CME395 Syllabus - Casting And Welding Processes - 2021 Regulation Anna University

CME395 Syllabus - Casting And Welding Processes - 2021 Regulation Anna University

CME395

CASTING AND WELDING PROCESSES

 L T P C

3003

COURSE OBJECTIVES:
1 To study the ferrous casting metallurgy and its applications.
2 To study the nonferrous casting metallurgy and its applications.
3 To study the ferrous welding metallurgy and its applications.
4 To study the welding metallurgy of alloy steels and nonferrous metals and its applications
5 To Identifying the causes and remedies of various welding defects; applying welding standards and codes.

UNIT I

FERROUS CAST ALLOYS

9

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 structure-Segregation 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 irons- family & microstructures-Alloying effects- Malleable Iron, ADI, Charge calculations- Effect of normal elements and alloying elements in steels- Compositional aspects and properties of alloy steels- melting procedure and composition control for carbon steels- low alloy steels - stainless steels- composition control- slag-metal reactions-desulphurization- dephosphorization, specifications for carbon steels- low alloy steels and stainless steels

UNIT II

NON-FERROUS CAST ALLOYS

9

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


UNIT III

PHYSICAL METALLURGY OF WELDING

9

Welding of ferrous materials: Iron- Iron carbide diagram, TTT and CCT diagrams, effects of steel composition, formation of different microstructural zones in welded plain-carbon steels. Welding of C-Mn and low-alloy steels, phase transformations in weld and heat - affected zones, cold cracking, role of hydrogen and carbon equivalent, formation of acicular ferrite and effect on weld metal toughness.

UNIT IV

WELDING OF ALLOY STEELS AND NON-FERROUS METALS

9

Welding of stainless steels, types of stainless steels, overview of joining ferritic and martensitic types, welding of austenitic stainless steels, Sensitisation, hot cracking, sigma phase and chromium carbide formation, ways of overcoming these difficulties, welding of cast iron. Welding of non-ferrous materials: Joining of aluminium, copper, nickel and titanium alloys, problems encountered and solutions

UNIT V

DEFECTS, WELDABILITY AND STANDARDS

9

Defects in welded joints: Defects such as arc strike, porosity, undercut, slag entrapment and hot cracking, causes and remedies in each case. Joining of dissimilar materials, weldability and testing of weldments. Introduction to International Standards and Codes

TOTAL: 45 PERIODS

OUTCOMES: At the end of the course the students would be able to
1. Explain the ferrous casting metallurgy and its applications.
2. Explain the non ferrous casting metallurgy and its applications.
3. Explain the ferrous welding metallurgy and its applications.
4. Explain the welding metallurgy of alloy steels and non ferrous metals and its applications.
5. Identify the causes and remedies of various welding defects; apply welding standards and codes.

TEXT BOOKS:
1. Heine R W, Loper C R and Rosenthal P C, "Principles of Metal Castings", Tata McGraw Hill, 2017.
2. A.K.Chakrabarthi, ‘Casting Technology and Cast Alloys,Prentice Hall, 2005.

REFERENCES:
1. ASM International. Handbook Committee, ASM Handbook: Casting. Volume 15, ASM International, 2008.
2. Baldev Raj, Shankar V, Bhaduri A K, “Welding Technology for Engineers”, Narosa Publications, 2009.
3. Beeley P, “Foundry Technology" Butterworth-Heinemann, 2001.
4. R.S.Parmar, ‘Welding Engineering and Technology’, Khanna Publishers, 2010
5. John Campbell, “Casting", Butterworth-Heinemann, 2003.

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