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 Gating and Risering:
Purpose of the gating system. Components of the gating System and its functions. Design of the gating System. Different 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 and Quality Control:
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 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 furnaces. Resistance, Arc and Induction furnaces-their construction. Operation and application. Heat treatment furnaces and drying ovens used in foundry.
Gray Cast - Iron Foundry Practice Malleable Cast Iron:
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. Chemical composition and structure of White-heart and black-heart malleable cast iron. Melting malleabilisation heat treatment and application of malleable cast iron.
Aluminium Foundry Practice:
Composition, properties and application of common aluminum alloy casting. Melting and casting of AI-alloys. Gating and risering of AI-alloy 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 shakeout units. Material handling equipments and conveyor systems. Brief sketches and description of layouts of job. Captive and mechanized foundries.