PR3401 Metal Casting Technology Syllabus:

PR3401 Metal Casting Technology Syllabus – Anna University Regulation 2021

COURSE OBJECTIVES:

1. To impart knowledge about principles/methods of casting with detail design of gating/riser system needed for casting, defects in cast objects and requirements for achieving better casting.
2. To understand the basic principle, procedure and applications of various Foundry and Welding methods.
3. To inculcate the principle, thermal and metallurgical aspects during solidification of metal and alloys.
4. To impart knowledge to the students about the principles of melting and pouring.
5. To impart knowledge on casting design.

UNIT – I CASTING PROCESSES

Introduction to casting – pattern – materials allowances – coding – types – moulds – mould making, sand – properties, types and testing of sands – core making – type of cores – single box, two box and three box moulding processes, runner, riser and gate and chills chaplets.

UNIT – II SPECIAL CASTING PROCESSES

Pressure die casting – Centrifugal – continuous – investment – shell moulding – squeeze – electro slag casting – CO2 moulding – Plaster Mould castings – Antioch process – Slush casting- Counter gravity low pressure casting – electro-magnetic casting.

UNIT – III SOLIDIFICATION PROCESS

Solidification – Definition, nucleation, solidification variables. Directional solidification-need and methods. Degasification in liquid metals-sources of gas, degasification methods. Fettling and cleaning of castings – Basic steps involved. Sand Casting defects- causes, features and remedies. Advantages & limitations of casting process.

UNIT – IV MELTING AND POURING

Principles of melting practice-fluxing- Degasification and inoculation- Types of furnaces- Crucibles, Cupola, Oil fired furnaces – Electric arc and induction furnaces –Melting practice of cast iron, S G iron, steel, aluminum and copper alloys.

UNIT – V CASTING DESIGN

Solidification of pure metals and alloys-shrinkage in cast metals-design of sprue, runner, gate and risers-problems in design and manufacture of thin and unequal sections – design for directional solidification, minimum distortion and for overall economy – design problems of L,T,V,X and Y junctions.

COURSE OUTCOMES

Upon successful completion of the course, students should be able to:
CO1: Understand the process of Pattern making, Moulding and core making
CO2: Analyze the thermal, metallurgical aspects during solidification in casting and welding and their role on quality of cast or weld objects.
CO3: Understand the process of solidification of casting process.
CO4: The student will be able to melt and pour metals.
CO5: The student will be able design cast alloys.

TEXT BOOKS:

1. John Campbell. “Complete Casting Handbook Metal Casting Processes, Metallurgy, Techniques and Design, Elsevier Science, 2015, ISBN: 9780444635099.
2. Jain.P.L., “Principle of Foundry Technology”, Tata McGraw Hill ,4th edition, 2004.

REFERENCES:

1. Taylor HF Fleming, “Foundry Engineering”, M.C. and Wiley Eastern Ltd., 2003.
2. Heime, Looper and Rosenthal, “Principle of metal casting”, Tata McGraw Hill, 2nd edition 2002.