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Mold Casting and Welding Processes

Understand the principles and characteristics of mold casting and welding processes in this free online course.

Publisher: NPTEL
The end product in manufacturing processes can be obtained from the raw material either through casting or joining (welding). In this free online course, you will learn the various casting processes, cost analysis as well as casting defects. You will also study the types, characteristics, and features of the welding processes. This course is very important for students in the manufacturing industries or related fields. Start learning today!
Mold Casting and Welding Processes
  • Duration

    4-5 Hours
  • Students

  • Accreditation






View course modules


The metal casting process is a process in which molten metal is poured into a mold or cavity and allowing it to solidify. The metal casting process can be classified into two categories, expendable and permanent mold casting processes. In the introductory section of this course, you will be introduced to the expendable mold casting process and emphasis will be on the shell molding and investment casting processes. You will learn the steps involved in both shall and investment casting, the types of shall molding patterns, the characteristics, advantages, and disadvantages of the shell molding, and investment casting processes. A short video on how the investment casting process is carried out will be shown. Then, you will study how permanent mold castings are made. The steps, characteristics, applications, merits, and demerits will be explained. You will also be taught the die casting and centrifugal processes which are very important casting processes. The design and the setup of the hot and cold chambers of the die casting machine will be highlighted. Thereafter, you will consider how the cost analysis of casting is normally done. The equations of the total cost of casting which includes all costs, both direct and indirect, that results from the design, production, distribution, and use of the cast over its lifetime will be explained. Also, the various casting defects and their causes will be examined.

The end products in manufacturing processes can be obtained from the raw material by either the constant mass operation, that is casting, or the mass addition process which is joining. Next, you will be introduced to the joining processes with a focus on welding. You will study the classifications, mechanisms, impertinence, limitations, and drawbacks of welding processes. Joints and their types in welding will also be considered. Then, you will cover the principle, sources of heat, and some processes of fusion welding such as arc welding, resistance welding, and oxyfuel gas welding. The heat density within which welding can be performed will be discussed. Thereafter, you will be taught the solid-state welding processes which include diffusion welding, friction welding, ultrasonic welding, etc. The effects and steps relating to the cooling of the weld (solidification) and the applications of electron beam welding, laser beam welding, and plasma arc welding in the physical world will also be examined.

Furthermore, you will be introduced to the liquid state welding processes. You will be shown a schematic diagram that exhibits the detailed processes involved in arc welding. You will study the principles, characteristics, sources of heat, and the structure of arc welding. The steps and methods of initiating an electric arc as well as the consumable and non-consumable electrodes of the arc welding will be highlighted. Then the shielded metal arc welding, also known as stick arc welding will be considered. A short video clip on the stick arc welding will be shown to give a clear idea of what the welding involves. Thereafter, the arc welding processes that use non-consumable electrodes and their various features will be discussed in detail. Also, you will learn about the various types of welding defects, their causes, and preventions. Anyone studying manufacturing processes or related courses and is interested in casting and welding will benefit from this fascinating course as you will gain unique knowledge of the manufacturing processes. This course is a complex, highly technical, exciting, and rewarding course. Are you ready to take on this challenge? Start today and enrol in this Mold Casting and Welding Processes course!

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