Answer: c [Reason:] The process of reducing cross section of a metal by forcing it to flow through a die is known as extrusion. It is one of the forming processes.

Answer: d [Reason:] All the above mentioned is a type of extrusion process.Extrusion may be direct, indirect or impact.

Answer: b [Reason:] No time is lost in changing the shape as the dies may be readily removed in the process of extrusion.

Answer: a [Reason:] In direct extrusion process the direction of flow of metal is in same direction as that of ram Where as it is opposite in indirect extrusion.

Answer: c [Reason:] As friction is the major problem in direct extrusion,hence molten glasses are used to avoid friction.

Answer: b [Reason:] Indirect extrusion method is not used because of the problem of handling extruded metal coming out through moving ram.

Answer: c [Reason:] Impact extrusion is also known as cold extrusion process because working temperature is low in impact extrusion.

Answer: d [Reason:] In hydrostatic extrusion process frictional loss is eliminated at the billet container interface. This elimination increases the quality of product.

Answer: d [Reason:] In hydrostatic extrusion process fluid medium is used to apply the load on the billet. As hydro stands for fluid and static for rest.

Answer: a [Reason:] Extrusion is similar rolling in producing constant cross sectional shape.

Answer: c [Reason:] Both the defects arise due to high speed or friction. This should be eliminated during the process of extrusion.

Answer: c [Reason:] Surface cracking defect is also known as bamboo defect.In this cracks appear on the surface of metal.

Answer: d [Reason:] Pipe defect tends to draw surface oxides and impurities towards the centre of billet.

Answer: b [Reason:] Pipe defect is also known as fish tailing. Fish tail like structure appears on metal. It should be eliminated for better quality of product.

Answer: d [Reason:] Internal cracking is also known as centre cracking, centre burst or arrow headed fracture.

Answer: d [Reason:] Iron from its ore is converted to pig iron in blast furnace. Ore iron is purest form but it can not be used in this form.

Answer: a [Reason:] Iron from its pig iron form is converted to cast iron in cupola. As pig iron is very weak in strength hence it can not be used for practical purpose.

Answer: c [Reason:] Iron from its pig iron form is converted to wrought iron in pudding furnace. As pig iron is very weak in strength hence it can not be used for practical purpose.

Answer: d [Reason:] Iron from its pig iron form is converted to steel in Bessemer converter.As pig iron is very weak in strength hence it can not be used for practical purpose.

Answer: a [Reason:] Red hardness means capability of material to retain hardness at high temperature. Tungsten have very high melting point and is used to improve red hardness.

Answer: d [Reason:] Titanium has very high abrasive resistance property. Titanium is used to improve abrasive resistance of base metal in an alloy.

Answer: c [Reason:] Manganese has very high wear resistance property. Magnesium is alloyed with base metal to increase its wear resistance property.

Answer: c [Reason:] Chromium has very high corrosion and oxidation resistance property. Chromium is alloyed with base metal to increase its corrosion resistance.

Answer: a [Reason:] Nickel can improve tensile strength as well as toughness of alloy steel. It is alloyed with base metal in small quantity.

Answer: b [Reason:] Vanadium induces fine grain distribution in alloy steel. It helps in improving uniformity in base metal.

Answer: b [Reason:] Smith forging operation is very simple operation and no special die is used.

Answer: a [Reason:] In drop forging operation repeated hammering and closed die is used.

Answer: d [Reason:] In press forging operation instead of repeated hammering gradual force is applied.

Answer: b [Reason:] Coining and forming are two special kind of press forging operation.

Answer: a [Reason:] Upset forging operation is used for parts having uniform cross section.

Answer: d [Reason:] In swaging technique shaping of cross section of tubes or rods is done by means of repeated impacts or blows.

Answer: c [Reason:] Heading is a kind of upsetting forging operation.

Answer: c [Reason:] In heading to avoid buckling the length to diameter ratio should be 3:1.

Answer: b [Reason:] Embossing is used in making raised figures on sheets with its corresponding relief on the other side.

Answer: a [Reason:] Skew rolling operation is used to make ball bearing.

Answer: d [Reason:] Depending upon the temperature the forming process can be classified as hot working, cold working, and warm working.

Answer: b [Reason:] If Tm is the melting temperature then in hot working the value of Tm is .6 T. Hot working is done above recrystyllization temperature.

Answer: a [Reason:] In hot working no strain hardening is produced. Hot working is done above recrystyllization temperature.

Answer: b [Reason:] During hot working the Grain Growth can takes place in the interior part of the material because the interior part cools slowly the remaining parts.

Answer: c [Reason:] Blow hole defect is eliminated by hot working process. Hot working is done above recrystyllization temperature.

Answer: b [Reason:] The working temperature of cold working is below a certain temperature. That temperature is known as Re crystallization temperature.

Answer: b [Reason:] In cold working process the ductility of material decreases. Cold working is done below recrystyllization temperature.

Answer: a [Reason:] Strain hardening is not relieved in cold working. Cold working is done below recrystyllization temperature.

Answer: c [Reason:] In warm working plastic deformation takes place.

Answer: d [Reason:] In metal forming process the hardness of the material increases.

Answer: c [Reason:] The work involved with the internal shearing process due to non-uniform deformation is redundant work.

Answer: d [Reason:] Slab method, upper bound method, slip line method are used for analyzing metal forming processes.

Answer: a [Reason:] Slab method is commonly used for analyzing metal forming processes. Slab method, upper bound method, slip line method are used for analyzing metal forming processes.

Answer: d [Reason:] Warm working is done at a temperature below re crystallization temperature and above room temperature.

Answer: a [Reason:] Hot working process got a better dimensional accuracy. Hot working is done at a temperature below re crystallization temperature and above room temperature.

Answer: b [Reason:] Electric-arc furnaces, are used extensively in foundries and have such advantages as a high rate of melting (and thus high-production rate), much less pollution than other types of furnaces, and the ability to hold the molten metal for alloying purposes.

Answer: a [Reason:] Induction furnaces, are especially useful in smaller foundries and produce smaller Composition-controlled melts.

Answer: a [Reason:] The coreless induction furnace consists of a Crucible completely surrounded with a water-Cooled copper coil through which a high-frequency current passes. Because there is a strong electromagnetic stirring action during induction heating, this type of furnace has excellent mixing characteristics for alloying and adding a new charge of metal.

Answer: c [Reason:] The channel furnace, uses a low-frequency Current (as low as 60 Hz) and has a coil that surrounds only a small portion of the unit.

Answer: d [Reason:] Channel furnace are used in nonferrous foundries and are particularly suitable for (a) superheating (that is, heating above normal Casting temperature to improve fluidity), (b) holding (which makes it suitable for die-casting applications), and (c) duplexing (using two furnaces-for instance, melt the metal in one furnace and transfer it to another).

Answer: c [Reason:] Crucible furnaces, which have been used extensively throughout history, are heated with various fuels, such as commercial gases, fuel oil, and fossil fuel, as well as electricity. Crucible furnaces may be stationary, tilting, or movable.

Answer: a [Reason:] Cupolas are basically vertical, refractory-lined steel vessels charged with alternating layers of metal, coke, and flux. Although they require major investments and increasingly are being replaced by induction furnaces, cupolas operate continuously, have high melting rates, and produce large amounts of molten metal.

Answer: b [Reason:] Levitation melting involves magnetic suspension of the molten metal. An induction coil simultaneously heats a solid billet and stirs and confines the melt, thus eliminating the need for a crucible.

Answer: d [Reason:] Automation minimizes labor, reduces the possibility of human error, increases the production rate, and attains higher quality levels.

Answer: d [Reason:] Industrial robots are now used extensively in foundry operations, such as cleaning, riser cutting, mold venting, mold spraying, pouring, sorting, and inspection.