ML3501 Foundry Metallurgy Syllabus:
ML3501 Foundry Metallurgy Syllabus – Anna University Regulation 2021
COURSE OBJECTIVES:
The main learning objective of this course is to prepare students for:
1. Getting acquainted with the various patterns, moulding materials and furnaces used in foundries.
2. Choosing molding process for casting components.
3. Designing gating system for castings.
4. Making use of basics of ferrous casting metallurgy for casting quality ferrous castings
5. Making use of basics of non- ferrous casting metallurgy for casting quality nonferrous castings
UNIT I PATTERN, MOULDING MATERIALS, FURNACES
Introduction to foundry process-Pattern, types- allowances- selection of pattern materials, -SandCore for foundry applications – types, properties of prepared sand-Moulding and Cores additivespreparations-Types of furnaces –Crucible, Cupola, Oil fired furnaces, Electric furnaces, Arc and Induction types.
UNIT II MOULDING PROCESSES
Green Sand -Hand Moulding, Jolt Squeeze and High Pressure Moulding, – CO2 and Nishiyama process- No Bake- Two part and Three-part Process, – Shell- Investment Casting- Permanent Moulding – Pressure Die casting processes- Ceramic- Plaster of Paris- Centrifugal- SqueezeElectro Magnetic – Lost Foam process.
UNIT III DESIGN OF GATING SYSTEM
Design of Gating Systems –Types – Pressure & Un pressurized systems -Sprue- runner- gates – problems in design and manufacture of thin and unequal Sections-designing for directional solidification- Riser design-Chvorinov’s rule, Caines- Section Modulus- Naval Research Laboratory methods, feeding distances – Calculations and number of Risers required, chills and feeding aids – Exothermic And Insulating sleeves Design problems of L, T, V, X and Y junctions, Computer Applications in casting design—Software for casting design CAE –Stress, Liquid metal flow and solidification analysis.
UNIT IV FERROUS CAST ALLOYS
Solidification of pure metals and alloys and eutectics -Nucleation – Growth Process, Critical nucleus size- Super cooling- Niyama Criterion -G/R ratio- Cell- Dendritic – Random dendritic structureSegregation and Coring- Eutectics-Compositions and alloys in Cast Irons, FG-CGI- SG structures, Metallic Glass- Mold dilation, Mold metal reactions- Structure and Section sensitivity Cast ironsfamily & microstructures-Alloying effects- Malleable Iron, ADI, Charge calculations- Effect of normal elements and alloying elements in steels- Compositional aspects and properties of alloy steelsmelting procedure and composition control for carbon steels- low alloy steels – stainless steelscomposition control- slag-metal reactions-desulphurization-dephosphorisation, specifications for carbon steels- low alloy steels and stainless steels
UNIT V NON-FERROUS CAST ALLOYS
Copper- Aluminium- Magnesium- zinc – Nickel base alloys- melting practices – Al alloys, Mg alloys, Nickel alloys, Zinc alloys and copper alloys-modification and grain refinement of Al alloys- problems in composition control- degassing techniques -Heat Treatment of Aluminium alloys – Basics of Solution and Precipitation process. – Applications of Aluminium Alloy castings in various fields. Residual Stresses- defects in castings
TOTAL: 45 PERIODS
COURSE OUTCOMES:
Upon completion of the course, the student will be able to
1. Select a proper material for making a pattern, design patterns, and decide on the composition of sand and core and know about the different furnaces for available for melting metals.
2. Describe the various casting processes for casting a component.
3. Design suitable gating system for casting a component.
4. Use suitable casting techniques to produce sound ferrous castings.
5. Employ suitable casting techniques to produce sound nonferrous castings.
TEXT BOOKS
1. A.K.Chakrabarthi ‘Casting Technology and Cast Alloys ,Prentice Hall of India
2. Heine R W, Loper C R and Rosenthal P C, “Principles of Metal Castings”, Tata McGraw Hill, 2017
REFERENCES
1. Manufacturing Technology – Foundry, Farming and Welding | Volume1 | 5th Edition, P N Rao, McGraw-Hill Education 2018
2. ASM Metals, Hand book “Casting”, Volume 15, ASM International, 2007.
3. Beeley P, “Foundry Technology” Butterworth-Heinemann London, 2001.
4. John Campbell, “Casting”, Butterworth- Heinemann, 2003.
5. The Foseco “Foundryman’s Hand book”, Pergamon Press, 2007.