Foundry Craft Practice

course outline

Topics

• Common Foundry Tools and Devices

  Naming, identifying, and describing the use of various foundry tools and devices.

• Types and Techniques of Foundry Works

  Principles, techniques, classes, types, advantages, and disadvantages of foundry work.

• Principles of Common Pattern Making Tools and Their Application

  Working principles, application, usage, maintenance, and materials for pattern making tools.

• Safety Aspects of Pattern Making

  Factory safety acts, identification of devices, and associated hazards in the pattern making workshop.

• Essential Features and Working Principles of Core Making Machines

  Features and working principles of core machines for mixing sand, drying, and manipulation, and properties of sand used in core making.

• Simple Calculations Involving Core Sand Preparation

  Simple calculations involving ingredients for mixing volumes, test results, and losses in core sand preparation.

• Types of Moulds, Their Uses, Techniques and Methods of Production

  Explanation of all types, techniques, and methods of moulding, properties of sand, use of moulding fixtures, and calculations relating to pressure and force.

• The Importance of Facing and Dressing the Mould with Appropriate Materials

  Importance of facing and dressing moulds, and the selection of dressing materials based on sand properties.

• The Principle of Post Casting Knocking Cleaning and Fettling

  Manual and mechanical knock-out operations, dangers of premature knock-out, and safety measures.

• Maintenance and Operation of Common Foundry Melting Furnaces

  Construction, function, operation, melting losses and gains, and tapping operations of common foundry furnaces.

• The Principles of Heat Effect of the Heat on Materials

  Mathematical calculations involving the effect of heat on metals, heat transfer processes, thermal efficiency, and heat treatment.

• Casting Finishing Using Machining, Polishing, Painting, and Chemical Treatment

  Principles of machining, polishing, painting, and chemical treatments like electroplating, anodizing, and galvanizing on cast surfaces.

• Industrial Methods of Removing Scales and Oxide Films from Metal Surfaces Prior to Electroplating

  Importance of surface cleanliness, structure of scales and oxide films, and different methods of surface cleaning.

• Electroplating Processes and Methods

  Metal coating methods, hot dipping process, cementation process, vapour deposition methods, and conversion processes.

• Different Electroplating Solution or Metallic Coatings and Their Applications

  Industrial process of zinc coatings, aluminium coatings, bright and hard anodizing, nickel electro-deposition, and chromium plating.

• Waste Control, Management and Disposal in an Electroplating Industry

  Sources and control of solid and liquid waste, handling and disposal of waste, and estimation of cyanide and pH value in waste chemicals.

• Methods of Inspection and Identification of Faults and Defects on Electroplated Components

  Reasons and causes of defects and faults on electroplated components and proper selection of materials and chemicals.