Unit I Metal Casting Processes: Advantages and limitations, sand mold making procedure. Patterns and
Cores: Pattern materials, pattern allowances, types of pattern, color coding. Molding materials: Molding
sand composition, sand preparation, sand properties and testing, Sand molding processes
Unit II Cores: Types of cores, core prints, chaplets, and chills. Gating systems: Gates and gating systems risers.
Melting practice: Cupola, charge calculations. Casting cleaning and casting defects, Fettling, defects in
castings and their remedies, methods of testing of castings for their soundness.
Unit III Special Casting Processes: Shell molding, precision investment casting, permanent mold casting, die
casting, centrifugal casting, continuous casting,
Unit IV Metal Forming Processes: Nature of plastic deformation, hot working and cold working .Principles of
rolling, roll passes, roll pass sequences. Forging: Forging operations, smith forging, drop forging, press
forging, forging defects.
Unit V Extrusion and other processes: Extrusion principle, hot extrusion, cold extrusion, wire drawing, swaging,
tube making. Sheet metal operations: Press tools operations, hearing action, drawing dies, spinning,
bending, stretch forming, embossing and coining.
Unit VI Gas and Arc Welding: Classification: oxy- acetylene welding equipment and techniques. Electric arc
welding: Electrodes, manual metal arc welding, inert gas shielded arc welding, tungsten inert gas
welding (TIG), metal inert gas welding(MIG), submerged arcwelding (SAW).
Unit VII Resistance Welding: Principles, resistance spot welding, resistance seam welding, upset welding, flash
welding,
Unit VIII Other Welding Processes: Introduction thermit welding, electro slag welding, electron beam
welding, forge welding, friction welding, diffusion welding, brazing and soldering.