mm3/s. Considering the end of down
sprue to be open to atmosphere and an acceleration due to gravity of 104 mm/s2, the area of the down sprue in mm2 at its end (avoiding aspiration
e"ect) should be
(A) 650.0 (B) 350.0 (C) 290.7 (D) 190
Show Answer
Answer : (C) 290.7

GATE - 2007 (../../../GATE2007) 02

The force requirement in a blanking operation of low carbon steel sheet is 5.0 kN. The thickness of the sheet is ‘t’ and diameter of the blanked part is ‘d’.
For the same work material, if the diameter of the blanked part is increased to 1.5 d and thickness is reduced to 0.4 t, the new blanking force in kN is
(A) 3.0 (B) 4.5 (C) 5.0 (D) 8.0
Show Answer
Answer : (A) 3.0
Subjects of Materials, Manufacturing and Industrial Engineering
Engineering Materials (Engineering-Materials)
Casting, Forming and Joining Processes (Metal-Casting-Forming-Joining-Processes)
Machining and Machine Tool Operations (Machining-Machine-Tool-Operations)
Metrology and Inspection (Metrology-Inspection)
Computer Integrated Manufacturing (CIM-Computer-Integrated-Manufacturing)
Production Planning and Control (PPC-Production-Planning-Control)
Inventory Control (Inventory-Control)
Operations Research (OR-Operations-Research)

Casting, Forming and Joining Processes GATE Questions

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12/21/2019 Casting, Forming and Joining Processes | Materials, Manufacturing and Industrial Engineering | ME | GATE Syllabus, Paper Solution,

| GATE Syllabus, Paper Solution, Question Answer

Casting, Forming and Joining Processes 77 Question(s)

GATE - 2018 (../../../GATE2018) 01

The type of weld represented by the shaded region in the figure is

(A) groove (B) spot (C) fillet (D) plug

Answer : (C) fillet

GATE - 2018 (../../../GATE2018) 02

(A) 0.865 (B) 0.826 (C) 0.777 (D) 0.632

Answer : (D) 0.632

Question No. 46 (../../Mechanical-GATE-2018-Question-46) GATE - 2018 (../../../GATE2018) 02

Enter Your Answer Here

Answer : 52.00 to 54.00

Question No. 124 (../../Mechanical-GATE-2018-Question-124) GATE - 2018 (../../../GATE2018) 01

Match the following products with the suitable manufacturing process

Product Manufacturing Process

R Plastic bottles 3 Rolling

Answer : (C) P-4, Q-1, R-2, S-3

Question No. 157 (../../Mechanical-GATE-2018-Question-157) GATE - 2018 (../../../GATE2018) 02

drawing stress σf , (in MPa) is given as:

Enter Your Answer Here

Answer : 315.00 to 317.00

GATE - 2018 (../../../GATE2018) 02

Enter Your Answer Here

Answer : 42.00 to 52.00

GATE - 2018 (../../../GATE2018) 02

Enter Your Answer Here

Answer : 7.49 to 7.51

GATE - 2017 (../../../GATE2017) 01

Enter Your Answer Here

Answer : 245 to 246

GATE - 2017 (../../../GATE2017) 01

Answer : (D) reduce by 50%

GATE - 2017 (../../../GATE2017) 02

Enter Your Answer Here

Answer : 28.71 to 28.73

GATE - 2017 (../../../GATE2017) 02

Enter Your Answer Here

Answer : 2.04 to 2.07

GATE - 2017 (../../../GATE2017) 01

(A) Welding (B) Casting (C) Metal forming (D) Machining

Answer : (C) Metal forming

GATE - 2017 (../../../GATE2017) 02

(A) -0.5 (B) -0.69 (C) -0.75 (D) -1.0

Answer : (B) -0..69

GATE - 2017 (../../../GATE2017) 02

Enter Your Answer Here

Answer : 9.4 to 9.8

GATE - 2016 (../../../GATE2016) 01

(D) Twelding > Tbrazing > Tsoldering

Answer : (D) Twelding > Tbrazing > Tsoldering

GATE - 2016 (../../../GATE2016) 01

(A) pouring basin (B) runner (C) choke (D) ingate

Answer : (C) choke

GATE - 2016 (../../../GATE2016) 02

(A) 150 (B) 200 (C) 100 (D) 125

Answer : (A) 150

GATE - 2016 (../../../GATE2016) 02

Enter Your Answer Here

Answer : 1.90 : 1.94

GATE - 2016 (../../../GATE2016) 01

The welding process which uses a blanket of fusible granular flux is

Answer : (B) submerged arc welding