CM4006 Advances in Welding and Casting Technology Syllabus:
CM4006 Advances in Welding and Casting Technology Syllabus – Anna University PG Syllabus Regulation 2021
COURSE OBJECTIVES:
To impart knowledge on Metallurgy of welding.
To be acquainted with Special welding processes.
To elaborate gating system design and metallurgy.
To provide knowledge on Special casting processes.
To familiarize the students with automation and environmental aspects of welding and casting.
UNIT I WELDING DESIGN
Introduction – Fusion zone – Heat flow in welding -Weld solidification –Weldability of steels – Cast iron – Stainless steels, aluminum, copper and titanium alloys – Pre and Post weld heat treatments – Weld joint design- residual stress – Testing of Welding joints -Weld defects – Case study on welding design.
UNIT II SPECIAL WELDING PROCESSES
Principles, Equipment, Types, Advantages and Limitations of High frequency induction welding, Diffusion bonding, Cold pressure welding, Friction welding, Explosive welding, Plasma arc welding, Ultrasonic welding, Electron beam welding and Laser beam welding.
UNIT III CASTING DESIGN
Introduction – Solidification shrinkage- – Pattern allowances- Design of gating System-Design of thin and unequal sections -Rapid solidification processing (RSP) – Melt spinning -Roll quenching – Vibratory solidification -Splat cooling – Thixoforming – Rheocasting – Single crystal growing Casting defects, inspection, diagnosis and rectification – Case study on casting design.
UNIT IV SPECIAL CASTING PROCESSES
Evaporative Pattern Casting Process and full mould process – Vaccum sealed moulding – vacuum casting – Magnetic Moulding – Squeeze Casting-types – Plaster mould casting – Ceramic mould casting Investment casting – Shell Moulding – Continuous casting – Electro slag casting.
UNIT V AUTOMATION AND ENVIRONMENTAL ASPECTS OF WELDING AND CASTING
Mechanization and automation in foundries: Sand Plant, Material Handling, Mould and Core Making Pollution control, energy and waste management in foundries. Automated welded joint- Welding robots, Positioners and Manipulators -Microprocessor based control of resistance and arc welding- Arc sensing, Weld Seam Tracking and Vision system – Effects of welding fumes on environment.
COURSE OUTCOMES:
At the end of this course, the students shall be able to:
CO1: Use design knowledge to overcome defects in welding.
CO2: Select suitable welding process for the given applications.
CO3: Use design knowledge to produce quality casting.
CO4: Select suitable casting process for the given applications.
CO5: Implement automation principles with environment consciousness techniques in welding and casting plants
REFERENCES:
1. American Welding Society,”Welding Handbook”, Volume 1-5, 9th Edition, 2001.
2. Dieter Radaj, “Design and Analysis of Fatigue Resistant Welded Structures”, Woodhead Publishing, United Kingdom, 1990, ISBN: 978-1855730045.
3. John Campbell, “Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques and Design”, 2nd edition, Butterworth-Heinemann., United Kingdom, 2015, ISBN: 978-1856178099.
4. Mahi Sahoo and Sam Sahu, “Principles of Metal Casting”, McGraw-Hill Education, United States, 3rd Edition, 2014, ISBN: 978-0071789752.
5. Robert B. Tuttle, “Foundry Engineering: The Metallurgy and Design of Castings”, Create Space Independent Publishing Platform, Amazon, 2012, ISBN: 9781478157434.