INTRODUCTION & BASIC MATERIALS USED IN FOUNDRYIntroduction: Definition, Classification of manufacturing processes. Metals cast in the foundryclassification, factors that determine the selection of a casting alloy.Introduction to casting process & steps involved. Patterns: Definition, classification, materialsused for pattern, various pattern allowances and their importance.Sand molding: Types of base sand, requirement of base sand. Binder, Additives definition, needand types
Preparation of sand molds: Molding machines- Jolt type, squeeze type and Sand slinger. Studyof important molding process: Green sand, core sand, dry sand, sweep mold, CO2 mold, shellmold, investment mold, plaster mold, cement bonded mold.Cores: Definition, need, types.Method of making cores, concept of gating (top, bottom, parting line, horn gate) and risering(open, blind) Functions and types
MELTING & METAL MOLD CASTING METHODSMelting furnaces: Classification of furnaces, Gas fired pit furnace, Resistance furnace, Corelessinduction furnace, electric arc furnace, constructional features & working principle of cupolafurnace.
Casting using metal molds: Gravity die casting, pressure die casting, centrifugal casting,squeeze casting, slush casting, thixocasting, and continuous casting processes
SOLIDIFICATION & NON FERROUS FOUNDRY PRACTICESolidification: Definition, Nucleation, solidification variables, Directional solidification-needand methods. Degasification in liquid metals-Sources of gas, degasification methods.Fettling and cleaning of castings: Basic steps involved. Sand Casting defects- causes, featuresand remedies. Advantages & limitations of casting process
Nonferrous foundry practice: Aluminum castings - Advantages, limitations, melting ofaluminum using lift-out type crucible furnace. Hardeners used, drossing, gas absorption, fluxingand flushing, grain refining, pouring temperature. Stir casting set up, procedure, uses, advantagesand limitations.
WELDING PROCESSWelding process: Definition, Principles, Classification, Application, Advantages & limitationsof welding. Arc welding: Principle, Metal arc welding (MAW), Flux Shielded Metal ArcWelding (FSMAW), Inert Gas Welding (TIG & MIG) Submerged Arc Welding (SAW) andAtomic Hydrogen Welding (AHW).Special type of welding: Resistance welding principles, Seam welding, Butt welding, Spotwelding and Projection welding. Friction welding, Explosive welding, Thermit welding, Laserwelding and electron beam welding.
SOLDERING , BRAZING AND METALLURGICAL ASPECTS IN WELDINGStructure 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. Weldingdefects- Detection, causes & remedy.
Soldering, brazing, gas welding: Soldering, Brazing, Gas Welding: Principle, oxy-Acetylenewelding, oxy-hydrogen welding, air-acetylene welding, Gas cutting, powder cutting.
Inspection methods: Methods used for inspection of casting and welding. Visual, magneticparticle, fluorescent particle, ultrasonic. Radiography, eddy current, holography methods ofinspection.