Lesson Plan for M. Tech.

(Third semester) Mechanical engineering ( I & P)

Advanced Metal Casting (MTIP-606C)
Name of the Faculty: Upender Dhull
Semester:M.Tech. 3rd Sem
Discipline: M.Tech. (Third semester) Mechanical engineering ( I & P)
Subject: Advanced Metal Casting (MTIP-606C)
Lecture Plan Duration: 9 Weeks
Workload Per Week: 4 Lecture hours
Lecture Lecture
no.
L1 Functional Requirement of Moulding Materials: Principal ingredients of moulding
L2 Sands; Different Types of Sands; Clays, Different types of Clay structures, Moisture
L3 Bonding mechanism of silica –clay-water System, Hardened Mould or dry sand practice
L4 The Requirement of core sands, Indian Foundry Industry and challenges.
L5 Specification and testing of Moulding Sands
L6 Grain Size, Grain Shape, Clay content, Moisture Content, Bulk Density and Specific Surface Area
L7 ADV, Fines Content, Sintering Temperature, Mould hardness
L8 Permeability, Strength,'Deformation & toughness
L9 Compactability, Mouldability, 'High Temperature Characteristics.
L10 Solidifications of Metals, Nucleation, free energy concept, critical radius of nucleus,
L11 Distribution coefficient and Constitutional Undercooling, Solidification in Pure Metals and Alloys
L12 Directional Solidification, Casting Characteristics related to Solidification; Fluidity
L13 Dendritic Growth, Dendritic coherency, Segregation, Inverse Segregation, Hot tearing
L14 Hipping, Solidification under pressure.
L15 Heat Transfer during casting process: Resistance to Heat Transfer, Centerline Feeding Resistance
L16 Rate of solidification, Solidification of Large casting in an insulating mould
L17 Solidification with predominant interface resistance,
L18 Solidification with constant casting surface temperature,
L19 Solidification with predominant resistance in mould and solidified Metal
L20 Solidification Time and Chvorinov rule, Numerical Exercises.
L21 Gating System Design: Gating system defined, Types of Gating Systems, Types of Gates
L22 Elements of Gating System, Gating System design, Factors involved in Gating design
L23 Pouring time, Choke Area, Sprue design, Gating Ratio, Sprue runner gate ratio
L24 Elimination of Slag and Dross, Filtration, Numerical exercises.
L25 Riser Design: Need for riser, Basic requirements of an effective feeding system for a casting,
L26 Feeding Efficiency, Types of Risers, Effective feeding distances for simple and complex Shapes
L27 shapes. Use of chills, Directional solidification, Stresses in castings, Metal Mould reactions,
L28 Claine’s Method, Modulus Method, Naval Research Laboratory (NRL) Method
L29 Pouring Rate and Temperature, Padding, Use of exothermic materials, Chills, Feeding Aids,
L30 Numerical exercises on Riser and Gating system design.
L31 Special casting Processes: Shell Moulding, Investment Casting, Permanent Mould Casting,
L32 Diecasting, Centrifugal casting.
L33 Inspection and testing of casting: Visual, Optical, Dimensional inspection, Laser Scanning,
L34 White light scanning, Radiographic Inspection, ultrasonic testing,
L35 Magnetic Particle Testing,dye penetration, Casting Defects; Classification, Causes and remedies.
L36 Solution to Students' Queries and Review of Syllabus

Teacher's Name- Upender Dhull

 Lesson Plan for M. Tech. (Third semester) Mechanical engineering ( I & P)
Advanced Welding Processes (MTIP-608C)
Name of the Faculty: Upender Dhull
Semester:M.Tech. 3rd Sem
Discipline: M.Tech. (Third semester) Mechanical engineering ( I & P)
Subject: Advanced Welding Processes (MTIP-608C)
Lecture Plan Duration: 9 Weeks
Workload Per Week: 4 Lecture hours
Lecture Lecture
no.
L1 WELDING METALLURGY: Introduction, Weld Metal Zone
L2 Theory of solidification of metals and Alloys
L3 Homogeneous Nucleation, Heterogeneous Nucleation
L4 Freezing of alloys
L5 Epitaxial Soldification
L6 Fusion boundary zone, Heat affected Zone ,Under bead zone,
L7 Grain Refined Zone, Partial transformed zone, Properties of HAZ
L8 WELDING ARC: Definition of Arc, Structure and characteristics, Arc efficiency, arc blow.
L9 Electrical Characteristics of arc, Types of Welding Arcs
L10 Mechanism of arc initiation and Maintenance
L11 Role of electrode polarity on arc behaviour and arc stability
L12 Analysis of the arc.
L13 Arc length regulation in mechanized welding processes.
L14 WELDING POWER SOURCES: Requirement of an Arc welding power sources,
L15 Basic characteristics of power sources for various arc welding processes, duty cycles
L16 Selection of a static Volt-Ampere characteristic for a welding process
L17 AC/DC welding power source, DC rectifiers
L18 Thyristor controlled rectifiers, transistorized units, inverter systems
L19 Mathematical Problems on 'Static volt ampere characteristics
L20 COATED ELECTRODES: Electrode coatings, classification of coatings of electrodes for SMAW
L21 SAW fluxes, role of flux ingredients and shielding gases,
L22 Classification of solid and flux code wires.
L23 METAL TRANSFER & MELTING RATE: Mechanism and types of metal transfer
L24 Forces affecting metal transfer, modes of metal transfer
L25 Metal transfer in various welding processes,
L26 Effective of polarity on metal transfer and melting rate.
L27 SOLID STATE WELDING: Theory and mechanism of solid state welding.
L28 Techniques and scope of friction welding,
L29 Diffusion welding,
L30 Cold pressure welding and ultrasonic welding.
L31 High energy rate welding.
L32 Analysis of the Solid State Welding Processes.
L33 WELDING TECHNIQUES: Technique, scope and application of the electron beam Welding Process
L34 Scope and application of the laser Welding Processs
L35 Under water welding - process & problem.
L36 Solution to Students' Queries and Review of the Syllabus

Teacher's Name- Upender Dhull

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2 50 0.7
3 100 0.9
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23 50 0.7
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1530 18.9