15ME35A Metal Casting and Welding syllabus for ME

INTRODUCTION & BASIC MATERIALS USED IN FOUNDRY

Introduction:
Definition, Classification of manufacturing processes. Metals cast in the foundry-classification, factors thatdetermine the selection of a casting alloy.Introduction to casting process & steps involved. Patterns: Definition, classification, materials used for pattern, variouspattern allowances and their importance.
Sand molding:
Types of base sand, requirement of base sand. Binder, Additives definition, need and types
Preparation of sand molds:
Molding machines- Jolt type, squeeze type and Sand slinger. Study of important moldingprocess: Green sand, core sand, dry sand, sweep mold, CO2 mold, shell mold, investment mold, plaster mold, cementbonded mold.
Cores:
Definition, need, types. Method of making cores, concept of gating (top, bottom, parting line, horngate) and risering (open, blind) Functions and types

MELTING & METAL MOLD CASTING METHODS

Melting furnaces:
Classification of furnaces, Gas fired pit furnace, Resistance furnace, Coreless induction furnace,electric arc furnace, constructional features & working principle of cupola furnace.
Casting using metal molds:
Gravity die casting, pressure die casting, centrifugal casting, squeeze casting, slush casting,thixocasting, and continuous casting processes

Solidification:
Definition, Nucleation, solidification variables, Directional solidification-need and methods. Degasificationin liquid metals-Sources of gas, degasification methods.
Fettling and cleaning of castings:
Basic steps involved. Sand Casting defects- causes, features and remedies. Advantages& limitations of casting process
Nonferrous foundry practice:
Aluminum castings - Advantages, limitations, melting of aluminum using lift-out typecrucible furnace. Hardeners used, drossing, gas absorption, fluxing and flushing, grain refining, pouring temperature. Stircasting set up, procedure, uses, advantages and limitations.

Welding process:
Definition, Principles, Classification, Application, Advantages & limitations of welding. Arc welding:Principle, Metal arc welding (MAW), Flux Shielded Metal Arc Welding (FSMAW), Inert Gas Welding (TIG & MIG)Submerged Arc Welding (SAW) and Atomic Hydrogen Welding (AHW).
Special type of welding:
Resistance welding principles, Seam welding, Butt welding, Spot welding and Projectionwelding. Friction welding, Explosive welding, Thermit welding, Laser welding and electron beam welding.

SOLDERING , BRAZING AND METALLURGICAL ASPECTS IN 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 ofelectrodes, filler rod and fluxes. Welding defects- Detection, causes & remedy.
Soldering, brazing, gas welding:
Soldering, Brazing, Gas Welding: Principle, oxy-Acetylene welding, oxy-hydrogenwelding, air-acetylene welding, Gas cutting, powder cutting.
Inspection methods:
Methods used for inspection of casting and welding. Visual, magnetic particle, fluorescent particle,ultrasonic.Radiography, eddy current, holography methods of inspection.