Manufacturing Processes

Steps in making a casting; advantages and applications; Patterns and pattern making; types of patterns; pattern allowances; moulding and cores; Principles of gating, risers and casting design considerations; Special casting processes: centrifugal, die, investment and shell moulding

Classification of welding processes; types of welded joints; gas welding, flames and oxy-acetylene cutting; Arc welding: MMAW, submerged arc, TIG and MIG, electro-slag welding; Resistance, friction, friction-stir, forge, explosive, thermit, plasma-arc, laser and electron-beam welding; Soldering and brazing; heat affected zones; pre- and post-heating

Plastic deformation; recovery, recrystallization and grain growth; hot and cold working; strain hardening and annealing; Forging: types, defects and remedies; Rolling: types of mills and products, forces and power requirements; Extrusion (impact and hydrostatic); wire drawing and tube drawing

Blanking and piercing; forces and power requirements; Deep drawing, stretch forming, bending, spring back and remedies; Coining, spinning; types of presses and press tools; High energy rate forming: explosive, electromagnetic, electro-hydraulic and rubber pad forming

Methods of producing metal powders: milling, atomization, granulation, reduction and electrolytic deposition; Compacting methods; Sintering and methods of manufacturing sintered parts; Secondary operations and applications of powder metallurgical products