Introduction & basic materials used in foundry:
Introduction:
Definition, Classification of manufacturing processes. Metals cast in the foundry-classification, factors that determine the selection of a casting alloy.
Introduction to casting process & steps involved:
Patterns:
Definition, classification, materials used for pattern, various pattern allowances and their importance.
Sand moulding:
Types of base sand, requirement of base sand. Binder, Additives definition, need and types; preparation of sand moulds. Melding machines- Jolt type, squeeze type and Sand slinger.
Study of important moulding process:
Green sand, core sand, dry sand, sweep mould, CO2mould, shell mould, investment mould, plaster mould, cement bonded mould.
Cores:
Definition, need, types. Method of making cores,
Concept of gating
(top, bottom, parting line, horn gate) and risers (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 moulds:
Gravity die casting, pressure die casting, centrifugal casting, squeeze casting, slush casting, thixocasting, and continuous casting processes.
SOLIDIFICATION &NON-FERROUS FOUNDRY PRACTICE
Solidification:
Definition, nucleation, solidification variables. Directional solidification-need and methods. Degasification in 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:
Aluminium castings - advantages, limitations, melting of Aluminium using liftout type crucible furnace. Hardeners used, drossing, gas absorption, fluxing and flushing, grain refining, pouring temperature. Stir casting 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 Projection welding. Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding.
METALLURGICAL ASPECTS IN WELDING, SOLDERING, AND BRAZING
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, gas welding:
Soldering, Brazing, Gas Welding: Principle, oxy-Acetylene welding, oxyhydrogen welding, 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.
Course Outcomes:
At the end of the course, the student will be able to:
CO1: Describe the casting process and prepare different types of cast products.
CO2: Acquire knowledge on Pattern, Core, Gating, Riser system and to use Jolt, Squeeze, Sand Slinger moulding machines.
CO3: Compare the Gas fired pit, Resistance, Coreless, Electrical and Cupola Metal Furnaces.
CO4: Compare the Gravity, Pressure die, Centrifugal, Squeeze, slush and Continuous Metal mold castings.
CO5: Understand the Solidification process and Casting of Non-Ferrous Metals.
CO6: Describe the Metal Arc, TIG, MIG, Submerged and Atomic Hydrogen Welding processes etc. used in manufacturing.
CO7: Describe methods for the quality assurance of components made of casting and joining process
Question paper pattern:
• The question paper will have ten full questions carrying equal marks.
• Each full question will be for 20 marks.
• There will be two full questions (with a maximum of four sub- questions) from each module.
• Each full question will have sub- question covering all the topics under a module.
• The students will have to answer five full questions, selecting one full question from each module.
Textbook/s
1 Principles of metal casting Rechard W. Heine, Carl R. Loper Jr., Philip C. Rosenthal Tata McGraw Hill Education Private Limited 1976
2 Manufacturing Process-I Dr.K.Radhakrishna Sapna Book House, 5th Revised Edition 2009.
3 Manufacturing Technology- Foundry, Forming and Welding P.N.Rao Tata McGraw Hill 3rd Ed., 2003.
Reference Books
4 Process and Materials of Manufacturing Roy A Lindberg Pearson Edu 4th Ed. 2006
5 Manufacturing Technology SeropeKalpakjianSteu en. R Sechmid Pearson Education Asia 5th Ed. 2006