UPMSP Intermediate Metal Craft: Moulding in Ferrous Metals study guide
UPMSP Intermediate Metal Craft: Moulding in Ferrous Metals · Work through your exam, one topic at a time.
The Intermediate Metal Craft subject with the Moulding in Ferrous Metals module is a vocational qualification in the Uttar Pradesh senior secondary stream, examined by the Board of High School and Intermediate Education, Uttar Pradesh (UPMSP). It suits students who want a recognised school-level credential in foundry work rather than a purely academic science stream, and it is also useful for apprentices and workshop helpers who already handle sand, moulds and molten iron and want their skills documented. The UPMSP Intermediate Metal Craft: Moulding in Ferrous Metals study guide has 11 sections and about 3,561 words.
01Foundry safety, health and environment
This domain tests hazard recognition in a ferrous foundry, correct personal protective equipment, safe handling of molten metal and environmental control of sand, fume and waste. Molten iron at about 1300–1400 °C and steel at 1550–1650 °C causes deep burns; trapped moisture flashes to steam and ejects metal.
337 words, about 2 min02Moulding sands: composition, properties, testing and preparation
This domain examines what makes a moulding sand work: the silica base, clay binder, water and additives, the properties tested in the sand laboratory, and how mulling, tempering and reclamation change those properties. Silica sand (SiO2) provides refractoriness.
353 words, about 2 min03Patterns, pattern making and core boxes
This domain tests pattern allowances, pattern types, pattern materials and core-box design. The exam expects you to convert a finished casting dimension into a pattern dimension and to choose a pattern for a given shape and production quantity.
349 words, about 2 min04Moulding tools, equipment and hand moulding practice
This domain tests the hand tools of a moulder, the sequence of making a green-sand mould, and the reasons behind each step. Shovel, riddle, rammer, trowel, slick, lifter, swab, sprue pin, vent wire, gate cutter, draw spike, mallet, strike-off bar and bellows are hand tools.
343 words, about 2 min05Cores and core making
This domain tests how internal cavities are formed: core sands and binders, core-box types, core prints, venting, baking and support against buoyancy. Core sand is high-silica sand with a binder and little clay, because it needs high dry strength and permeability.
313 words, about 2 min06Gating and feeding (risering) systems
This domain tests how liquid metal is introduced and fed: gating elements, gating ratios, flow behaviour, riser design and the use of chills and exothermic materials. The system comprises a pouring basin, sprue, sprue well, runner, slag trap and ingates.
309 words, about 2 min07Melting and pouring of ferrous metals
This domain tests furnace choice, cupola operation, charge materials, melt treatment, pouring temperature and ladle practice for cast iron and steel. The cupola is a continuous shaft furnace for cast iron; charge materials are pig iron, scrap, coke and limestone.
313 words, about 2 min08Specialised moulding and casting processes
This domain tests when to use shell, investment, die, centrifugal, CO2, no-bake, lost-foam and permanent-mould processes, and their advantages and limits for ferrous castings. Shell moulding uses resin-coated sand on a heated metal pattern; it gives good finish and dimensional accuracy.
293 words, about 1 min09Casting defects, inspection and quality control
This domain tests defect identification, causes and remedies, and the inspection methods used to accept or reject castings. Blowholes: large, smooth, round gas cavities from sand moisture or low permeability.
315 words, about 2 min10Fettling, finishing and heat treatment of castings
This domain tests how castings are cleaned, how gates and risers are removed, and how heat treatment relieves stress and develops properties. Fettling removes gates, risers, flash, sand and cores.
312 words, about 2 min11Workshop calculation, applied science and measuring instruments
This domain tests numerical problems used in the foundry and the correct use of measuring instruments, together with basic applied science. Typical calculations include pattern allowances, gating ratios, riser modulus, charge mixing, sand moisture, volume and surface area, density and buoyancy, and cost.
324 words, about 2 min