Course Plan

Course Outcomes (COs):

On completion of the Course in Foundry Technology, students will be able to:

1. Indicate the factors to be considered while designing a casting incorporating adequate risering and suitable gating system.
2. Suggest suitable techniques that can be employed during melt treatment, pouring and solidification to control the cast structure of metals.
3. Suggest suitable moulding techniques, melting furnaces and foundry practices for ferrous and non-ferrous castings.
4. Explain the recent advances and the use of modern technology in foundry industries.

Topic Title	Description	Duration
1.     Foundry Metallurgy	Oxidation of liquid metals, gas dissolution in liquid metals, methods of degassing, fluidity, factors affecting fluidity, fluidity tests, hot tearing, shrinkage of liquid metals.	06 Hours
2.     Casting Design	Introduction to casting design, redesign considerations, design for minimum casting stresses, design for directional solidification, design for metal flow, safety factors, design for low pattern cost and model making as an aid in design.	06 Hours
3.     Solidification of Castings	Crystallization and development of cast structure - nucleation, growth and dendritic growth. Structure of castings – significance and practical control of cast structure, grain shape and orientation, grain size, refinement and modification of cast structure. Concept of progressive and directional solidification, solidification time and derivation of Chvorinov’s equation, influence on mold characteristics and cast metal.	07 Hours
4.     Risering and Gating	Need for risering, general considerations of risering, riser shapes, riser size, and location. Requirements of a riser. Sand, insulating, and exothermic materials used for risers. Riser feeding distance and theory of risering. Internal chills, external chills, use of mould materials of different chill capacities, padding for directional solidification. Open type and blind risers. Riser treatment using exothermic and insulating compounds. Gating system – theoretical consideration of gating, laws of fluid flow, turbulence in gating system, use of ceramic foam filters in gating, need for tapered sprue, gating ratio, simple problems.	07 Hours
5.     Special Moulding Techniques & Cupola Melting	Principles, materials used, process details and application of no-bake sand systems, vacuum moulding, flaskless moulding, and high pressure moulding. Cupola melting: Developments in cupola melting – hot blast cupola, water cooled cupola, balanced blast cupola, cokeless cupola, cupola charge calculations	07 Hours
6.     Ferrous Foundry	Melting procedures, casting characteristics, production, specification, and properties of some typical steels, grey cast iron, malleable iron, and spheroidal graphite cast iron castings.	07 Hours
7.     Non-ferrous Foundry	Melting procedures, casting characteristics, production, specification, and properties of some typical aluminum, copper, and magnesium based alloy castings.	06 Hours
8.    Modernization and Mechanization of Foundry	Need for modernization, and mechanization, moulding and core making, melting, pouring, shake out equipment and fettling, dust and fume control, material handling equipments for sand moulds and cores, molten metal and castings, reclamation of sands. Pollution control – norms, and agencies.	06 Hours