CASTING PROCESS
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 patternallowances and their importance.Classification of patterns.
Sand Moulding : Types of base sand, requirement of base sand.Moulding sand mixture ingredients for different sand mixtures. Method used for sand moulding, such as Green sand, dry sand and skin dried moulds.
Binder: Definition, Types of binder used in moulding sand. Additives: Need, Types of additives used and their properties
Cores:
Definition, Need, Types. Method of making cores, Binders used,core sand moulding.
Concept of Gating & Risers.
Principle and types. Fettling and cleaning of castings.Basic steps, Casting defects, Causes,features and remedies.
MouldingMachines :
Jolt type, Squeeze type, Jolt & Squeeze type and Sandslinger.
Special moulding Process:
Study of important moulding processes, No bakemoulds, Flasklessmoulds, Sweep mould, CO2 mould, Shell mould,Investmentmould.
Metal moulds:
Gravity die-casting, Pressure die casting, Centrifugal casting,Squeeze Casting, Slush casting, Thixo-casting and Continuous CastingProcesses.
Melting Furnaces: Classification of furnaces. Constructional features &working principle of coke fired, oil fired and Gas fired pit furnace, Resistancefurnace, Coreless Induction furnace, Electric Arc Furnace, Cupola furnace
WELDING
Welding process:
Definition, Principles, Classification, Application,Advantages& limitations of welding.
Arc Welding:
Principle, Metal Arc welding (MAW), Flux Shielded MetalArc Welding (FSMAW), Inert Gas Welding (TIG & MIG) Submerged ArcWelding (SAW) and Atomic Hydrogen Welding processes. (AHW)
Gas Welding:
Principle, Oxy – Acetylene welding, Chemical Reaction inGas welding, Flame characteristics. Gas torch construction &working.Forward and backward welding
Special types of welding:
Resistance welding - principles, Seam welding,Butt welding, Spot welding and projection welding.Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding.
Inspection Methods –
Methods used for Inspection of casting and welding.Visual, Magnetic particle, Fluorescent particle, Ultrasonic, Radiography,Eddy current, Holography methods of Inspection