Syllabus - Foundry and Welding Engineering (IP-504 (B))

Moulding Tools-Moulding sands – Types-properties-ingredients. Types of moulding methods - floor, bench and machine moulding. Patterns: types allowances - pattern constructions. Core and core making- types of cores - Gating and Risering principles.

Metal melting - Melting furnaces – cupola, Electric arc furnace, Induction furnace. Casting Procedure-advantages-limitations-Applications. Types of casting processes- sand, centrifugal, die & investment castings. Defects in castings - methods of control - fettling and cleaning of castings. Casting of cylinder block & head - cylinder liners - pistons and piston rings.

Design of Weldment: Weld geometry, Eccentric torsion and bending, designing welding fixtures. Distortion and Discontinuities in weldment, Testing, Inspection and Specifications: Weldment distortion and its control, various discontinuities in Welds, Residual stresses in Weldments, Trouble shooting. loading design in

Working Principle, advantages, limitations and applications of Friction welding and Friction Stir Welding, Thermit welding, Electron Beam Welding, Laser beam welding, Soldering and Brazing. Robotics and Automation in Welding, Modes of Automation, Positioners, Welding fixtures, Arc motion devices, seam tracking devices. Under water welding.

Problems during welding of carbon steels, stainless steels, aluminium alloys, magnesium alloys and dissimilar metals – remedies. Welding defects, types of joints, welding symbols, post weld heat treatments, non-destructive testing of welded joints. Destructive and non-destructive methods of testing weldments, WPS, PQR and ASME section IX Welding.