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Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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Teaching Plan
Unit Topics to be explored Completion of
No topic : Date
Unit Introduction & classification of welding processes, Basic electrical – 03/07/2019
01 Electrodes – coding of electrodes – Electrode efficiency, Welding symbol.
Physics of welding – arc structure, characteristics and power – chemical
heat source- contact resistance heat source- heat flow characteristics-
cooling of weld Arc welding processes- carbon arc, submerged arc,
Tungsten inert gas (TIG), Metal Inert gas (MIG), Plasma arc, stud welding-
Theory, comparison on merits, limitations and applications.
Fluxes used in arc welding. (8 hrs)
Unit GAS welding: - processes and equipment used, type of flames, adjustment 27/07/2019
02 of flames, oxyacetylene welding, gas cutting –merits, limitations and
applications. Electric resistance welding- processes and equipment used,
spot, seam, projection, butt, percussion welding, resistance tube welding,
- merits, limitations and applications. (8 hrs)
Unit Pressure welding, diffusion welding, ultrasonic, friction, explosive, forge, 14/08/2019
03 thermit welding, laser, electron beam welding- equipment used- merits,
limitations and applications of above processes. Brazing, braze welding and
soldering processes. Inspection and testing of welding: - visual inspection,
destructive & non-destructive testing. Estimation of welding cost. Protection
and safety in welding. (8 hrs)
Unit Sand casting processes, Principles of casting, steps involved in casting, 31/08/2019
04 Introduction of sand casting. Patterns, Pattern materials, pattern allowances
and design. Core prints and core seats. Mould strength, Ingredients of moulding
materials and their effect on mould strength-testing of mould strength, testing
of moulding sand. Melting and pouring of metals: - melting furnace- types,
Cupola, electric arc furnace, Induction furnace- Construction, operations and
zones, cleaning, finishing of casting. (8 hrs)
Unit Special casting processes Pressure and gravity die casting (hot and cold 18/09/2019
05 chamber), shell moulding, centrifugal casting, continuous casting, investment
casting, - their typical applications, merits and limitations. Casting defects-
defects, Inspection- analysis of casting defects- Quality control. Foundry
mechanization and automation. (8 hrs)
Unit Casting Design, Metal pouring, Gating system- design of gating system, 05/10/2019
06 solidification time, riser design, Principles of gating, risering and their design
methods. Progressive and directional solidification, casting design
consideration, Chvornov‟s rule, numerical on casting, defects in casting.
Fluidity- method of measuring fluidity of metal by spiral technique. Computer
applications in casting design and software (8 hrs)
Text Books:
1. Rao P.N., “Manufacturing Technology, Foundry, Forming and welding”, 2ed., Tata
McGraw-hill publishing, 2006, ISBN 0-07-463180-2.
2. Khanna O.P., “Welding Technology”, Dhanpat Rai& sons, 1996.
3. Khanna O.P., “Foundry Technology”, Dhanpat Rai& sons, 1999.
4. Parmar R.S., “Welding Process and Technology”, 2ed.,Khanna Publishers, 1997.
Reference Books:
1. KalpakjianSerope and Schmid Steven, “Manufacturing Engineering & Technology”, 2004.
Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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Text Books:
2. Degarmo E.P. and Black J.T., “Materials &Processes in Manufacturing”, 9ed., Prentice hall of India
Pvt.Ltd., 2002.
3. Little Richard., “Welding & Welding Technology”,Tata Mc-graw hill Publishing, 1992, ISBN 0-07-
099409-9.
Visit no. Week / Date Actual date of visit Name of industry visited
proposed
1 Last week of August Aditya foundries, Nashik
Schedule of Expert lectures
Week / Actual date of Name of speaker Topic of Lecture
Date conduction
proposed
First week Somnath Avhad, Quality Investment
of engineer, OK ferm, Sinnar Casting
September
Schedule of submission
(The assessment with final index signature is to be closed on or before five days of conclusion of
teaching)
Ex 01 To find out grain fineness number by using sand sieve shaker test.
Ex 02 Permeability testing of green sand.
Ex 03 Green compression test for molding sand.
Ex 04 Fluidity testing of any metal using fluidity spiral.)
Ex 05 Study of TIG/MIG welding process parameters for ferrous and nonferrous metals.
Ex 06 Tensile test on a welded specimen.
Ex 07 Impact test on a welded specimen.
Ex 08 Non-destructive test on a weldment- dye penetrant test.
Ex 09 Non-destructive test on a weldment- magnaflux test.
Ex 10 Industrial visit to any foundry.
Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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Schedule of Online tests (Weightage of this test is 10 marks)
Instruction for Online test:
1. Link of the test will be share on your what’s app group.
2. You have to log in with your name as username and Password is sbs3
Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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