Course name: Metal Casting and Joining

Course Code: MM 359

Course Instructor:
Solidification: Prof. K. Bhanumurthy
Casting: Prof. S. Basu
Welding: Prof. K. Bhanumurthy
Motivation behind the course:
The course is intended to give a feel of casting and joining. The courses content is divided into
three parts. These are (a) solidification which revolves around the different theoretical
methodology of solidification. It can be considered as a brief description of Phase
Transformation course.
The second part is joining which tends to provide knowledge about the casting, casting
methods and study of type of defects in casting and their remedies. Along with the various
defects detection techniques.
The last part is welding/joining which discusses about the classification of welding, type of
welding and its application in real life. It also discusses about the various metallurgical and nonmetallurgical defects and their detection techniques.
The course runs parallel with the Joining and Casting lab which provides hands on experience
on principles and techniques of joining and casting. It helps in better understanding of the
course.
Course Content:
The course content is divided into three partsa) Solidification
b) Casting
c) Joining
Detailed course content for the following is as followsa)

Solidification:
Nucleation: Homogeneous and Heterogeneous
Nucleation, growth and their rates
Nucleation and growth of crystals with mechanism
Nucleation Kinetics
Transformation rate

Time-Temperature Transformation( TTT )diagram

Rapid Solidification
Solidification in pure metals
Cooling curves of metals, alloys and non-metals
Concepts of super cooling, superheating and under cooling
Liquid -> Solid phase transformation
Driving force for solidification
Dendrite structures and their formation
Freezing in alloys
Constitutional super cooling
Solidification of solid solution alloys
Freezing of Ingots (Practical Implications)
Solute redistribution partition coefficient
Complete equilibrium and Scheil equation
Single, binary, isomorphous, eutectic, peritectic, peritectoid, eutectoid andnonequilibrium alloys systems
Intermediate compounds and phases with examples

b)

Casting:
Introduction to casting
Casting terminologies
Moulding techniques
Properties of mould sand
Shapes and size of grains
Cast iron white and grey cast iron
Properties of white and grey cast iron
Special casting techniques
Shrinkage and casting related problems
Casting defects and their remedies
Detection of casting defects

c)

Joining:
Why study joining of materials including the history of welding
Classification of welding/joining (Fusion vs Solid state bonding and Thermit welding )
Ternary diagrams A Basics
Ternary diagrams B Invariant reactions, Pseudo binary, isothermal, liquid projections
and Fe-Cr-Ni system
Fusion methods part A Gas and Arc welding (Flux, chemical reactions)
Fusion methods part B - Electron beam and laser welding
Welding geometrics and welding defects

Non-fusion processes part A - Diffusion bonding, HIP and Liquid phase bonding
Concepts of diffusion path in binary and ternary systems
Non- fusion processes part B Friction Welding, explosion welding and Friction stir
welding
Basic concepts of residual stress and their remedy
Welding metallurgy
Basic concept Brazing and soldering and metal/ ceramics contacts
Fusion welding of Al alloys
Weld defects in steel metallurgical aspects
Fusion welding of steels
NDT and evaluation of weld joints

Prerequisites:
There are no as such prerequisites required as Professors will cover every part in the class but
the solidification part involves certain important terms related to the Phase transformation
course. It would be beneficial if you remember course content of Phase transformation.

Feedback on tutorials, assignments and exams:

The marks distribution is even which provides opportunity to score at various points of time
during the semester. The marks distribution for batch 2015-16 was as follows:1) Quiz 1 (Solidification) - 10 marks - Objective (MCQs) type questions Negative marking
on incorrect answer
2) Quiz 2 (Casting) - 9 marks Subjective + MCQs type question No negative marking
3) Tutorial (Casting) 2 marks Shrinkage problem + Heat extracted problem - Conducted
in a group of 4
4) Mid-semester exam 15 marks (Solidification) + 15 Marks ( Casting ) MCQs +
Subjective + Problem solving type questions No negative marking
5) Quiz 3 (Welding) 9 marks - Problem solving + Subjective questions + MCQs Negative
marking in MCQs
6) End-semester exam 10 marks (Casting) + 24 marks (Welding) + 6 marks (Solidification)
Theoretical + MCQs + Problem solving No negative marking
Study material and references:
a) Solidification:
Book - D. A. Porter, K. E. Easterling - Phase Transformations in Metals and AlloysSpringer US (1992)
Class notes and slides are crucial.

b) Casting:
Slides and class notes are sufficient
c) Joining:
Books - Welding Metallurgy by Sindo Kou, Principles of Welding by R. W. Messler.
Reference materials Ternary Phase Diagrams in Materials Science by D. R. F. West and
S. Saunders.
Class notes and slides are crucial.
It is recommended to make class notes and write as much details as possible into notebook as
dictated by the professors during lectures in each part of the course.
Miscellaneous:
Class notes & regular lectures are keys to score a good grade in this course. The questions in
exams are directly from the problems which were being solved in the class especially in the case
of casting. Prof. K. Bhanumurthy teaches concepts which are either not explained properly in
the book recommended by Prof. or it is difficult to get it from online study material. It is
recommended to be regular in class and note down as much details as possible. Both professors
are student friendly and are inclined towards learning of students. Also, it is been observed that
going through previous year papers and solving back questions of relevant chapters of
recommended books helps a lot in scoring good marks.

Thanks
Shubham Chourasiya