Section 3: Manufacturing Processes I
Casting: types of casting processes and applications; patterns – types and materials; allowances; moulds and cores – materials, making, and testing; casting
techniques of cast iron, steels and nonferrous metals and alloys; analysis ofsolidification andmicrostructure development; design of gating and riser; origin of defects.
Metal Forming: Stress-strain relations in elastic and plastic deformation; concept of flow stress; hot and cold working – forging, rolling, extrusion and wire drawing; sheet metal working processes – blanking, bending and deep drawing; ideal work and slab analysis;origin of metal workingdefects.
Joining of materials: Principles of fusion welding processes(manual metal arc, MIG, TIG, plasma arc, submerged arc welding processes)–different heat sources (flame, arc, resistive, laser, electron beam), and heat transfer and associated losses, flux application, feeding of filler rod; Principles of solid state welding processes (friction, explosive welding, ultrasonic welding processes); Principles of adhesive, brazing and soldering processes; Origins of welding defects.
Powder processing: Production of metal/ceramic powders, compaction and sintering of metals and ceramic powders.
Polymers and Composites: Plastic processing – injection, compression and blow molding, extrusion, calendaring and thermoforming; molding of composites.
Casting: types of casting processes and applications; patterns – types and materials; allowances; moulds and cores – materials, making, and testing; casting
techniques of cast iron, steels and nonferrous metals and alloys; analysis ofsolidification andmicrostructure development; design of gating and riser; origin of defects.
Metal Forming: Stress-strain relations in elastic and plastic deformation; concept of flow stress; hot and cold working – forging, rolling, extrusion and wire drawing; sheet metal working processes – blanking, bending and deep drawing; ideal work and slab analysis;origin of metal workingdefects.
Joining of materials: Principles of fusion welding processes(manual metal arc, MIG, TIG, plasma arc, submerged arc welding processes)–different heat sources (flame, arc, resistive, laser, electron beam), and heat transfer and associated losses, flux application, feeding of filler rod; Principles of solid state welding processes (friction, explosive welding, ultrasonic welding processes); Principles of adhesive, brazing and soldering processes; Origins of welding defects.
Powder processing: Production of metal/ceramic powders, compaction and sintering of metals and ceramic powders.
Polymers and Composites: Plastic processing – injection, compression and blow molding, extrusion, calendaring and thermoforming; molding of composites.
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