MP-1 (B-TECH Mechanical Engineering 3rd)

MANUFACTURING PROCESS –I 

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 and their design. Cupola and its operation charge calculations 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. Metallurgical considerations in casting, Solidification of metals and alloys, directional solidification, segregation, nucleation and grain growth, critical size of nucleus, casting of copper alloys. Cleaning and finishing of castings, Testing and Inspecting of castings.

WELDING

Welding introduction and classification of welding, processes, welding terminology, general principles, welding positions, filler metals. Gas welding and gas cutting, principle, oxyacetylene welding equipment oxyhydrogen welding. Flame cutting. Electric are 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. Heat affected zone grain size and its control. Resistance welding- principle and their types i.e. spot, seam, projection, upset and flash Thermit welding, electro slag welding, friction welding, plasma are welding electron beam welding, atomic hydrogen hydrogen welding. Basic considerations in joint design, Welding defects, their cases and remedies. Brazing, braze welding and soldering.