Introduction:Introduction to casting process and the steps involved; Components produced bycasting process, Comparison of metal casting with metal joining, Advantages and limitations ofcasting process; Overview of the industrySolidification of metals: Introduction, freezing of pure metals; Nucleation and Growth,shrinkage, solidification of alloys; dendritic growth and segregation; shrinkage in alloys; Alloysfreezing in two stages; solidification process in eutectic and non-eutectic alloys; Propertiesrelated to the solidification mechanism – Fluidity, Hot tearing or hot cracking, Evolution ofdissolved gases, Effect of inoculation; Solidification of actual castings; Progressive anddirectional solidification; Centerline feeding resistance; Rate of solidification; Chvorinov\'s Rule.
Foundry Furnaces: Types of foundry furnaces – crucible, pot and reverberatory furnace;Cupola; Electric arc furnace, Induction furnace.Patterns and pattern making: Definition, functions; Materials used for patterns, patternallowances and their significance; Classification of patterns; BIS colour coding of patterns, Coreboxes.
Sand molding: Types and requirements of base sand; Binders and additives used – types andproperties; Molding tools and equipment – hand molding tools, molding machines – Jolt type,squeeze type, Jolt and Squeeze type and Sand slinger; Cores – types, core prints, core ventingand baking, core shifting and chaplets, method of making cores, binders used, core sandmolding; Gating systems - principles and types of gates and risers, gating ratios and chills, riserlocation and design in actual casting; Molding processes – bench molding, floor molding, pitmolding, stack molding, green sand molding, dry sand molding, loam molding, machinemolding.
Study of important molding processes, No bake molds, Flask lessmolds, Sweep mold, CO2 mold, Shell mold, Investment mold. Metal Molds: Gravity die casting,Pressure die casting, Centrifugal casting, Squeeze casting, Slush casting, Thixo-casting,Continuous casting.Non-metal molding, Plaster and Ceramic molding; Expandable pattern moldcasting. Finishing processes: Fettling and cleaning of castings; removal of gates and risers,grinding. Non-Ferrous Foundry practice: Casting of Al-Si and Al-Mg alloys, Cu-base castingalloys.
Foundrypractice for cast irons – gray iron, white cast iron; Ductile iron, malleable iron, SG iron, Steelcastings – steel melting in the foundry; Metallurgy of cast steel; Casting design considerations;Inspection and testing of castings: Defects in castings – types, causes and remedies; Inspectionand non-destructive testing of castings. Modernization and mechanization of foundry; Materialhandling; Pollution control in foundry; Application of computers in casting process; Softwareavailable for casting process simulation.