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Introduction to Casting Processes

Learn about the principles and characteristics of various casting processes in this free online course.

Publisher: NPTEL
Casting is one of the most important processes in the manufacturing industry. Casting is a shape obtained by pouring liquid materials into a mould and allowing it to solidify and thereby taking the form of the mould. In this free online course, you will learn about casting and analyze the various aspects of casting processes. Are you a student studying manufacturing or simply want to learn about casting? Then this course is for you. Register now!
Introduction to Casting Processes
  • Duration

    4-5 Hours
  • Students

    17
  • Accreditation

    CPD

Description

Modules

Outcome

Certification

View course modules

Description

A metal casting is a shape obtained by pouring liquid metals into a mould or cavity and allowing it to solidify. Casting is one of the oldest constant volume manufacturing processes and often, the fastest and most economical method for making parts with desired compositions and properties. Casting can be used to produce small and big parts from tiny backyard projects to big companies and industries like ship and aeroplane manufacturing plants, therefore the importance of casting in the manufacturing processes is very crucial. You will start by learning the position of casting in the manufacturing processes, that is where casting falls in all the processes involved in processing raw materials. Next, study the various classifications of the casting processes and how modern industrial casting is produced by a wide variety of processes. Then, the historical background of casting, as well as the advantages and disadvantages of casting will be discussed. Thereafter, the entire foundry practice of casting and how to cast an iron BMW wheel will be explained in a short video clip.

The principles of casting are very simple. However, during the process, several aspects of casting, have to be considered in order to get a defect-free casting. Five short video clips on how to cast an engine block the BMW way, the Indian way of casting foundry technique, the automation process of casting, how to cast a propeller, and how the casting of a mirror, is made will be shown. Just imagine that a mirror is also made by the casting process! Also, this course will teach you the pattern processes, which is also an important part of the casting. Depending on the pattern, an appropriate internal cavity, and the particular part that needs to be gotten by the casting, will be attained. Learn the various types of patterns, shrinkages, and machining allowances that are involved. Observe how they can be estimated, and which factors should be taken into consideration while calculating. As you will come to understand, the accuracy of the final product or the casting depends on the number of shrinkages and the machining allowance that is given. Then, you will become familiar with the various types of sand moulds and their respective parts. The classifications and properties of the moulding sand will be highlighted.

Furthermore, you will learn how the gating system, which is one of the most important aspects of the casting is made. A good gating design ensures the distribution of metals in the mould cavity at a proper rate without excessive temperature loss, turbulence, and entrapping gases and slags. The vertical and bottom gating systems as well as the permeable and impermeable mould aspiration effects will be analyzed. Next, the solidification processes will be discussed. This is a very complicated process, but it would be sufficiently broken down and explained to your understanding. The solidification time, temperature, and freezing for both pure metals and alloys will be examined. Furthermore, you will be taught the steps involved in sand casting, making the sand mould, and the desirable mould properties and characteristics. This course is complex and highly technical but anyone studying manufacturing or who is involved in any related discipline, will find it interesting and captivating. Are you ready to take on this challenge? Register today and enjoy learning about the casting processes.

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