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Metal Casting(6)Metal Working (Hot, Warm, Cold)(13)Metal Joining and Powder Metallurgy(12)Non-destructive Testing (NDT)(5)

Metal Casting

6 Questions

GATE→2025→Manufacturing Processes→Metal Casting

Q1

MCQ[1 Mark]

In metal casting, which one of the following gating ratios (sprue-runner-gate area ratio) represents a non-pressurized gating system? (A) $1:2:3$ (B) $3:2:1$ (C) $4:3:1$ (D) $5:4:1$

(A)

1:2:3

(B)

3:2:1

(C)

4:3:1

(D)

5:4:1

Explanation

GATE→2025→Manufacturing Processes→Metal Casting

Q2

MCQ[2 Marks]

Match the casting defects in Column I with the characteristic features in Column II.\nColumn I:\nP. Misrun\nQ. Expansion scab\nR. Pin holes\nS. Hot tearing\nColumn II: 1. Penetration of liquid metal behind surface layer of sand moulds 2. Metal solidifies prematurely in the mould and some sections of the casting are not filled 3. Cracking because of restraint to contraction in certain areas of the casting during solidification and cooling to room temperature 4. Evolution of gases during solidification resulting in porosity (A) P-2, Q-4, R-3, S-1 (B) P-1, Q-3, R-2, S-4 (C) P-1, Q-2, R-4, S-3 (D) P-2, Q-1, R-4, S-3

(A)

P-2, Q-4, R-3, S-1

(B)

P-1, Q-3, R-2, S-4

(C)

P-1, Q-2, R-4, S-3

(D)

P-2, Q-1, R-4, S-3

Explanation

GATE→2024→Manufacturing Processes→Metal Casting

Q3

NAT[2 Marks]

In casting, for a simple vertical gating system with a gate of cross-sectional area $2\text{ cm}^2$ and sprue height of $10\text{ cm}$, the filling time for a mould of dimensions $40\text{ cm} \times 20\text{ cm} \times 10\text{ cm}$, is ___ $\text{s}$ (Round off to one decimal place).\nGiven: Acceleration due to gravity $g = 980\text{ cm s}^{-2}$.

Explanation

GATE→2023→Manufacturing Processes→Metal Casting

Q4

MCQ[2 Marks]

Match the components in Column I with corresponding manufacturing processes in Column II.\nColumn I: (P) Crank shaft (Q) Machine bed (R) Automobile brake pad (S) Beverage can\nColumn II: (1) Sheet metal forming (2) Forging (3) Casting (4) Powder metallurgy (A) P-2, Q-3, R-4, S-1 (B) P-3, Q-4, R-1, S-2 (C) P-4, Q-1, R-3, S-2 (D) P-2, Q-3, R-1, S-4

(A)

P-2, Q-3, R-4, S-1

(B)

P-3, Q-4, R-1, S-2

(C)

P-4, Q-1, R-3, S-2

(D)

P-2, Q-3, R-1, S-4

Explanation

GATE→2023→Manufacturing Processes→Metal Casting

Q5

MSQ[2 Marks]

Compared to top gating, the effect(s) of bottom gating in sand mold casting is/are (A) reduced melt oxidation (B) reduced mold erosion (C) enhanced melt oxidation (D) enhanced mold erosion

(A)

reduced melt oxidation

(B)

reduced mold erosion

(C)

enhanced melt oxidation

(D)

enhanced mold erosion

Explanation

GATE→2022→Manufacturing Processes→Metal Casting

Q6

MCQ[1 Mark]

In green sand moulding, the casting defect resulting from the displacement of mould cavity by an oversized core is known as (A) crush (B) hot tear (C) blow (D) fin

(A)

crush

(B)

hot tear

(C)

blow

(D)

fin

Explanation

Metal Working (Hot, Warm, Cold)

13 Questions

GATE→2026→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q7

MCQ[2 Marks]

Match the type of defects in Column I with the corresponding metal manufacturing processes listed in Column II:\nColumn I: (P) Edge Cracking (Q) Flashline Cracking (R) Chevron Cracking (S) Cracked Core\nColumn II: (1) Casting (2) Forging (3) Rolling (4) Extrusion (A) P-3, Q-4, R-2, S-1 (B) P-4, Q-3, R-1, S-2 (C) P-4, Q-2, R-3, S-1 (D) P-3, Q-2, R-4, S-1

(A)

P-3, Q-4, R-2, S-1

(B)

P-4, Q-3, R-1, S-2

(C)

P-4, Q-2, R-3, S-1

(D)

P-3, Q-2, R-4, S-1

Explanation

GATE→2026→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q8

NAT[2 Marks]

For cold-rolling an aluminium plate from $50\text{ mm}$ to $25\text{ mm}$ with roll diameter $1250\text{ mm}$, the minimum required coefficient of friction is ___.

Explanation

GATE→2025→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q9

MSQ[2 Marks]

Front tension is applied during cold rolling of a thin metal sheet. Which of the following statements is/are TRUE? (A) The neutral point shifts towards the roll entrance. (B) The rolling load is decreased. (C) The neutral point shifts towards the roll exit. (D) The rolling load is increased.

(A)

The neutral point shifts towards the roll entrance.

(B)

The rolling load is decreased.

(C)

The neutral point shifts towards the roll exit.

(D)

The rolling load is increased.

Explanation

GATE→2025→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q10

NAT[2 Marks]

A cylindrical Al alloy billet of $300\text{ mm}$ diameter is hot extruded to produce a cylindrical rod of $75\text{ mm}$ diameter at a constant true strain rate ($\dot{\epsilon}$) of $10\text{ s}^{-1}$. The flow stress ($\sigma$) of the alloy at the extrusion temperature is given by $\sigma = 10(\dot{\epsilon})^{0.3}\text{ MPa}$. Assume the alloy is perfectly plastic and there is no temperature rise during the extrusion process. The ideal plastic work of deformation per unit volume is ___ $\times 10^6\text{ J m}^{-3}$ (rounded off to one decimal place).

Explanation

GATE→2024→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q11

MCQ[1 Mark]

Match the defects listed in Column I with the associated manufacturing processes listed in Column II.\nColumn I:\nP. Misrun\nQ. Earing\nR. Alligatoring\ns. Chevron cracking\nColumn II: 1. Extrusion 2. Rolling 3. Casting 4. Deep drawing (A) P-3, Q-1, R-2, S-4 (B) P-3, Q-4, R-2, S-1 (C) P-2, Q-4, R-3, S-1 (D) P-1, Q-3, R-2, S-4

(A)

P-3, Q-1, R-2, S-4

(B)

P-3, Q-4, R-2, S-1

(C)

P-2, Q-4, R-3, S-1

(D)

P-1, Q-3, R-2, S-4

Explanation

GATE→2024→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q12

NAT[1 Mark]

The extrusion force required to extrude an aluminum rod of cross-sectional area of $150\text{ mm}^2$ to cross-sectional area of $50\text{ mm}^2$ is ___ $\text{N}$ (Round off to the nearest integer). Assume that the extrusion constant, which accounts for flow stress, strain hardening, friction and inhomogeneous deformation, is equal to $2\text{ MPa}$ ($2\text{ N/mm}^2$).

Explanation

GATE→2024→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q13

MCQ[2 Marks]

For rolling of slabs, determine the correctness or otherwise of the following Assertion [a] and Reason [r].\nAssertion [a]: Grooves are made on the surface of the rolls parallel to their roll axes to achieve large thickness reduction in a short time.\nReason [r]: Given $\mu$ is the coefficient of friction between the rolls and the slab, and $\alpha$ is the angle of bite between the entrance plane and the centerline of the rolls, unaided entry of slab in the rolls can take place only if $\mu < \tan\alpha$. (A) Both [a] and [r] are true, and [r] is the correct reason of [a]. (B) Both [a] and [r] are true, but [r] is not the correct reason of [a]. (C) Both [a] and [r] are false. (D) [a] is true, but [r] is false.

(A)

Both [a] and [r] are true, and [r] is the correct reason of [a].

(B)

Both [a] and [r] are true, but [r] is the not the correct reason of [a].

(C)

Both [a] and [r] are false.

(D)

[a] is true, but [r] is false.

Explanation

GATE→2023→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q14

MCQ[1 Mark]

Match the defects in Column I with corresponding metal forming techniques in Column II.\nColumn I: (P) Cold shut (Q) Zipper breaks (R) Stretcher strains (S) Center burst\nColumn II: (1) Rolling (2) Sheet metal forming (3) Drawing (4) Forging (A) P-4, Q-1, R-2, S-3 (B) P-4, Q-2, R-3, S-1 (C) P-1, Q-4, R-2, S-3 (D) P-3, Q-1, R-4, S-2

(A)

P-4, Q-1, R-2, S-3

(B)

P-4, Q-2, R-3, S-1

(C)

P-1, Q-4, R-2, S-3

(D)

P-3, Q-1, R-4, S-2

Explanation

GATE→2023→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q15

MCQ[1 Mark]

In rolling, the point on the surface of contact between roll and sheet where surface velocity of the roll is equal to velocity of the sheet is referred as (A) no-slip point (B) no-stick point (C) maximum slip point (D) maximum stick point

(A)

no-slip point

(B)

no-stick point

(C)

maximum slip point

(D)

maximum stick point

Explanation

GATE→2023→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q16

NAT[2 Marks]

Strain hardening behavior of an alloy is given by $\sigma = 1100\text{ }\epsilon^{0.3}$, where $\sigma$ and $\epsilon$ are true stress and true strain, respectively. The alloy is cold drawn to an unknown amount of strain, followed by tensile testing. If the tensile test showed $10\%$ reduction in area at maximum load, then the unknown amount of strain from prior cold work is ___ (round off to 2 decimal places).

Explanation

GATE→2022→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q17

MCQ[1 Mark]

Neutral point in rolling is defined as the point along the surface of contact between the roll and the sheet, where the surface velocity of the roll is (A) zero (B) half the velocity of the sheet (C) twice the velocity of the sheet (D) equal to the velocity of the sheet

(A)

zero

(B)

half the velocity of the sheet

(C)

twice the velocity of the sheet

(D)

equal to the velocity of the sheet

Explanation

GATE→2022→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q18

MCQ[1 Mark]

Match the processes (Column I) with the corresponding defects (Column II).\nColumn I: (P) Extrusion (Q) Deep drawing (R) Forging (S) Rolling\nColumn II: (1) Earing (2) Cold shut (3) Edge cracking (4) Fir-tree cracking (A) P-1, Q-4, R-2, S-3 (B) P-2, Q-1, R-4, S-3 (C) P-4, Q-1, R-3, S-2 (D) P-4, Q-1, R-2, S-3

(A)

P-1, Q-4, R-2, S-3

(B)

P-2, Q-1, R-4, S-3

(C)

P-4, Q-1, R-3, S-2

(D)

P-4, Q-1, R-2, S-3

Explanation

GATE→2022→Manufacturing Processes→Metal Working (Hot, Warm, Cold)

Q19

NAT[2 Marks]

A cylindrical specimen of an Al alloy with diameter of $30\text{ mm}$ is cold extruded to a diameter of $20\text{ mm}$. If the flow behavior of the alloy is expressed by the equation, $\sigma = 350\text{ }\epsilon^{0.3}\text{ MPa}$, the ideal plastic work of deformation per unit volume is ___ $\times 10^6\text{ J}$ (answer rounded off to the nearest integer).

Explanation

Metal Joining and Powder Metallurgy

12 Questions

GATE→2026→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q20

MCQ[1 Mark]

Which one of the following fusion welding techniques results in least Heat-Affected Zone (HAZ)? (A) Submerged Arc Welding (SAW) (B) Tungsten Inert Gas Welding (TIG) (C) Electron Beam Welding (EBW) (D) Oxy-Acetylene Welding (OAW)

(A)

Submerged Arc Welding (SAW)

(B)

Tungsten Inert Gas Welding (TIG)

(C)

Electron Beam Welding (EBW)

(D)

Oxy-Acetylene Welding (OAW)

Explanation

GATE→2026→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q21

NAT[2 Marks]

Iron powder is compacted at room temperature to 75% of its theoretical density. The as-pressed iron compact is sintered in inert-gas atmosphere at $1200^\circ\text{C}$ to 90% of its theoretical density. Assuming isotropic shrinkage, the linear shrinkage (in percent) undergone by the iron compact during sintering (rounded off to one decimal place) is ___ %.

Explanation

GATE→2025→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q22

MSQ[2 Marks]

Which of the following statements is/are CORRECT with respect to fusion welding and solid-state welding of metals and alloys? (A) Thermomechanically affected zone is found in the fusion welding of pure metals. (B) Partially melted zone is NOT found in the fusion welding of pure metal. (C) Diffusion bonding is one type of solid-state welding process. (D) Partially melted zone is found in the fusion welding of alloys with a large freezing range.

(A)

Thermomechanically affected zone is found in the fusion welding of pure metals.

(B)

Partially melted zone is NOT found in the fusion welding of pure metal.

(C)

Diffusion bonding is one type of solid-state welding process.

(D)

Partially melted zone is found in the fusion welding of alloys with a large freezing range.

Explanation

GATE→2025→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q23

MSQ[2 Marks]

Which of the following welding processes does NOT / do NOT utilize consumable electrode? (A) Plasma arc welding (B) Gas metal arc welding (C) Shielded metal arc welding (D) Electron beam welding

(A)

Plasma arc welding

(B)

Gas metal arc welding

(C)

Shielded metal arc welding

(D)

Electron beam welding

Explanation

GATE→2024→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q24

MCQ[1 Mark]

Which one of the following is NOT involved in the sintering of a green compact of ceramic powders? Assume that sintering is performed without external pressure. (A) Surface diffusion (B) Dynamic recrystallization (C) Lattice diffusion (D) Grain boundary diffusion

(A)

Surface diffusion

(B)

Dynamic recrystallization

(C)

Lattice diffusion

(D)

Grain boundary diffusion

Explanation

GATE→2024→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q25

MSQ[2 Marks]

Which of the following statements is/are correct for welding processes? (A) In TIG welding, the filler material (if used) generally has a melting point comparable to or higher than/suitable for the base metal, or tungsten is non-consumable. (B) In TIG welding, tungsten is the filler material. (C) Friction welding is a solid-state joining process. (D) The reaction $C_2H_2 + 5/2 O_2 \rightarrow 2CO_2 + H_2O + Heat$ is associated with thermit welding.

(A)

Option A

(B)

Option B

(C)

Option C

(D)

Option D

Explanation

GATE→2024→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q26

NAT[2 Marks]

During arc welding, the actual heat input is $200\text{ J mm}^{-3}$ and the current and voltage are $200\text{ A}$ and $20\text{ V}$, respectively. For a weld cross-sectional area of $2\text{ mm}^2$ and heat transfer efficiency of $0.9$, the velocity of welding is ___ $\text{mm s}^{-1}$ (Round off to the nearest integer).

Explanation

GATE→2023→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q27

MCQ[2 Marks]

Match the welding techniques in Column I with the most appropriate applications in Column II.\nColumn I: (P) Submerged arc welding (Q) Electroslag welding (R) Shielded metal arc welding (S) Resistance spot welding\nColumn II: (1) Thick sections (2) Surfacing and repair (3) Thin sheets (4) Flat position (A) P-4, Q-1, R-2, S-3 (B) P-3, Q-2, R-1, S-4 (C) P-1, Q-3, R-4, S-2 (D) P-2, Q-4, R-3, S-1

(A)

P-4, Q-1, R-2, S-3

(B)

P-3, Q-2, R-1, S-4

(C)

P-1, Q-3, R-4, S-2

(D)

P-2, Q-4, R-3, S-1

Explanation

GATE→2023→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q28

NAT[2 Marks]

During arc welding, the actual heat input is $200\text{ J mm}^{-3}$ and the current and voltage are $200\text{ A}$ and $20\text{ V}$, respectively. For a weld cross-sectional area of $2\text{ mm}^2$ and heat transfer efficiency of $0.9$, the velocity of welding is ___ $\text{mm s}^{-1}$ (Round off to the nearest integer).

Explanation

GATE→2022→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q29

MCQ[1 Mark]

Which one of the following figures illustrates a lap joint with fillet weld?

(A)

I

(B)

II

(C)

III

(D)

IV

Explanation

GATE→2022→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q30

MSQ[2 Marks]

Which of the following parameter(s) influence(s) the melting rate of the consumable wire in a gas metal arc welding process? (A) Stick-out length (B) Welding speed (C) Welding current (D) Diameter of the consumable wire

(A)

Stick-out length

(B)

Welding speed

(C)

Welding current

(D)

Diameter of the consumable wire

Explanation

GATE→2022→Manufacturing Processes→Metal Joining and Powder Metallurgy

Q31

NAT[2 Marks]

Steel plates are welded autogenously using Gas Tungsten Arc welding with an arc heat transfer efficiency of $0.65$. The first weld is made using a welding current of $200\text{ A}$ at an arc voltage of $18\text{ V}$ with a welding speed of $0.002\text{ m}\cdot\text{s}^{-1}$. The second weld is made at a welding speed of $0.0022\text{ m}\cdot\text{s}^{-1}$ with the same arc voltage. If both the welds have identical heat input, the welding current of the second weld is ___ $\text{A}$ (round off to the nearest integer).

Explanation

Non-destructive Testing (NDT)

5 Questions

GATE→2026→Manufacturing Processes→Non-destructive Testing (NDT)

Q32

MCQ[2 Marks]

Match the descriptions listed in Column I with the corresponding non-destructive testing methods listed in Column II:\nColumn I: (P) Internal flaws in railroad wheel (Q) In-service monitoring of crack (R) Inclusion in mild steel (S) Surface crack in Al-based alloy\nColumn II: (1) Ultrasonic (2) Radiography (3) Dye Penetrant (4) Acoustic Emission (A) P-1, Q-4, R-2, S-3 (B) P-3, Q-2, R-4, S-1 (C) P-3, Q-2, R-1, S-4 (D) P-1, Q-3, R-4, S-2

(A)

P-1, Q-4, R-2, S-3

(B)

P-3, Q-2, R-4, S-1

(C)

P-3, Q-2, R-1, S-4

(D)

P-1, Q-3, R-4, S-2

Explanation

GATE→2025→Manufacturing Processes→Non-destructive Testing (NDT)

Q33

MSQ[1 Mark]

Which of the following techniques can be used to detect an internal defect in a metal casting? (A) Ultrasonic inspection (B) Liquid (or dye) penetrant inspection (C) Gamma-ray radiography (D) X-ray radiography

(A)

Ultrasonic inspection

(B)

Liquid (or dye) penetrant inspection

(C)

Gamma-ray radiography

(D)

X-ray radiography

Explanation

GATE→2024→Manufacturing Processes→Non-destructive Testing (NDT)

Q34

MSQ[2 Marks]

Which of the following statements is/are correct for non-destructive testing? (A) Liquid dye penetration technique can be utilized for detecting surface cracks. (B) In radiographic examination, internal cracks cannot be detected. (C) Eddy current-based techniques can be used for detecting sub-surface defects in pure alumina at room temperature. (D) Ultrasonic inspection is unsuitable for inspecting sub-surface defects in high damping capacity material (e.g., cast iron).

(A)

Liquid dye penetration technique can be utilized for detecting surface cracks.

(B)

In radiographic examination, internal cracks cannot be detected.

(C)

Eddy current-based techniques can be used for detecting sub-surface defects in pure alumina at room temperature.

(D)

Ultrasonic inspection is unsuitable for inspecting sub-surface defects in high damping capacity material (e.g., cast iron).

Explanation

GATE→2023→Manufacturing Processes→Non-destructive Testing (NDT)

Q35

MSQ[1 Mark]

The non-destructive testing technique(s) for detecting internal defects in a steel component is/are (A) X-ray tomography (B) Ultrasonic technique (C) Gamma radiography (D) Dye penetrant technique

(A)

X-ray tomography

(B)

Ultrasonic technique

(C)

Gamma radiography

(D)

Dye penetrant technique

Explanation

GATE→2022→Manufacturing Processes→Non-destructive Testing (NDT)

Q36

MCQ[1 Mark]

Which one of the following Non Destructive Testing (NDT) techniques CANNOT be used to identify volume defects in the interior of a casting? (A) Ultrasonic testing (B) X-ray computed tomography (C) Dye-penetrant testing (D) Gamma ray radiography

(A)

Ultrasonic testing

(B)

X-ray computed tomography

(C)

Dye-penetrant testing

(D)

Gamma ray radiography

Explanation