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Metal Casting

Metal Casting. Instructor: Dr. D. B. Karunakar, Department of Mechanical and Industrial Engineering, IIT Roorkee. This course is an elective subject for manufacturing students. The subject comprises a little wider and deeper on the manufacturing techniques by casting process. It covers bigger spectrum for manufacture products by the casting techniques with required attributes specified for certain purpose such as intricacy, features detail, soundness and others. Among topics or issues include in this course are liquid metals, solidification, molding material, casting design, production techniques, Metal melting and treatment, and casting quality and evaluation. (from nptel.ac.in)

Lecture 25 - Solidification

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Introduction and Overview

Lecture 01 - Introduction

Lecture 02 - Overview of Different Casting Processes 1

Lecture 03 - Overview of Different Casting Processes 2

Lecture 04 - Overview of Different Casting Processes 3

Sand Casting Process

Lecture 05 - Terminology and Tools of Sand Moulding

Lecture 06 - Moulding Sands and Design

Lecture 07 - Moulding Sands and Design (cont.)

Lecture 08 - Moulding Sand Properties

Lecture 09 - Moulding Sand Properties Testing

Lecture 10 - Cores and Core Sands

Lecture 11 - Patterns and Allowances

Lecture 12 - Steps involved in Making a Sand Casting

Lecture 13 - Design Of Risering System: Caine's Method, Modulus Method, Chvorinov's Rule

Lecture 14 - Design Of Risering System: Naval Research Laboratory Method

Lecture 15 - Design Of Risering System: NRL Method (cont.)

Lecture 16 - Design Of Risering System: Feed Metal Volume, Riser Efficiency, Feeding Distance

Lecture 17 - Design Of Risering System: Feeding Length, Bottle Risering, Safety Margin

Lecture 18 - Design of Gating System

Lecture 19 - Design of Gating System (cont.)

Lecture 20 - Sand Casting Defects

Lecture 21 - Sand Casting Defects (cont.)

Melting, Fluidity and Solidification

Lecture 22 - Melting Furnaces and Practice

Lecture 23 - Treatment of Molten Metal

Lecture 24 - Fluidity of Molten Metal

Lecture 25 - Solidification

Common Cast Alloys

Lecture 26 - Cast Irons and Steels

Lecture 27 - Aluminium and Magnesium Cast Alloys

Lecture 28 - Copper, Zinc and Titanium Cast Alloys

Permanent Mould and Special Casting Processes

Lecture 29 - Die Casting Process

Lecture 30 - Die Casting Process (cont.)

Lecture 31 - Investment Casting Process

Lecture 32 - Investment Casting Process (cont.)

Lecture 33 - Continuous Casting Process

Lecture 34 - Centrifugal Casting Process

Lecture 35 - Evaporative Pattern Casting and Plaster Moulding

Lecture 36 - Vacuum Sealed Moulding and Squeeze Casting

Finishing Design and Environment

Lecture 37 - Shakeout, Fettling and Finishing

Lecture 38 - Inspection, Testing and Quality Control

Lecture 39 - Design Considerations and Economics

Lecture 40 - Environment, Health and Safety Aspects