Manufacturing Processes and Workshop Technology MCQs 2026

Closed-die or impression-die forging produces

1. A only flat plates ✓
2. B powder compacts ✓
3. C near-net-shape parts in one or few blows ✓
4. D sand castings ✓

Flash in impression-die forging is

1. A a welding defect ✓
2. B excess metal squeezed into gutter at parting line ✓
3. C a casting riser ✓
4. D a grinding wheel grade ✓

Forging temperature for steel is typically

1. A below room temperature ✓
2. B at melting point ✓
3. C above recrystallization but below burning point ✓
4. D exactly at Curie point only ✓

Cold forging is done

1. A always above 1200°C ✓
2. B below recrystallization temperature ✓
3. C only in vacuum ✓
4. D with molten metal ✓

Upsetting in forging increases

1. A length without diameter change ✓
2. B cross-section and reduces length of billet ✓
3. C only surface hardness by quenching ✓
4. D mould permeability ✓

Rolling process reduces thickness by

1. A compressive forces between rotating rolls ✓
2. B tensile pulling only ✓
3. C explosive forming only ✓
4. D electrochemical deposition ✓

Hot rolling is performed

1. A always at room temperature ✓
2. B only on non-metals ✓
3. C without any lubrication ever ✓
4. D above recrystallization temperature ✓

Cold rolling improves

1. A only internal porosity of castings ✓
2. B melting point of alloy ✓
3. C mould hardness ✓
4. D surface finish, dimensional accuracy and strength ✓

A blooming mill produces

1. A large square or rectangular cross-sections from ingots ✓
2. B thin foil directly ✓
3. C investment cast turbine blades ✓
4. D welded pipe seams ✓

Roll gap in rolling is controlled to determine

1. A only surface colour ✓
2. B final thickness of the strip or plate ✓
3. C chemical composition ✓
4. D hardness by quenching only ✓

Extrusion forces metal to flow

1. A only in circular rolling mills ✓
2. B through a die opening to create constant cross-section ✓
3. C into sand mould cavities ✓
4. D by explosive welding only ✓

Direct extrusion means

1. A billet and ram move in same direction; die is stationary ✓
2. B die moves toward stationary billet ✓
3. C no ram is used ever ✓
4. D only powder is compacted ✓

Indirect extrusion has the advantage that

1. A higher friction at container always ✓
2. B no die is required ✓
3. C only cold extrusion is possible ✓
4. D there is no relative motion between billet and container wall ✓

Hydrostatic extrusion uses

1. A fluid pressure around billet to reduce friction ✓
2. B only dry sand packing ✓
3. C oxy-acetylene heating ✓
4. D permanent mould casting ✓

Extrusion ratio is defined as

1. A initial cross-section area divided by final extruded area ✓
2. B length divided by diameter only ✓
3. C temperature divided by pressure ✓
4. D hardness divided by density ✓

Deep drawing forms a sheet metal blank into

1. A only by cutting with shear ✓
2. B a cup or box by plastic flow over a punch ✓
3. C by casting molten metal ✓
4. D by powder sintering only ✓

Blank holder force in deep drawing must be

1. A zero always ✓
2. B sufficient to prevent wrinkles but not cause tearing ✓
3. C maximum press capacity always ✓
4. D equal to forging flash force ✓

Bending allowance accounts for

1. A only elastic recovery after welding ✓
2. B casting shrinkage only ✓
3. C material stretch on outer fiber during sheet bending ✓
4. D roll gap setting ✓

Springback after sheet bending occurs because

1. A elastic recovery remains after plastic bending ✓
2. B metal melts partially ✓
3. C oxidation layer grows ✓
4. D die casting flash forms ✓

Shearing of sheet metal produces

1. A rolled threads only ✓
2. B investment shells ✓
3. C forged flash ✓
4. D straight cut by punch and die clearance action ✓

Optimum punch-die clearance in shearing is typically

1. A equal to full sheet thickness ✓
2. B zero clearance always ✓
3. C 50 percent of thickness ✓
4. D about 5 to 10 percent of sheet thickness ✓

Powder metallurgy compact is formed by

1. A pouring molten metal only ✓
2. B rolling ingots hot only ✓
3. C pressing metal powder in a die at room temperature ✓
4. D submerged arc welding ✓

Sintering in powder metallurgy is

1. A melting entire compact to liquid ✓
2. B cold rolling only ✓
3. C sand mould baking ✓
4. D heating compact below melting point to bond particles ✓

Powder metallurgy is advantageous for

1. A very large single sand castings ✓
2. B continuous billet casting only ✓
3. C mass production of small complex parts with minimal waste ✓
4. D manual stick welding only ✓

Apparent density of metal powder affects

1. A only weld penetration ✓
2. B lathe spindle speed ✓
3. C fill ratio and compaction behavior in die ✓
4. D governor sensitivity ✓

Annealing heat treatment is used to

1. A maximize hardness always ✓
2. B create martensite only ✓
3. C soften metal, relieve stresses and refine grain structure ✓
4. D increase brittleness purposely ✓

Normalizing involves heating steel above Ac3 and

1. A quenching in water instantly ✓
2. B cooling in still air ✓
3. C holding at cryogenic temperature ✓
4. D submerged arc welding ✓

Quenching of steel aims to

1. A form martensite by rapid cooling from austenite ✓
2. B slow cooling in furnace only ✓
3. C increase grain size greatly ✓
4. D remove all carbon ✓

Tempering after quenching is done to

1. A increase martensite fraction only ✓
2. B melt the surface layer ✓
3. C reduce brittleness and adjust hardness-toughness balance ✓
4. D eliminate all carbon ✓

Case hardening produces

1. A uniform soft structure throughout ✓
2. B only surface decarburization ✓
3. C complete melting of part ✓
4. D hard wear-resistant surface with tough core ✓

Carburizing introduces carbon into

1. A only copper alloys ✓
2. B surface layer of low-carbon steel ✓
3. C already fully hardened martensite core only ✓
4. D sand mould walls ✓

Nitriding hardens surface by

1. A diffusion of nitrogen to form hard nitrides ✓
2. B adding zinc galvanizing only ✓
3. C sand blasting only ✓
4. D deep drawing only ✓

Martensite in steel is

1. A soft ferrite-pearlite mixture ✓
2. B liquid slag in casting ✓
3. C hard brittle phase formed by rapid quenching of austenite ✓
4. D flux coating on electrode ✓

TTT diagram shows

1. A only rolling mill forces ✓
2. B lathe feed rates ✓
3. C transformation products of austenite versus time at temperature ✓
4. D gear tooth profile only ✓

Hardenability of steel indicates

1. A only surface roughness after rolling ✓
2. B extrusion ratio limit ✓
3. C depth to which martensite can form upon quenching ✓
4. D sand permeability ✓

Stress relieving heat treatment reduces

1. A residual stresses without major microstructure change ✓
2. B alloy content in melt ✓
3. C pattern draft angle ✓
4. D roll diameter only ✓

Age hardening in aluminium alloys occurs by

1. A sand casting shrinkage only ✓
2. B forge flash removal ✓
3. C sheet shearing clearance ✓
4. D precipitation of fine particles during controlled aging ✓

Full annealing of hypoeutectoid steel heats to

1. A below freezing point ✓
2. B about 50°C above upper critical temperature then furnace cools ✓
3. C melting point only ✓
4. D room temperature without heating ✓

Spheroidizing annealing produces

1. A martensite needles throughout ✓
2. B liquid metal pool ✓
3. C spheroidal carbides in ferrite matrix for machinability ✓
4. D sand mould cores ✓

Slag inclusion in welds is prevented by

1. A increasing moisture in flux ✓
2. B removing shielding gas ✓
3. C proper cleaning between passes and correct technique ✓
4. D maximum travel speed always ✓

Electroslag welding is used for

1. A thin sheet spot welding only ✓
2. B thick section vertical welds in plate construction ✓
3. C powder compact sintering ✓
4. D investment wax removal ✓

Plasma arc welding uses

1. A constricted high-temperature ionized gas arc ✓
2. B only oxy-fuel without electricity ✓
3. C sand mould pouring ✓
4. D forge hammer blows only ✓

Electrodes for welding cast iron often contain

1. A pure aluminium wire only ✓
2. B sand and clay ✓
3. C zinc die casting alloy only ✓
4. D nickel or nickel-iron alloy for machinable weld ✓

Pattern material for large sand castings is often

1. A wood or resin-bonded board ✓
2. B hardened tool steel die always ✓
3. C molten wax only for all sizes ✓
4. D powder metal compact ✓

Gating system in casting includes

1. A only riser without sprue ✓
2. B pouring basin, sprue, runner and gates ✓
3. C welding electrode holder ✓
4. D lathe tailstock ✓

Distortion in welded structures is minimized by

1. A welding all joints from one side only ✓
2. B maximum heat input always ✓
3. C balanced welding sequence, fixturing and intermittent welds ✓
4. D avoiding tack welds ✓

Undercut in welding appears as

1. A excess reinforcement on crown ✓
2. B groove melted into base metal adjacent to weld toe ✓
3. C slag inclusion at root only ✓
4. D complete lack of fusion at surface ✓

Weld defect porosity is commonly caused by

1. A perfectly dry electrodes only ✓
2. B correct travel speed always ✓
3. C adequate gas flow only ✓
4. D trapped gas from moisture, contamination or improper shielding ✓

Oxy-acetylene cutting of steel relies on

1. A melting aluminium oxide only ✓
2. B carbon arc without oxygen ✓
3. C hydrogen embrittlement ✓
4. D exothermic reaction of iron with oxygen jet ✓

Neutral oxy-acetylene flame is used for

1. A most general welding and cutting of steel ✓
2. B only cutting without welding ✓
3. C aluminium TIG replacement always ✓
4. D submerged arc deposition ✓

Oxy-acetylene welding flame with excess acetylene is

1. A carburizing flame ✓
2. B neutral flame ✓
3. C oxidizing flame ✓
4. D submerged arc ✓

In MIG welding, argon-CO2 mixtures are used to

1. A weld only cast iron without preheat ✓
2. B replace all filler wire ✓
3. C eliminate need for grounding ✓
4. D balance penetration, spatter and weld profile on steel ✓

MIG welding is characterized by

1. A non-consumable tungsten only ✓
2. B powder flux submerged arc only ✓
3. C continuous consumable wire electrode and gas shield ✓
4. D explosive cladding only ✓

TIG welding uses

1. A consumable flux-coated stick only ✓
2. B fuel gas without electricity ✓
3. C no shielding gas ever ✓
4. D non-consumable tungsten electrode and inert gas shield ✓

Submerged arc welding uses

1. A granular flux that covers the arc and molten pool ✓
2. B no filler wire ✓
3. C only gas shielding without flux ✓
4. D oxy-acetylene flame exclusively ✓

In SMAW, reverse polarity (DCEP) generally provides

1. A only shallow weld pools ✓
2. B deeper penetration and cleaner plate surface ✓
3. C no arc stability ✓
4. D exclusive use on aluminium ✓

SMAW stands for

1. A Shielded Metal Arc Welding ✓
2. B Submerged Metal Alloy Welding ✓
3. C Shielded Metal Alloy Work ✓
4. D Standard Metal Arc Work ✓

In arc welding, the function of flux coating on electrode is

1. A to increase arc voltage only ✓
2. B to replace filler metal ✓
3. C to cool the weld instantly ✓
4. D to shield molten pool and refine weld metal ✓

Hot tearing in castings results from

1. A restrained contraction while still weak in the solid state ✓
2. B too fast pattern withdrawal ✓
3. C excessive mould permeability ✓
4. D low pouring temperature only ✓

Cold shut in casting is caused by

1. A excessive riser size only ✓
2. B high permeability sand ✓
3. C proper preheating of mould ✓
4. D two metal streams meeting at too low a temperature ✓

Misrun defect in casting occurs when

1. A too much metal is poured ✓
2. B molten metal fails to fill the mould cavity completely ✓
3. C pattern has excessive draft ✓
4. D core is perfectly positioned ✓

Chill casting uses a metal insert to

1. A slow cooling uniformly ✓
2. B remove gases from melt ✓
3. C promote rapid local solidification for hard surface ✓
4. D replace all sand cores ✓

Continuous casting produces

1. A single complex investment castings ✓
2. B semi-finished sections such as billets, blooms and slabs ✓
3. C powder metal compacts ✓
4. D sheet metal stampings only ✓

In centrifugal casting, impurities tend to move

1. A to the outer dense layer only ✓
2. B uniformly through the section ✓
3. C toward the inner surface or bore ✓
4. D out of the mould entirely ✓

Centrifugal casting is used primarily to produce

1. A flat sheet metal panels ✓
2. B powder metallurgy gears ✓
3. C hollow cylindrical parts such as pipes and bushings ✓
4. D welded plate structures ✓

Flash in die casting is

1. A a type of riser ✓
2. B excess metal squeezed into parting line clearance ✓
3. C a core material ✓
4. D a lubricant for dies ✓

Cold-chamber die casting is preferred for

1. A aluminium and copper alloys with higher melting points ✓
2. B zinc die casting only ✓
3. C investment casting wax patterns ✓
4. D sand mould preparation ✓

Hot-chamber die casting is commonly used for

1. A high-melting steel only ✓
2. B titanium exclusively ✓
3. C cast iron only ✓
4. D low-melting alloys such as zinc and magnesium ✓

Die casting differs from sand casting mainly because

1. A sand is always used as mould material ✓
2. B no pressure is applied during fill ✓
3. C only non-ferrous metals can be cast ✓
4. D metal is injected under pressure into a permanent steel die ✓

Shell moulding uses

1. A a thin resin-bonded sand shell heated on a metal pattern ✓
2. B only green sand without resin ✓
3. C permanent graphite moulds only ✓
4. D lost foam exclusively ✓

Investment casting is best suited for

1. A complex shapes and high-precision small parts ✓
2. B very large ship propellers only ✓
3. C continuous billet production ✓
4. D rough sand castings only ✓

Investment casting is also known as

1. A lost-wax process ✓
2. B green sand process ✓
3. C centrifugal casting ✓
4. D continuous casting ✓

A core in casting is used to

1. A increase metal pouring rate only ✓
2. B replace the riser function ✓
3. C form internal cavities or undercuts in the casting ✓
4. D serve as permanent mould liner ✓

Permeability of moulding sand refers to

1. A ability to retain moisture only ✓
2. B ability to allow gases to escape during pouring ✓
3. C resistance to metal erosion only ✓
4. D hardness after baking ✓

Green sand in sand casting typically contains

1. A only pure silica without binder ✓
2. B clay, water, silica sand and additives ✓
3. C molten metal and flux only ✓
4. D cement and gravel mix ✓

Shrinkage allowance on a pattern is provided to

1. A increase mould permeability ✓
2. B reduce pouring time only ✓
3. C eliminate need for risers ✓
4. D compensate for metal contraction during solidification ✓

Draft angle on a sand casting pattern allows

1. A higher melting point of metal ✓
2. B increased weld strength ✓
3. C lower carbon content ✓
4. D easy withdrawal of pattern from mould ✓

A chaplet in sand casting is used to

1. A increase pouring temperature ✓
2. B support a core and prevent its displacement ✓
3. C measure mould hardness ✓
4. D grind flash from casting ✓

The primary purpose of a riser in sand casting is

1. A to increase mould hardness only ✓
2. B to cool the casting faster ✓
3. C to remove slag from melt ✓
4. D to feed molten metal and compensate shrinkage ✓

Open-die forging is performed between

1. A closed impression dies only ✓
2. B rolling mill rolls exclusively ✓
3. C flat or simple-shaped dies with manual repositioning ✓
4. D investment moulds ✓