Unit 1

Melt processing techniques for ferrous and non-ferrous alloys such as stainless steels, nickel, titanium alloys. Vacuum melting equipment and practice.
Elementary aspects of pattern and mould design using CAD softwares. Resin-bonded mould and core making processes and machines. Special casting processes and their applications- low pressure die casting, investment casting, squeeze casting, thixo-forming. Illustrations of automotive and aerospace applications.

Unit 2

Gating and riser design – principles of fluid flow, governing equations, heat transfer applied to casting solidification, governing equations, boundary conditions for different casting methods, concept of directional solidification, gating and risers, application of simulation methods. Use of casting software in solving practical problems.

Unit 3

Casting defects and remedies. Inspection methods – visual, penetrant, magnetic, metallurgical, X-ray and Gamma ray radiography and Mechanization and Automation

Course Objectives

• To understand the advanced casting processes and equipment
• To facilitate usage of software packages in design and application for advanced casting methods
• To impart knowledge on the characterization and inspection methods for advanced casting

Course Outcomes

After successful completion of this course the student will be able to

• CO1: Design the basic tooling requirements for advanced casting process
• CO2: Select suitable process for manufacturing of casting components
• CO3: Analyse the liquid metal flow and solidification characteristics using casting software
• CO4: Identify the defects in castings and suggest improvements

CO – PO Mapping

Textbook(s)

• Jain P. L. – ‘Principles of Foundry Technology’ – Tata McGraw Hill, New Delhi – 2011 – 3^rd Edition

Reference(s)

• Heine R. W., Loper C. R., and Rosenthal P. C. – ‘Principles of Metal Castings’ – Tata McGraw Hill, New Delhi – 1997 – 2^nd Edition
• Beeley- P. R.- ‘Foundry Technology’ – Butterworth Scientific, London – 2001

Evaluation Pattern