BMS 405: PE-I: ADVANCED CASTING AND WELDING (3-1-0): Syllabus
Module-I
Casting processes: Classification, Metal mould casting processes, advanced casting processes,
investment casting, Rheocasting, mould and core making materials and their characteristics.
[04 Lectures]
Technology of Selected casting Processes: Clay bonded, synthetic resin bonded, inorganic material
bonded mould and core making, sand additives, mould coating, continuous casting process,
centrifugal casting process. [06 Lectures]
Module-II
Casting defects, inspection, diagnosis and rectification, mechanization and automation in foundries,
use of robots, casting design, near net shape casting, pollution control, energy and waste
management in foundries. [04 Lectures]
Physics of welding arc, characteristics of arc, modes of metal transfer, welding fluxes, electrode
coating, classification of electrode, characteristics of welding power source, pulsed and inverter
type power source, power source for resistance welding, weldability, weldability tests, Weldability
of cast iron, Plain carbon steel, Determination of preheating temperature, Stainless steel, use of
Scheffler’ s diagram. [10 Lectures]
Module-III
Heat flow in welding, significance, theory of heat flow, cooling rate determination, selection of
welding parameters based on heat flow analysis, residual stress and its measurement, types and
control of distortion. [08 Lectures]
Module-III
Analysis of fatigue of welded joint, fracture and toughness testing and its application on welded
joint, automated welded joint, microprocessor based of control resistance and arc welding, quality
assurance in welding, effects of welding fumes on environment. [08 Lectures]
TEXT BOOK(S):
1. Principle of Metal Casting- Heine, R.W. Loper ,C. Philip and C.R.Rosenthal, McGraw Hill.
2. Principle of Metal Casting- P.L.Jain,TMH
3. Manufacturing Technology- P.N.Rao,TMH
4. Welding Engineering and Technology- R.S. Parmar Khanna publisher
REFERENCE(S):
1. Metallurgy of Welding Technology-D. Seferian, Chapman & Hall
2. Welding and Welding Technology- R.Little, TMH.
1
, Module-I
Casting processes: Classification, Metal mould casting processes, advanced casting
processes, investment casting, Rheocasting, mould and core making materials and their
characteristics. Technology of Selected casting Processes: Clay bonded, synthetic resin
bonded, inorganic material bonded mould and core making, sand additives, mould coating,
continuous casting process, centrifugal casting process.
1. Introduction to Casting processes
Metal casting process begins by creating a mold, which is the ‘reverse’ shape of the part
we need. The mould is made from a refractory material, for example, sand. The metal is
heated in an oven until it melts, and the molten metal is poured into the mould cavity. The
liquid takes the shape of cavity, which is the shape of the part. It is cooled until it solidifies.
Finally, the solidified metal part is removed from the mould.
A large number of metal components in designs we use every day are made by casting.
The reasons for this include:
(a) Casting can produce very complex geometry parts with internal cavities and hollow
sections
(b) It can be used to make small (few hundred grams) to very large size parts (thousands of
kilograms)
(c) It is economical, with very little wastage: the extra metal in each casting is re-melted and
re-used
(d) Cast metal is isotropic – it has the same physical/mechanical properties along any
direction
Common examples: door handles, locks, the outer casing or housing for motors, pumps,
etc., wheels of many cars. Casting is also heavily used in the toy industry to make parts,
e.g. toy cars, planes, and so on. Typical metal cast parts are shown in Fig.1
2
, Fig.1: Typical metal cast parts
Table 1 summarizes different types of castings, their advantages, disadvantages and
examples.
Table 1
3
, 1.1 Sand Casting: Sand casting uses natural or synthetic sand (lake sand) which is mostly
refractory material called silica (SiO2). The sand grains must be small enough so that it can
be packed densely; however, the grains must be large enough to allow gasses formed
during the metal pouring to escape through the pores. Larger sized molds use green sand
(mixture of sand, clay and some water). Sand can be re-used, and excess metal poured is
cut-off and re-used also.
Typical sand molds have the following parts (Fig 2):
• The mold is made of two parts, the top half is called the cope, and bottom part is the
drag.
• The liquid flows into the gap between the two parts, called the mold cavity. The
geometry of the cavity is created by the use of a wooden shape, called the pattern. The
shape of the patterns is (almost) identical to the shape of the part we need to make.
• A funnel shaped cavity; the top of the funnel is the pouring cup; the pipe-shaped neck
of the funnel is the sprue– the liquid metal is poured into the pouring cup, and flows
down the sprue.
• The runners are the horizontal hollow channels that connect the bottom of the sprue
to the mould cavity. The region where any runner joins with the cavity is called the gate.
Fig 2: Schematic representation of a typical sand mould cross-section
Some extra cavities are made connecting to the top surface of the mold. Excess metal
poured into the mould flows into these cavities, called risers. They act as reservoirs; as
4
Module-I
Casting processes: Classification, Metal mould casting processes, advanced casting processes,
investment casting, Rheocasting, mould and core making materials and their characteristics.
[04 Lectures]
Technology of Selected casting Processes: Clay bonded, synthetic resin bonded, inorganic material
bonded mould and core making, sand additives, mould coating, continuous casting process,
centrifugal casting process. [06 Lectures]
Module-II
Casting defects, inspection, diagnosis and rectification, mechanization and automation in foundries,
use of robots, casting design, near net shape casting, pollution control, energy and waste
management in foundries. [04 Lectures]
Physics of welding arc, characteristics of arc, modes of metal transfer, welding fluxes, electrode
coating, classification of electrode, characteristics of welding power source, pulsed and inverter
type power source, power source for resistance welding, weldability, weldability tests, Weldability
of cast iron, Plain carbon steel, Determination of preheating temperature, Stainless steel, use of
Scheffler’ s diagram. [10 Lectures]
Module-III
Heat flow in welding, significance, theory of heat flow, cooling rate determination, selection of
welding parameters based on heat flow analysis, residual stress and its measurement, types and
control of distortion. [08 Lectures]
Module-III
Analysis of fatigue of welded joint, fracture and toughness testing and its application on welded
joint, automated welded joint, microprocessor based of control resistance and arc welding, quality
assurance in welding, effects of welding fumes on environment. [08 Lectures]
TEXT BOOK(S):
1. Principle of Metal Casting- Heine, R.W. Loper ,C. Philip and C.R.Rosenthal, McGraw Hill.
2. Principle of Metal Casting- P.L.Jain,TMH
3. Manufacturing Technology- P.N.Rao,TMH
4. Welding Engineering and Technology- R.S. Parmar Khanna publisher
REFERENCE(S):
1. Metallurgy of Welding Technology-D. Seferian, Chapman & Hall
2. Welding and Welding Technology- R.Little, TMH.
1
, Module-I
Casting processes: Classification, Metal mould casting processes, advanced casting
processes, investment casting, Rheocasting, mould and core making materials and their
characteristics. Technology of Selected casting Processes: Clay bonded, synthetic resin
bonded, inorganic material bonded mould and core making, sand additives, mould coating,
continuous casting process, centrifugal casting process.
1. Introduction to Casting processes
Metal casting process begins by creating a mold, which is the ‘reverse’ shape of the part
we need. The mould is made from a refractory material, for example, sand. The metal is
heated in an oven until it melts, and the molten metal is poured into the mould cavity. The
liquid takes the shape of cavity, which is the shape of the part. It is cooled until it solidifies.
Finally, the solidified metal part is removed from the mould.
A large number of metal components in designs we use every day are made by casting.
The reasons for this include:
(a) Casting can produce very complex geometry parts with internal cavities and hollow
sections
(b) It can be used to make small (few hundred grams) to very large size parts (thousands of
kilograms)
(c) It is economical, with very little wastage: the extra metal in each casting is re-melted and
re-used
(d) Cast metal is isotropic – it has the same physical/mechanical properties along any
direction
Common examples: door handles, locks, the outer casing or housing for motors, pumps,
etc., wheels of many cars. Casting is also heavily used in the toy industry to make parts,
e.g. toy cars, planes, and so on. Typical metal cast parts are shown in Fig.1
2
, Fig.1: Typical metal cast parts
Table 1 summarizes different types of castings, their advantages, disadvantages and
examples.
Table 1
3
, 1.1 Sand Casting: Sand casting uses natural or synthetic sand (lake sand) which is mostly
refractory material called silica (SiO2). The sand grains must be small enough so that it can
be packed densely; however, the grains must be large enough to allow gasses formed
during the metal pouring to escape through the pores. Larger sized molds use green sand
(mixture of sand, clay and some water). Sand can be re-used, and excess metal poured is
cut-off and re-used also.
Typical sand molds have the following parts (Fig 2):
• The mold is made of two parts, the top half is called the cope, and bottom part is the
drag.
• The liquid flows into the gap between the two parts, called the mold cavity. The
geometry of the cavity is created by the use of a wooden shape, called the pattern. The
shape of the patterns is (almost) identical to the shape of the part we need to make.
• A funnel shaped cavity; the top of the funnel is the pouring cup; the pipe-shaped neck
of the funnel is the sprue– the liquid metal is poured into the pouring cup, and flows
down the sprue.
• The runners are the horizontal hollow channels that connect the bottom of the sprue
to the mould cavity. The region where any runner joins with the cavity is called the gate.
Fig 2: Schematic representation of a typical sand mould cross-section
Some extra cavities are made connecting to the top surface of the mold. Excess metal
poured into the mould flows into these cavities, called risers. They act as reservoirs; as
4
