EDMM 1500 Exam 2 WMU Questions with Verified Solutions Latest Update 2025/2026
Which casting process would have the lowest tooling cost? - Answers green sand
Casting - Answers manufacturing process in which a liquid material is usually poured into a
mold, which contains a hollow cavity of the desired shape, and then allowed to solidify
Expendable mold reusable casting - Answers casting method where clay bonds sand around
reusable patterns to form a mold
porosity - Answers occurs when liquid metal can't reach sections of the metal casting where
solidification is occurring
In the casting process shrinkage causes porosity
Problem that hydrogen(gas) solubility causes in Aluminum castings
What materials can castings be made out of? - Answers metal alloys, plastics, gases and
ceramics
spure - Answers in the casting process the canal molten metal is poured through that is located
at the point where both halves of the mold unite. While also helping collect unwanted sand at
the end
riser - Answers source of liquid metal that attaches to casting to compensate for shrinkage by
feeding extra material into the casting
reduces porosity
pattern - Answers a full size model of the part that makes an impression in the sand mold
core - Answers sand shape inserted into the mold to shape the casting interior
drag - Answers the lower half of the mold that is filled with sand first is called?
cope - Answers the upper half of the mold that contains the pattern and core is called what?
three types of molten metal flow - Answers gentle: minimizes gas and sand entrapment
rapid: to prevent freezing before filling
, diversionary: to skim off or filter slag and contaminants
three types of solidification grain structures - Answers pure metals: columnar zone structure
most alloys have equiaxed zone structure with columns on outside
controlled nucleation: equiaxed structure all the way through; provides lots of spots for crystals
to start forming
what causes porosity in a casting? - Answers shrinkage during freezing/solidification (solid
occupies less volume than liquid)
shell molding - Answers an expendable mold casting process that uses a resin covered sand to
form the mold
more precise than green sand casting but with moderate tooling cost
lost foam or expendable pattern casting - Answers This type of casting has a high tooling cost
and long cycle while being made out of polystyrene resin. its a type of evaporative-pattern
casting process that is similar to investment casting except foam is used for the pattern instead
of wax
investment casting (lost wax) - Answers a technique for making small, accurate castings in
refractory alloys using a mold formed around a tree pattern of wax or similar material which is
then removed by melting
superior finish, sound structure, and accurate parts near net-shape
produces jewlery
die casting - Answers a metal casting process that is characterized by forcing molten metal
under high pressure into a mold cavity. (high cost)
hot chamber: used with metals that require more heat
Which casting process would have the lowest tooling cost? - Answers green sand
Casting - Answers manufacturing process in which a liquid material is usually poured into a
mold, which contains a hollow cavity of the desired shape, and then allowed to solidify
Expendable mold reusable casting - Answers casting method where clay bonds sand around
reusable patterns to form a mold
porosity - Answers occurs when liquid metal can't reach sections of the metal casting where
solidification is occurring
In the casting process shrinkage causes porosity
Problem that hydrogen(gas) solubility causes in Aluminum castings
What materials can castings be made out of? - Answers metal alloys, plastics, gases and
ceramics
spure - Answers in the casting process the canal molten metal is poured through that is located
at the point where both halves of the mold unite. While also helping collect unwanted sand at
the end
riser - Answers source of liquid metal that attaches to casting to compensate for shrinkage by
feeding extra material into the casting
reduces porosity
pattern - Answers a full size model of the part that makes an impression in the sand mold
core - Answers sand shape inserted into the mold to shape the casting interior
drag - Answers the lower half of the mold that is filled with sand first is called?
cope - Answers the upper half of the mold that contains the pattern and core is called what?
three types of molten metal flow - Answers gentle: minimizes gas and sand entrapment
rapid: to prevent freezing before filling
, diversionary: to skim off or filter slag and contaminants
three types of solidification grain structures - Answers pure metals: columnar zone structure
most alloys have equiaxed zone structure with columns on outside
controlled nucleation: equiaxed structure all the way through; provides lots of spots for crystals
to start forming
what causes porosity in a casting? - Answers shrinkage during freezing/solidification (solid
occupies less volume than liquid)
shell molding - Answers an expendable mold casting process that uses a resin covered sand to
form the mold
more precise than green sand casting but with moderate tooling cost
lost foam or expendable pattern casting - Answers This type of casting has a high tooling cost
and long cycle while being made out of polystyrene resin. its a type of evaporative-pattern
casting process that is similar to investment casting except foam is used for the pattern instead
of wax
investment casting (lost wax) - Answers a technique for making small, accurate castings in
refractory alloys using a mold formed around a tree pattern of wax or similar material which is
then removed by melting
superior finish, sound structure, and accurate parts near net-shape
produces jewlery
die casting - Answers a metal casting process that is characterized by forcing molten metal
under high pressure into a mold cavity. (high cost)
hot chamber: used with metals that require more heat
