Syllabus
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Course Code: MTIP-101 Course Name: Advanced Metal Casting |
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| MODULE NO / UNIT | COURSE SYLLABUS CONTENTS OF MODULE | NOTES |
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| 1 | Functional Requirement of Moulding Materials: Principal ingredients of moulding Sands; Different Types of Sands;
Clays, Different types of Clay structures, Moisture; Theories of Clay sand bonding, Sand system equipment, Flow of
sand in a mechanized foundry, The Requirement of core sands,. Specification and testing of Moulding Sands Grain Size, Grain Shape, Clay content, Moisture Content, Bulk Density and Specific Surface Area, Acid Demand Value (ADV), Fines Content, Sintering Temperature, Mould hardness, Permeability, Strength, Deformation & toughness, Compactability, Mouldability, High Temperature Characteristics. |
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| 2 | Solidifications of Metals, Nucleation, free energy concept, critical radius of nucleus, Distribution coefficient and
Constitutional Undercooling, Solidification in Pure Metals and Alloys, Directional Solidification, Casting Characteristics
related to Solidification; Fluidity, Dendritic Growth, Dendrite coherency, Segregation, Inverse Segregation, Hot tearing,
Hipping, Solidification under pressure. Heat Transfer during casting process: Resistance to Heat Transfer, Centerline Feeding Resistance, Rate of solidification, Solidification of Large casting in an insulating mould, Solidification with predominant interface resistance, Solidification with constant casting surface temperature, Solidification with predominant resistance in mould and solidified Metal, Solidification Time and Chvorinov rule, Numerical Exercises |
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| 3 | Gating System Design: Gating system defined, Types of Gating Systems, Types of Gates, Elements of Gating System,
Gating System design, Factors involved in Gating design, Pouring time, Choke Area, Sprue design, Gating Ratio, Sprue
runner gate ratio, Elimination of Slag and Dross, Filtration, Numerical exercises. Riser Design: Need for riser, Basic requirements of an effective feeding system for a casting, Feeding Efficiency, Types of Risers, Effective feeding distances for simple and complex shapes. Use of chills, Directional solidification, Stresses in castings, Metal Mould reactions, Claine’s Method, Modulus Method, Naval Research Laboratory (NRL) Method, Pouring rate and Temperature, Padding, Use of exothermic materials, Chills, Feeding Aids, Numerical exercises. |
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| 4 | Special casting Processes: Shell Moulding, Investment Casting, Permanent Mould Casting, Diecasting, Centrifugal
casting. Inspection and testing of casting: Visual, Optical, Dimensional inspection, Laser Scanning, White light scanning, Radiographic Inspection, ultrasonic testing, Magnetic Particle Testing, dye penetration, Casting Defects; Classification, Causes and remedies. |
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