Introduction:
Concept of Manufacturing process, its importance. Classification of Manufacturing processes. Introduction to Casting process & steps involved. Varieties of components produced by casting process. Advantages & Limitations of casting process.
Patterns:
Definition, functions, Materials used for pattern, various pattern allowances and their importance. Classification of patterns. Binder: Definition, Types of binder used in molding sand.
Additives:
Need, Types of additives used. Types of base sand, requirement of base sand. Molding sand mixture ingredients (base sand, binder & additives) for different sand mixtures. Method used for sand molding, such as Green sand, dry sand and skin dried moulds.
Cores:
Definition, Need, Types. Method of making cores, Binders used, core sand molding.
Gates & Risers. Principle and types.
Fettling and cleaning of castings. Basic steps, Casting defects, Causes, features and remedies.
Special Moulding Process & Furnaces:
Moulding Machines : Jolt type, Squeeze type, Jolt & Squeeze type and Sand slinger.
Process: Study of important molding processes, No bake moulds, Flasklessmoulds, Sweep mould, CO2 mould, Shell mould, Investment mould.
Metal moulds: Gravity die-casting, Pressure die casting, Centrifugal casting, Squeeze Casting, Slush casting, and Thixocasting processes.
Furnaces: Constructional features & working principle of coke fired, oil fired and Gas fired pit furnace, Resistance furnace, Electric Arc Furnace, Cupola furnace.
Welding Process: Definition, Principles, Classification, Application, Advantages & limitations of welding.
Arc Welding: Principle, Metal Arc welding (MAW), Flux Shielded Metal Arc Welding (FSMAW).
Gas Welding: Principle, Oxy – Acetylene welding, Chemical Reaction in Gas welding, Flame characteristics. Gas torch construction & working. Forward and backward welding. Inert Gas Welding (TIG & MIG) Submerged Arc Welding (SAW) and Atomic Hydrogen Welding processes. (AHW)
Resistance welding: Principles, Seam welding, Butt welding, Spot welding and projection welding. Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding.
Structure of welds, Formation of different zones during welding. Heat affected zone (HAZ). Parameters affecting HAZ. Effect of carbon content on structure and properties of steel. Shrinkage in welds & Residual stresses. Concept of electrodes, Filler rod and fluxes. Welding defects – Detection causes & remedy.
Soldering, Brazing:
Parameters involved & Mechanism. Different Types of Soldering & Brazing Methods.
Inspection Methods:
Methods used for Inspection of casting and welding. Visual, Magnetic particle, Fluorescent particle, Ultrasonic, Radiography, Eddy current, Holography methods of Inspection.