Maharaja Education Trust (R), Mysuru

Maharaja Institute of Technology Mysore

Belawadi, Sriranga Pattana Taluk, Mandya – 571 477

Approved by AICTE, New Delhi,

Affiliated to VTU, Belagavi & Recognized by Government of Karnataka

Lecture Notes on
METAL CASTING & WELDING (18ME35/45B)

Prepared by

DEPARTMENT OF MECHANICAL ENGINEERING

 Maharaja Education Trust (R), Mysuru
Maharaja Institute of Technology Mysore
Belawadi, Sriranga Pattana Taluk, Mandya – 571 477

Vision/ ಆಶಯ

“To be recognized as a premier technical and management institution promoting extensive

education fostering research, innovation and entrepreneurial attitude"
,

Mission/

 To empower students with indispensable knowledge through dedicated teaching and

collaborative learning.

 To advance extensive research in science, engineering and management disciplines.

,

 To facilitate entrepreneurial skills through effective institute - industry collaboration and

interaction with alumni.
,

 To instill the need to uphold ethics in every aspect.

.

 To mould holistic individuals capable of contributing to the advancement of the society.

.
 Maharaja Institute of Technology Mysore
Department of Mechanical Engineering

Vision / ಆಶಯ

“To excel in technical education by producing Mechanical Engineers who are

competitive, contributing and sustainable in the global socio technological front.”

“ ,

ಮೂಲಕ ”

Mission /

1. To enrich teaching-learning experience through distinguished practices

and ever improving infrastructure
ಮೂಲಕ -

2. To enhance student performance through consistent guidance, motivation

and mentoring
, ಮೂಲಕ

3. To develop distinct skills, leadership qualities and creative thinking among

the learners through sensible endeavors
ಗಳ ಮೂಲಕ ,
 Maharaja Institute of Technology Mysore
Department of Mechanical Engineering

Program Outcomes

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and
design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of
the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modeling to complex engineering activities
with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to
the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader
in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and receive
clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member and
leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage
in independent and life-long learning in the broadest context of technological change.
 Maharaja Institute of Technology Mysore
Department of Mechanical Engineering
Course Overview
Subject: Metal Casting & Welding Subject Code: 18ME35/45B
Manufacturing engineers converts idea into reality. In order to create new product with high
quality and economical in cost one needs solid foundation of the basic principles and features
of various manufacturing process. This helps engineer not only to develop a new product but
also to develop and improve manufacturing process. The fundamental concepts of casting
process like sand moulding and die casting involves patterns making, core making, gating ,
Risering and melting the metal by using different types of furnaces and the final casted
component obtained after the phase transformation from liquid state to solid state through
solidification process for both ferrous and non-ferrous materials. The syllabus outlines good
amount of theoretical information and emphasizes more on welding processes such as arc
welding as well as the modern development in welding processes. Defects obtained by the
both casting and welding processes can be inspected through various inspection methods. To
gain theoretical knowledge in Metal casting processes and develops an understanding of the
dependent and independent variables which control materials casting in a production
processes and to provide a detailed discussion on the welding process and the physics of
welding.
Course Objectives
The objectives of this course is to make students to learn-
1. To provide adequate knowledge of quality test methods conducted on welded and cast components.
2. To provide knowledge of various casting process in manufacturing.
3. To provide in-depth knowledge on metallurgical aspects during solidification of metal and alloys.
4. To provide detailed information about the moulding processes.
5. To impart knowledge of various joining process used in manufacturing.
6. To impart knowledge about behavior of materials during welding, and the effect of process
parameters in welding.
Course Outcomes
CO’s DESCRIPTION OF THE OUTCOMES

Utilize the fundamentals of casting process to describe the preparation of various sand
C206.1
mounding techniques and types of molding machines.
Identify the various melting furnaces, infer their operation principle and various metallic
C206.2 molding techniques.
Apply the concept of solidification process to explain solidification variables, methods of
C206.3 degassing and casting of non-ferrous metals.
C206.4 Differentiate the working principle of metal joining processes for engineering applications.
Analyze the metallurgical aspects in welding and inspection methods for the quality
C206.5 assurance of components made of casting and joining process.

Faculty Faculty Course Coordinator

Criterion 3 Coordinator Dept. NBA Coordinator HOD

NBA Convener Principal

 Maharaja Institute of Technology Mysore
Department of Mechanical Engineering
Syllabus
Subject: Metal Casting & Welding Subject Code: 18ME35/45B

MODULE - 1
Introduction: Definition, Classification of manufacturing processes. Metals cast in the foundry-classification,
factors that determine the selection of a casting alloy.
Introduction to casting process & steps involved: Patterns: Definition, classification, materials used for
pattern, various pattern allowances and their importance. Sand moulding: Types of base sand, requirement of
base sand. Binder, Additives definition, need and types; preparation of sand moulds. Melding machines- Jolt
type, squeeze type and Sand slinger. Study of important moulding process: Green sand, core sand, dry sand,
sweep mould, CO2mould, shell mould, investment mould, plaster mould, cement bonded mould. Cores:
Definition, need, types. Method of making cores, Concept of gating (top, bottom, parting line, horn gate) and
risers (open, blind) Functions and types.
MODULE - 2
Melting furnaces: Classification of furnaces, Gas fired pit furnace, Resistance furnace, Coreless induction
furnace, electric arc furnace, constructional features & working principle of cupola furnace.
Casting using metal moulds: Gravity die casting, pressure die casting, centrifugal casting, squeeze casting,
slush casting, thixocasting, and continuous casting processes.
MODULE – 3
Solidification: Definition, nucleation, solidification variables. Directional solidification-need and methods.
Degasification in liquid metals-sources of gas, degasification methods.
Fettling and cleaning of castings: Basic steps involved. Sand Casting defects- causes, features and remedies.
Advantages & limitations of casting process
Nonferrous foundry practice: Aluminium castings - advantages, limitations, melting of Aluminium using lift-
out type crucible furnace. Hardeners used, drossing, gas absorption, fluxing and flushing, grain refining, pouring
temperature. Stir casting set up, procedure, uses, advantages and limitations.
MODULE – 4
Welding process: Definition, Principles, classification, application, advantages & limitations of welding. Arc
welding: Principle, Metal arc welding (MAW), Flux Shielded Metal Arc Welding (FSMAW), Inert Gas
Welding (TIG & MIG) Submerged Arc Welding (SAW) and Atomic Hydrogen Welding (AHW).
Special type of welding: Resistance welding principles, Seam welding, Butt welding, Spot welding and
Projection welding. Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam
welding
MODULE – 5
METALLURGICAL ASPECTS IN WELDING, SOLDERING, AND BRAZING:
Structure of welds, Formation of different zones during welding, Heat Affected Zone (HAZ), Parameters
affecting HAZ. Effect of carbon content on structure and properties of steel, Shrinkage in welds& Residual
stresses. Concept of electrodes, filler rod and fluxes. Welding defects- detection, causes & remedy.
Soldering, brazing, gas welding: Soldering, Brazing, Gas Welding: Principle, oxy-Acetylene welding, oxy-
hydrogen welding, air-acetylene welding, Gas cutting, powder cutting.
Inspection methods: Methods used for inspection of casting and welding. Visual, magnetic particle, fluorescent
particle, ultrasonic. Radiography, eddy current, holography methods of inspection.

Text Books:
1. Manufacturing Process-I, Dr.K.Radhakrishna, Sapna Book House,
2. Manufacturing Technology- Foundry, P.N.Rao, Tata McGraw Hill.
 Maharaja Institute of Technology Mysore
Department of Mechanical Engineering

Index

Subject: Metal Casting & Welding Subject Code: 18ME35/45B

SL. No. Contents Page No.

1 Introduction to Manufacturing Process

Module - 01 1-51
2 Sand Moulding & Moulding Machine

3 Melting Furnace
Module - 02 52-84
4 Metallic Moulds

5 Solidification Process
Module - 03 85-124
6 Non Ferrous Foundry - Practise

7 Welding Process
Module - 04 125-157
8 Special types of Welding

9 Soldering, Brazing and Gas Welding

Module - 05 158-189
10 Inspection Methods
 Module 1:
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 MODULE 2:
Melting Furnace
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 Module 3:
Solidification & Non-
Ferrous Foundry
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 Module 4:
Welding Process
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Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 126

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 127

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 128

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 129

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 130

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 131

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 132

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 133

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 134

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 135

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 136

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 137

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 138

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 139

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 140

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 141

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 142

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 143

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 144

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 145

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 146

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 147

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 148

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 149

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 150

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 151

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 152

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 153

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 154

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 155

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 156

Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-04: Welding Process 157

 Module 5:
Soldering, Brazing &
Metallurgical aspects
in welding
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 158
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 159
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 160
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 161
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 162
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 163
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 164
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 165
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 166
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 167
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 168
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 169
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 170
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 171
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 172
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 173
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 174
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 175
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 176
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 177
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 178
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 179
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 180
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 181
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 182
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 183
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 184
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 185
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 186
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 187
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 188
Maharaja Institute of Technology Mysore Department of Mechanical Engineering

Metal Casting and Welding (18ME35/45B), Module-05: Soldering, Brazing & Metallurgical aspects in welding 189