S4 MECHANICAL

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INTRODUCTION

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COURSE STRUCTURE
MODULE 1: FOUNDRY AND CASTING
MODULE 2: CASTING METHODS,
POWDER METALLURGY
MODULE 3: FORMING
MODULE 4: WELDING

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 Foundry
Casting
Pattern: types, material, allowances
Moulding sand: Properties, testing, Sand Muller.
Types of Mould: Green Sand & Dry Sand Mould
Carbon Dioxide, Shell, Ceramic, Plaster mould
Core: Sand, types, prints, baking
Gating system, directional solidification
Chills, Chaplets, Blind riser
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CASTING

PATTERN

FOUNDRY

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MOULD

SAND MULLER

CORE

CHAPLETS

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 Permanent Mould Casting: Gravity Die

Casting, Pressure Die casting
Centrifugal, Semi Centrifugal, Centrifuged
Casting, Continuous casting
Cleaning and Inspection, Defects
Power Metallurgy
Plastic Injection, Plastic Blow moulding
Forming & Shaping of glass
Processing of Metal & Ceramic matrix.
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PERMANENT MOULD CASTING

CASTING DEFECT

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CASTING DEFECT

POWDER METALLURGY

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 Welding, Types, Weldability, HAZ

Gas welding, flames
Arc Welding: Carbon Arc, Shielded metal arc,
submerged arc, TIG, MIG
Resistance Welding: Spot, Seam, Projection,
Butt, Flash butt, Percussion welding.
Solid Face welding: Forge, Friction, explosive,
ultrasonic.
Thermit Welding, Atomic Hydrogen, Electron
Beam
Weld defects and inspection
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HAZ: Heat Affected Zone

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GAS WELDING

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WELDING TORCH

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TYPES
OF
FLAMES

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WELD DEFECTS

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 Forming
Rolling
Forging
Press Forging
Roll Forging
Extrusion
Wire Drawing
Tube Drawing

Rotary Piercing
Rotary Swaging
Thread Rolling
Metal Spinning

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FORGING

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THREAD ROLLING

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METAL SPINNING

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