Manufacturing Processes - Casting And Joining

COURSE LAYOUT

Week 1:Casting: Introduction; Classification of casting processes; Advantages and drawbacks; Historical background; Foundry practice on video; Casting of BMW car wheels on video; Patterns; Shrinkage and Mechanical allowances; Moulds; Gating system; Properties of moulding sand; Gating design; Vertical gating: aspiration effect; Optimum riser design; Week 2:Solidification of pure metal and alloy; Solidification time: Chvorinov’s rule; Categories of metal casting processes; Steps in sand casting; Mould properties and characteristics; Shell moulding; Investment casting: Process characteristics, Process to show through video, Advantages and disadvantages; Multiple mould casting, Steps in permanent mould casting; Die casting: Hot and Cold Chamber die casting; Centrifugal casting; Continuous casting; Cost analysis of casting; Casting defects; Product design considerations in casting; Week 3:Joining Processes: Preamble, classification of joining processes; Welding: advantages and limitations; Joints in welding; Fusion welding processes; Heat density; Comparison among welding processes; Features of a Fusion Welded Joint; Typical Fusion Welded Joints; Heat Affected Zone; Solidification of Weld; Solid-State (Phase) Welding: Forge welding, butt welding, friction welding, explosion welding, resistance welding; Week 4:Ultrasonic welding: process characteristics and applications; Electron beam welding; Laser beam welding; Plasma arc welding; Arc welding: characteristics; Consumable and non-consumable electrodes; Power source; Shielded metal arc welding: Principles and applications; Gas metal arc welding; Gas Tungsten Arc Welding; Tungsten-Inert Gas Welding (TIG); Submerged Arc Welding; Gas Welding: Principles, types of flames; Brazing and Soldering: Process capabilities; Welding defects;