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1. MODULE SUMMARY
In this module, students learn advanced casting and joining processes and technologies. The principles,
parameters and application areas of traditional and advanced moulding / casting processes will be
discussed. Students will learn casting design, gating system design, mould filling simulation through
process modelling using ProCast.
Fusion and non-fusion welding, brazing, soldering and adhesive bonding techniques and their adaptability
to advanced engineering materials will be elucidated. Welding metallurgy, physics of arc welding,
welding design considerations, weldability and welding defects will be discussed. Students will be trained
on welding process modelling and simulation using SYSWELD.
A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment
and overall 40% marks are required for a pass
Special Features
80% attendance in theory and 80% attendance in laboratory are required.
It is likely that considerable time will be spent in School facilities outside of normal timetabled class time.
Courses for which this module is mandatory
None
Indicative Content
Class Room Lectures
Casting Technology
3. Principles Gating and Risering : Gating system, Functions of gating system, Design of gating
system, Pressurised and un pressurised gating system, Feeding aids like chills, Insulators and
Exothermic, Filters Risers, function, types, riser and directional solidification, Riser design methods
– Caine’s method, modulus method, NRL method, feeding distances.
4. Melting and Pouring of Castings: Furnaces, melting practice, ladle treatments- refining,
degasification, grain refinement, desulphurization, liquid metal cleanliness
5. Casting defects and Design of Castings : Casting defects and remedies, Design considerations in
casting- Design for economical molding, Design for eliminating defects, Non-destructive
examination- Dye penetrant test, Magnetic particle testing, Ultrasonic inspections, X- radiography,
Industrial computed tomography, Eddy current inspection
6. Heat Treatment Processes : Ferrous and non ferrous alloy heat treatment - techniques, phase
diagram, TTT diagram, process parameters and applications
Joining Technology
1. Solid State Welding Processes: Classification, Working principles of joining processes, Principle of
operation, equipment, process parameters, capability, application examples: Cold welding: Pressure,
ultrasonic, Explosive welding, Friction welding, Diffusion welding (diffusion bonding), Hot forge
welding. Resistance Welding – Spot welding, Seam welding, Projection welding, and High frequency
butt welding, and Flash butt welding.
5. Adhesive Bonding – Principle and steps in adhesive bonding, type of adhesives and application
examples.
6. Welding Physics, Instrumentation and Automation – Effect of polarity, arc physics, power
sources (self controlled arc and self adjusted arc), Metal transfer modes and heat transfer aspects of
fusion welding. Arc welding equipments, Automation in welding arc sensing & vision, seam
tracking, welding robots.
Laboratory Practice
Modelling and Simulation Exercises using Process Modelling Software: Modelling and simulation of
casting process and optimisation of process parameters using ProCast
Modelling and Simulation Exercises using Process Modelling Software: Modelling and simulation of
welding processes using SYSWELD
30 hours
3. Application Orientation and Problem Solving [45% of module time]
a. Reading
b. Research
c. Written Examination
d. Assignment Solving and Documentation
54 hours
Part-A
- Presentations
- Field work
The marks scored by the student will be scale down to 50% weight.
Part –B
Students are required to submit word processed assignment report on formally announced last day of the
module. Assignment tests students’ problem solving skills based on taught concepts. The assignment is
assessed for 100 marks but scored marks is scaled down to 50%
Assessment
Learning Outcomes 1 2 3 4 5
Part A X X X X
Part B X X X X X
Both written examination scripts and assignment reports will be double marked/valued
Re-assessment
A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment
are required for a pass in the module.
A student failing in any one of the components or both is considered as FAIL in the module. A failed
student is required to retake the module at the next opportunity. A maximum of 3 attempts including the
original are allowed.
Date of Last Amendment
May -2009
3. MODULE RESOURCES
Essential Reading
1. Module Notes
Recommended Reading
Books
1. Paul Degarmo E, Black Jt, Materials and Processes In Manufacturing, 9th edition, JWS, 2004
2. P N Rao, Manufacturing Technology, 2nd edition, TMH, 2003
3. ASM Metals hand book, Volume 15, Casting, 1998
4. ASM Metals Handbook, Volume 17 Non Destructive Evaluation and Quality Control,
1998
5. Peter Beeley, Foundry Technology, 2nd edition ,Butterworth-Heinemann, 2001,
6. ASM Metals Handbook, Volume 04 Heat Treatment,1998
Journals
1. Journal of Manufacturing Processes, Society of Manufacturing Engineers (SME), ELSEVIER
2. International Journal of Metal Casting, American Foundry Society
3. Indian Foundry Journal, Institute of Indian Foundrymen
4. International Welding Journal, American Welding Society
5. Indian Welding Journal, Indian Institute of Welding
6. International Journal for the Joining of Materials, Elsevier
7. Acta Materialia, Pergamon Press
Magazines
Internet Sites
Laboratory
Hardware: PCs
4. MODULE ORGANISATION
Module Leader
Room G-02
E-mail gnanamurthy@msrsas.org