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SYLLABUS

UNIT-I

CASTING Definition, Elements, Steps involved in making a casting – Types of patterns - Pattern and Pattern making – Materials used for patterns, Pattern allowances and their construction. Principles of Gating, Gating ratio and design of Gating systems, Time of filling the cavity. Design of core prints, Buoyancy principle. Moulds: Definition, Mould materials, Types of moulds, Moulding methods, Moulding machines, Tests. Solidification of casting – Concept of pure metal and alloys, Short & long freezing range alloys

UNIT-II

SPECIAL CASTING PROCESSES Process Mechanics, Characteristics, Parameters and applications of centrifugal, Die and Investment casting. RISERS – Types, Function and design, Casting design considerations, Design of feeding systems i.e., Sprue, Runner, Gate and riser, Moulding flasks METHODS OF MELTING Crucible melting and cupola operation, Steel making process. Casting inspection and defects

UNIT-III

WELDING Classification of welding processes types of welds and welded joints and their characteristics, design of welded joints, Gas welding, ARC welding, Forge welding, Resistance welding, Thermit welding and Plasma (Air and water ) welding. CUTTING OF METALS Oxy – Acetylene Gas cutting, Water plasma. Cutting of ferrous, Nonferrous metals

UNIT-IV

Mechanics, Characteristics, Process parameters, Applications of Inert Gas welding, TIG & MIG welding, Friction welding, Induction welding, Explosive welding, Laser welding, Soldering, Brazing and adhesive bonding. Heat affected zones in welding; Welding defects – Causes and remedies – Destructive and nondestructive testing of welds

UNIT-V

SURFACE ENGINEERING Surface treatment processes and their characteristics, applications (a) Overlay coatings (b) Diffusion coatings (c) Thermal or mechanical modification of surfaces