MME345 Foundry Engineering

4.00 Credit Hours    400 Marks

July 2018 Term

Lecture Notes

Part A:  Foundry Technology

Chapter One:  Introduction
A:01   Materials processing technology      [silde]
A:02   Casting as a metal forming process      [silde]
Chapter Two:  Moulding and Casting Methods
A:03   Introduction to moulding & casting methods      [silde]
A:04   Greensand moulding aggregate      [silde]
A:05   Sand bonding & moulding defects      [silde]
A:06   Testing & quality control      [silde]
A:07   Other sand-based casting methods 1      
A:08   Other sand-based casting methods 2      
A:09   Metal mould system 1      
A:10   Metal mould system 2      
Chapter Three:  Patternmaking and Core Making
A:11   Patternmaking and core making      
A:12   Pattern allowances and core print design      
Chapter Four:  Ferrous Foundry
A:13   Families of cast irons      
A:14   Solidification of grey iron      
A:15   Melting of cast iron in cupola      
A:16   Metallurgy of grey iron      
A:17   Grey iron foundry practice      
A:18   Melting and solidification of ductile iron      
A:19   Process control in ductile iron making      
A:20   Steel foundry practices      
Chapter Five:  Nonferrous Foundry
A:21   Aluminium foundry practices      
A:22   Copper foundry practices      
A:23   Magnesium and zinc foundry practices      
Chapter Six:  Finishing and Quality Control
A:24   Fettling, finishing and quality control      
Review Class 1

Part B:  Foundry Engineering

Chapter One:  Introduction
B:01   Creating quality casting      [slide]
Chapter Two:  Solidification
B:02   Heat transfer      [slide]
B:03   Nucleation and growth of solids      [Slide]
B:04   Solidification of metals and alloys      [Slide]
B:05   Formation of dendrites      [Slide]
B:06   Formation and control of grain structures      [Slide]
Chapter Three:  Feeding Design
B:07   Necessity of feeding      [Slide]
B:08   Feeding calculations 1      [Slide]
B:09   Feeding calculations 2      [Slide]
B:10   Design of feding system      [Docx File]
B:11   Case study in feding design      [Docx File]
Chapter Four:  Gating Design
B:12   Fluidity of liquid metal      [Slide]
B:13   Introduction to gating system      [Slide]
B:14   Theoretical considerations in gating design      [Slide]
B:15   Design of gating system 1      {Slide]
B:16   Design of gating system 2      [Slide]
B:17   Calculations of gating system dimensions      [Slide]     [Doc File]
B:18   Case study in gating design      [Slide]     [Doc File]
Chapter Five:  Casting Defects
B:19   Segregation & Gas porosity      
B:20   Hot tear      
B:21   Oxide film and bubble defects      
B:22   Effect of defects on properties      
Chapter Six:  Casting Design
B:23   Design considerations 1      
B:24   Design considerations 2      
Review Class 2