1. Casting processes
Introduction to metal casting, types of patterns, their materials and allowances. Moulding materials: Moulding
sand compositions and moulding sand properties, sand testing types of moulds, moulding machines cores, core
sands, types of cores, core banking, elements of gating system, and risers. Cupola and its operation, types of
furnaces, Casting processes: sand casting, shell mould casting, investment casting, permanent mould casting,
full mould casting, vacuum casting. Die casting. Centrifugal casting, continuous casting. Casting defects, their
causes and remedies. Solidification of metal and alloys
2. Welding
Welding introduction and classification of welding, processes, welding terminology, general principles, welding
positions, filler metals.
Gas welding and gas cutting, principle, and oxyacetylene welding equipment
Oxyhydrogen welding. Flame cutting.
Electric arc welding. Principle, equipment, types- MIG, TIG submerged arc and others.
Welding electrodes, classification and selection of electrodes, welding arc and its characteristics, arc stability, arc
blow. Thermal effects on weldment.
Resistance welding- principle and their types i.e. spot, seam, projection, upset and flash
Thermit welding, electro slag welding, friction welding, plasma arc welding, electron beam welding.
Welding defects, their cases and remedies.
Brazing, braze welding and soldering.
3. Metal Forming
Introduction : Classification of forming processes,
Rolling : Classification of rolling processes, rolling mills, rolling defects,
Drawing : Drawing of rods, wires and tubes, Draw benches.
Forging : Introduction to forging, their types, forging defects.
Extrusion : Classification of extrusion processes
Sheet metal forming operations : Spinning, deep drawing, bending.
Introduction to press working. Types of presses, press working operation, Press
working tools.
4. Metal cutting and Machine tools
Cutting tool materials, Signature of cutting tools, Twist Drill and milling cutter,
Coolants: Classification, purpose, its effect
Lathe: Machine and its accessories, Lathe operations,
Shaping and Planing Machine, slotting machine, Introduction to broaching machine
Milling machine and its classification, Indexing: Simple compound and differential
Drilling & Boring Operation and their machines
Grinding: Cylindrical, surface and centreless grinding
Introduction to non traditional machining