Solidification of Casting:
Concept of solidification of metals, Homogenous and heterogeneous nucleation, Growth mechanism, Solidification of pure metals and alloys, Mechanism of columnar and dendritic growth, Coring or Segregation, Solidification time and Chvorinov's rule, Concept of progressive and directional solidifications.
Principles of Casting and Risering:
Purpose of the gating system, Components of the gating System and its functions, Design of the gating System, types of gates, Gating ratio and its functions, Definition and functions of the riser, Types of risers and their application, Design of the riser - its shape, Size and location. Use of insulating material and exothermic compounds in risers.
Design of Casting:
Factors to be considered in casting design, Design consideration in pattern making, moulding techniques and core making and assembly, Cooling stresses and hot spots in casting and modification in casting geometry to overcome them.
Casting Quality Control:
Casting defects and factors responsible for them, Different inspection and testing methods to evaluate the casting, Quality control activities in a foundry, Salvaging methods of defective casting.
Furnace Technology:
Study of various furnaces used in foundry, construction and operation of crucible and hearth furnace, Resistance, Arc and Induction furnaces - their construction, Operation and application. Heat treatment furnaces and drying ovens used in foundry.
Gray Cast - Iron Foundry Practice:
Chemical Composition and structure of gray cast iron, Moulding, gating and risering techniques, melting of gray cast iron in Cupola and induction furnace, Inoculation of gray cast iron, Application of gray cast iron castings.
Ductile Cast Iron:
Chemical composition and structure of ductile cast iron, Melting and spherodization treatment, Inoculation of ductile iron, Properties and application of ductile iron casting.
Steel Casting Practice:
Common steel casting, their composition, structure and properties. Melting and refining of steel, Gating and risering system of steel castings cleaning of steel castings.
Aluminium Foundry Practice:
Composition, properties and application of common aluminium alloy casting, Melting and casting of AI-alloys, Gating and risering system of AIalloy casting.
Copper alloy Foundry Practice:
General characteristics of common cast copper alloys, Melting and casting of copper alloys, Gating and risering of cu-alloy castings.
Foundry Mechanization and Modernization:
Introduction to modernization, Mechanization of foundry and its advantages, Mechanization of sand plant, moulding and core making mechanization in melting, pouring and shake out units, Material handling equipments and conveyor systems, Brief sketches and description of layouts of job, Captive and mechanized foundries.