Prereq: TA202; ESO204A OR ME231A

Solidification: Introduction, Evolution of solid/liquid interface, Solidification transport phenomena and its mathematical modelling. Casting: Introduction, Solidification rates and microstructure in casting, Transport Phenomena in casting, Fluidity, Casting defects, Casting design, Case studies of selected casting processes, Advanced means to control casting structure, properties and defects. Joining: Introduction, Physics of welding. Advanced applications of solidification principles.

No. of Lectures

I. Solidification (12 Lectures) :

• Course structure, Introduction to solidification/ melting 1
• Nature of solid/liquid interface, Plane front solidification, Constitutional undercooling 3
• Dendritic growth, Directional solidification 2
• Solidification transport phenomena: Solidification of pure metals and alloys 2
• Mathematical modelling of solidification transport phenomena (mass and heat transfer, fluid dynamics, mushy zone, species transport), Micro and macro-segregation 4

II. Casting (23 Lectures) :

• Introduction to casting, Microstructure in casting, Mathematical treatment of solidification rates, Mold-casting heat transfer Transport Phenomena in casting 3
• Gating and risering, Solidification shrinkage, Fluidity and its measurement 3
• Casting defects - compositional, microstructural 2
• Mold filling, shrinkage and other flow and heat transfer related defects 2
• Causes - role of transport phenomena in their formation, and Remedies 2
• Casting design - by controlling the accompanied heat transfer, fluid Flow and solidification, Riser design, gating design, Feeding distance, Mold filling design 3
• Case studies of selected casting processes - critical assessment of technology of mold, die and investment casting, direct chill casting, ingot casting, micro casting 5
• Control of casting structure, properties and defects through advanced means - inoculation practices, rheocasting, thixocasting, multiphysics means involving electromagnetic fields 3

III. Welding (3 Lectures):

• Introduction to joining, Classification of welding 1
• Welding - physics of welding, Different zones in welding, Characteristics of arc and mode of metal transfer 2

IV. Advanced applications of solidification principles (2 Lectures):

• Manufacturing processes, Energy 2 (40 Lectures)

Term Paper:

It should be based on analysis of solidification process (in manufacturing, energy) using solidification transport phenomena.

Suggested Readings:

1. Science and Engineering of Casting Solidification, Doru M Stefanescu, 2nd ed.
2. Solidification Processing, M C Fleming, McGraw Hill.
3. Metals Handbook-Metal Casting, ASM.
4. Casting, J Campbell, Butterworth-Heinemann.
5. Principles of metal casting, R W Heine, C R Loper and Rosenthal, Tata McGraw Hill, New Delhi.
6. Manufacturing Engineering and Technology, S Kalpakjian.
7. Fundamentals of Modern Manufacturing, M P Groover.

Welding: Principles and Applications, Larry F. Jeffus, 4th ed., Thomson learning, 1999.