Introduction to Casting Processes

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. It can be used to produce small and big parts for tiny backyard projects or big companies and industries like ship and aeroplane manufacturing plants. You start by learning the position of casting in manufacturing processes or the processing of raw materials. Next, study the various classifications of different processes in modern industrial casting. Then, the historical background of casting, as well as its advantages and disadvantages, will be discussed. Thereafter, the entire foundry practice and how to cast an iron wheel will be explained in a short video clip.

The principles of casting are very simple. However, during the process, several factors have to be considered in order to get a defect-free result. Five short video clips - on how to cast an engine block, the Indian way of casting foundry technique, the automation process of casting, how to cast a propeller, and how the casting of a mirror - will be shown. This course will teach you pattern processes: depending on the pattern, an appropriate internal cavity and the particular part that needs to be created by the casting, will be attained. Learn about 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 during calculation. The accuracy of the final product 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 also be highlighted.

Next learn how the gating system is made. A good gating design ensures the distribution of metals in the mould cavity at a proper rate without excessive temperature loss, turbulence, or entrapment of 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 will be broken down into simple steps. The solidification time, temperature, and freezing for both pure metals and alloys will be examined. 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. Are you ready to take on this challenge? Register today and enjoy learning about casting processes.