Course

Unit 1

Advanced Casting: Recap of conventional casting processes and casting metallurgy. Advanced casting processes: Continuous casting, Investment casting, Vacuum casting, Squeeze casting and Stir Casting, Directional solidification process. Rapid solidification processes – Foil strip and thin/micro casting, metallic glasses. Analysis of casting processes using software tools – Case studies.

Unit 2

Advanced Welding: Recap of conventional welding processes and welding metallurgy. Introduction to welding standards. Weldability of stainless steels, Cu, Al, Ti, Ni alloys, dissimilar materials, non-metallic materials. Advanced welding processes: Plasma Arc welding, Laser beam welding, Electron beam welding and solid-state welding processes. Micro welding, Analysis of welding processes using software tools – Case studies.

Unit 3

Advanced machining processes: Electric Discharge Machining – Abrasive Jet Machining – Abrasive Water Jet Machining. Laser Beam machining and drilling. Laser cutting, Plasma Arc machining and Electron Beam Machining. Metal removal mechanisms, applications and case studies.

Unit 4

Advanced forming processes: Stress strain relations in elastic and plastic deformation – concept of flow stress determination – deformation mechanisms. Severe plastic deformation and High energy rate forming-Electro-magnetic forming, explosive forming, Hydro forming, Electro-hydraulic forming, Stretch forming, Contour roll forming and roll bonding. Applications and case studies.

Course Objectives

1. To familiarize the fundamentals of advanced casing processes and to understand the basic concepts of
2. To give exposure to various advanced welding techniques and to be familiarize with welding standards, weldability of different materials.
3. To select and apply various advanced machining processes for specific applications and to understand the optimization of parameters to obtain the desired machining quality.
4. To make students’ understand the concepts of severe plastic deformation and High energy rate forming and to be familiarize with basics of stress strain relations and the deformation mechanisms.

Course Outcomes

Skills Acquired

Ability to select the appropriate casting, welding processes, advanced machining processes, severe plastic deformation and high energy rate forming processes & to optimize its process parameters to obtain the desired quality.

1. Yu, O., “Modelling for Casting and Solidification Processing”, Marcel Dekker, 2002.
2. Sindo Kou, “Welding Metallurgy”, Second Edition, John Wiley Publications, New York,
3. Jain K., “Advanced Machining Processes”, Allied Publishers Pvt. Ltd., NewDelhi, 2007.
4. Hassan Abdel-Gawad El-Hofy “Advanced Machining Processes / Non Traditional and Hybrid Machining Processes”, McGraw-Hill Education, First Edition, 2005.
5. F. Benedict, Marcel Dekker, “Non-traditional Manufacturing Processes”, Marcel Dekker, 1987.
6. P. DeGarmo, J. T Black, R. A. Kohser, “Materials and Processes in Manufacturing”, 10th Edition, John Wiley & Sons, 2008.
7. Henry Valberg., “Applied Metal Forming”, Cambridge University Press, 2012.
8. Wagoner, H. and Chenot, J. L., “Metal Forming Analysis”, Cambridge University Press, 2005.