Introduction: Introduction to casting process and the steps involved; Components produced by casting process, Comparison of metal casting with metal joining, Advantages and limitations of casting process; Overview of the industry
Solidification of metals: Introduction, freezing of pure metals; Nucleation and Growth, shrinkage, solidification of alloys; dendritic growth and segregation; shrinkage in alloys; Alloys freezing in two stages; solidification process in eutectic and non-eutectic alloys; Properties related to the solidification mechanism – Fluidity, Hot tearing or hot cracking, Evolution of dissolved gases, Effect of inoculation; Solidification of actual castings; Progressive and directional solidification; Centerline feeding resistance; Rate of solidification; Chvorinov's Rule.
Foundry Furnaces: Types of foundry furnaces – crucible, pot and rever beratory furnace; Cupola; Electric arc furnace, Induction furnace.
Patterns and pattern making: Definition, functions; Materials used for patterns, pattern allowances and their significance; Classification of patterns; BIS colour coding of patterns, Core boxes.
Sand molding: Types and requirements of base sand; Binders and additives used – types and properties; Molding tools and equipment – hand mold ing tools, molding machines – Jolt type, squeeze type, Jolt and Squeeze type and Sand slinger; Cores – types, core prints, core venting and baking, core shifting and chaplets, method of making cores, binders used, core sand molding; Gating systems - principles and types of gates and risers, gating ratios and chills, riser location and design in actual casting; Molding processes – bench molding, floor molding, pit molding, stack molding, green sand molding, dry sand molding, loam molding, machine molding.
Special Molding Processes: Study of important molding processes, No bake molds, Flask less molds, Sweep mold, CO2 mold, Shell mold, Investment mold. Metal Molds: Gravity die casting, Pressure die casting, Centrifugal casting, Squeeze casting, Slush casting, Thixo-casting, Continuous casting.Non-metal molding, Plaster and Ceramic molding; Expandable pattern mold casting. Finishing processes: Fettling and cleaning of castings; removal of gates and risers, grinding. Non-Ferrous Foundry practice: Casting of Al-Si and Al-Mg alloys, Cu-base casting alloys.
Foundry Practices of Cast Irons, Steels, Inspection and Testing of Castings: Foundry practice for cast irons – gray iron, white cast iro n; Ductile iron, malleable iron, SG iron, Steel castings – steel melting in the foundry; Metallurgy of cast steel; Casting design considerations; Inspection and testing of castings: Defects in castings – types, causes and remedies; Inspection and nondestructive testing of castings. Modernization and mechanization of foundry; Material handling; Pollution control in foundry; Application of computers in casting process; Software available for casting process simulation.