MOHAMMED SATHAK A J COLLEGE OF ENGINEERING

Siruseri IT Park, OMR, Chennai - 603103.

LESSON PLAN
Department of Mechanical Engineering
Name of the Name of the
Casting and Welding Processes Mr.Rajesh J
Subject handling Faculty
Subject Code CME395 Year / Sem III/V

Acad Year 2023-2024 Batch 2021-2025

Course Objective

1. To study the ferrous casting metallurgy and its applications.

2. To study the nonferrous casting metallurgy and its applications.

3. To study the ferrous welding metallurgy and its applications.

4. To study the welding metallurgy of alloy steels and nonferrous metals and its applications

5. To Identifying the causes and remedies of various welding defects; applying welding standards and codes.

Course Outcome

CO1. Explain the ferrous casting metallurgy and its applications.

CO2. Explain the non ferrous casting metallurgy and its applications.

CO3. Explain the ferrous welding metallurgy and its applications.

CO4. Explain the welding metallurgy of alloy steels and non ferrous metals and its applications.
CO5. Identify the causes and remedies of various welding defects; apply welding standards and codes.

Lesson Plan
T / R* Mode of
Sl. Periods Teaching (BB Blooms Level
Topic(s) CO PO
No. Book Required / PPT / (L1-L6)
NPTEL /
UNIT I FERROUS CAST ALLOYS
Solidification of pure metals and alloys and eutectics - PO1 &
1 T1 1 BB L1 CO1
Nucleation - Growth Process PO2
Critical nucleus size- Super cooling- Niyama PO1 &
2 T1 1 BB L1 CO1
Criterion -G/R ratio PO2
Cell- Dendritic - Random dendritic structure- PO1 &
3 T1 1 BB L1 CO1
Segregation and Coring PO2
Eutectics-Compositions and alloys in Cast Irons, FG- PO1 &
4 T1 1 BB L2 CO1
CGI- SG structures, PO2
Metallic Glass- Mold dilation, Mold metal reactions- PO1 &
5 T1 1 BB L1 CO1
Structure and Section sensitivity PO2
Cast irons- family & microstructures-Alloying effects- PO1 &
6 T1 1 BB L2 CO1
Malleable Iron, ADI, Charge calculations PO2
Effect of normal elements and alloying elements in
PO1 &
7 steels, Compositional aspects and properties of alloy T1 1 BB L2 CO1
PO2
steels
melting procedure and composition control for PO1 &
8 T1 1 BB L3 CO1
carbon steels- low alloy steels - stainless steels PO2
composition control- slag-metal reactions-
PO1 &
9 desulphurization- dephosphorization, specifications T1 1 BB L3 CO1
PO2
for carbon steels- low alloy steels and stainless steels
Suggested Activity: Assignment
Evaluation method: Evaluation of Assignment

UNIT II NON-FERROUS CAST ALLOYS

PO1 &
10 Copper , Aluminium base alloys T1 1 BB L2 CO2
PO2
PO1 &
11 Magnesium, zinc, Nickel base alloys T1 1 BB L2 CO2
PO2
Melting practices - Al alloys, Mg alloys, Nickel PO1 &
12 T1 1 BB L3 CO2
alloys, PO2
PO1 &
13 Melting practices - Zinc alloys and copper alloys T1 1 BB L3 CO2
PO2
PO1 &
14 modification and grain refinement of Al alloys T1 1 BB L2 CO2
PO2
problems in composition control- degassing PO1 &
15 T1 1 BB L2 CO2
techniques PO2
Heat Treatment of Aluminium alloys – Basics of PO1 &
16 T1 1 BB L2 CO2
Solution and Precipitation process. PO2
Applications of Aluminium Alloy castings in various PO1 &
17 T1 1 BB L2 CO2
fields. PO2
PO1 &
18 Residual Stresses- defects in castings. T1 1 BB L3 CO2
PO2
Suggested Activity: Seminar
Evaluation method: Evaluation of Seminar

UNIT III PHYSICAL METALLURGY OF WELDING

Welding of ferrous materials: Iron- Iron carbide PO1 &
19 T1 1 BB / NPTEL L2 CO3
diagram PO2
PO1 &
20 TTT and CCT diagrams T1 1 BB L2 CO3
PO2
PO1 &
21 Effects of steel composition T1 1 BB L2 CO3
PO2
formation of different microstructural zones in PO1 &
22 T1 1 BB / NPTEL L3 CO3
welded plain-carbon steels PO2
PO1 &
23 Welding of C-Mn and low-alloy steels T1 1 BB L3 CO3
PO2
phase transformations in weld and heat - affected PO1 &
24 T1 1 BB L2 CO3
zones PO2
cold cracking, role of hydrogen and carbon PO1 &
25 T1 1 BB L2 CO3
equivalent PO2
PO1 &
26 formation of acicular ferrite T1 1 BB L1 CO3
PO2
PO1 &
27 effect on weld metal toughness. T1 1 BB L1 CO3
PO2
Suggested Activity: MCQ given
Evaluation method: Evaluation of MCQ.

UNIT IV WELDING OF ALLOY STEELS AND NON-FERROUS METALS

PO1 &
28 Welding of stainless steels, types of stainless steels T2 1 BB / NPTEL L1 CO4
PO2
PO1 &
29 overview of joining ferritic and martensitic types T2 1 BB L2 CO4
PO2
PO1 &
30 welding of austenitic stainless steels T2 1 BB / NPTEL L2 CO4
PO2
PO1 &
31 Sensitisation, hot cracking T2 1 BB L2 CO4
PO2
sigma phase and chromium carbide formation, ways PO1 &
32 T2 1 BB L2 CO4
of overcoming these difficulties PO2
 PO1 &
33 welding of cast iron T2 1 BB L3 CO4
PO2
Welding of non-ferrous materials: Joining of
PO1 &
34 aluminium, copper, problems encountered and T2 1 BB / NPTEL L3 CO4
PO2
solutions
Welding of non-ferrous materials: Joining of nickel , PO1 &
35 T2 1 BB / NPTEL L3 CO4
problems encountered and solutions PO2
Welding of non-ferrous materials: Joining of PO1 &
36 T2 1 BB / NPTEL L3 CO4
titanium alloys, problems encountered and solutions PO2
Suggested Activity: Assignment given

Evaluation method: Evaluation of Assignment.

UNIT V DEFECTS, WELDABILITY AND STANDARDS

PO1 &
37 Defects in welded joints T2 1 BB L1 CO5
PO2
Defects such as arc strike, porosity - causes and PO1 &
38 T2 1 BB L2 CO5
remedies in each case PO2
Defects such as undercut, slag entrapment - causes PO1 &
39 T2 1 BB L2 CO5
and remedies in each case PO2
PO1 &
40 Hot cracking, causes and remedy T2 1 BB L2 CO5
PO2
PO1 &
41 Joining of dissimilar materials T2 1 BB / NPTEL L2 CO5
PO2
PO1 &
42 weldability of weldments T2 1 BB / NPTEL L1 CO5
PO2
PO1 &
43 Testing of weldments T2 1 BB L1 CO5
PO2
PO1 &
44 Testing of weldments T2 1 BB L3 CO5
PO2
PO1 &
45 Introduction to International Standards and Codes T2 1 BB L1 CO5
PO2
Suggested Activity: Quiz
Evaluation method: Evaluation of Quiz.

Content Beyond the Syllabus Planned

1 Introduction to Gleeble 2.0

2 Introduction to Composites
Text Books
1 Heine R W, Loper C R and Rosenthal P C, "Principles of Metal Castings", Tata McGraw Hill, 2017.
2 A.K.Chakrabarthi, ‘Casting Technology and Cast Alloys,Prentice Hall, 2005.
Reference Books
ASM International. Handbook Committee, ASM Handbook: Casting. Volume 15, ASM International, 2008.
1
2 Baldev Raj, Shankar V, Bhaduri A K, “Welding Technology for Engineers”, Narosa Publications, 2009.
3 Beeley P, “Foundry Technology" Butterworth-Heinemann, 2001.
4 R.S.Parmar, ‘Welding Engineering and Technology’, Khanna Publishers, 2010
5 John Campbell, “Casting", Butterworth-Heinemann, 2003.
Website / URL References
1 https://archive.nptel.ac.in/courses/113/107/113107092/
2 https://archive.nptel.ac.in/courses/112/107/112107215/
Blooms Level
Level 1 (L1) : Remembering Level 4 (L4) : Analysing Higher
Fixed Projects /
Lower Order Order
Level 2 (L2) : Understanding Hour Level 5 (L5) : Evaluating Mini
Thinking Thinkin
Exams Projects
Level 3 (L3) : Applying Level 6 (L6) : Creating g

Mapping syllabus with Bloom’s Taxonomy LOT and HOT

Unit No Unit Name L1 L2 L3 L4 L5 L6 LOT HOT Total

Unit 1 FERROUS CAST ALLOYS 4 3 2 0 0 0 9 0 9

Unit 2 NON-FERROUS CAST ALLOYS 2 5 2 0 0 0 9 0 9

Unit 3 PHYSICAL METALLURGY OF WELDING 2 5 2 0 0 0 9 0 9

WELDING OF ALLOY STEELS AND NON-FERROUS
Unit 4 METALS
1 4 4 0 0 0 9 0 9

Unit 5 DEFECTS, WELDABILITY AND STANDARDS 4 4 1 0 0 0 9 0 9

Total 13 21 11 0 0 0 45 0 45

Total Percentage 28.89 46.67 24.44 0 0 0 100 0 100

CO PO Mapping

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2

CO1 1 1 1 1 2 1

CO2 1 1 1 1 2 1

CO3 1 1 1 1 2 1

CO4 1 1 1 1 2 1

CO5 1 1 1 1 2 1

Avg 1 1 1 1 2 1

Justification for CO-PO mapping

PO1:Applying of engineering concept is more predominent, PO2: Applying the formulas and analyze the problems considered
CO1
moderately. PO3 is related to Design Engineering Problems.
PO1:Applying of engineering concept is more predominent, PO2: Applying the formulas and analyze the problems considered
CO2
moderately. PO3 is related to Design Engineering Problems.
PO1:Applying of engineering concept is more predominent, PO2: Applying the formulas and analyze the problems considered
CO3
moderately. PO3 is related to Design Engineering Problems.
PO1:Applying of engineering concept is more predominent, PO2: Applying the formulas and analyze the problems considered
CO4
moderately. PO3 is related to Design Engineering Problems.
PO1:Applying of engineering concept is more predominent, PO2: Applying the formulas and analyze the problems considered
CO5
moderately. PO3 is related to Design Engineering Problems.
3 High level 2 Moderate level 1 Low level

Name & Sign of Faculty Incharge : Mr.Rajesh J

Name & Sign of Subject Expert : Dr.Prasath.S
Head of the Department : Dr.Shunmugasundaram

Format No :231