JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Prerequisites

Production Technology, Heat transfer, FEM.

Course Objectives:

• To impart the knowledge of advanced welding and casting techniques.
• To apply computer aided engineering to welding and casting.

Course Outcomes

Student will be in a position to analyze the advanced welding and casting

processes and can relate variables with performance measures.

UNIT - I

Laser Beam Welding: Types of lasers, equipment, power calculation, applications, dual laser beam welding, use of fibre optics in LBW. Friction Stir Welding: Details of process and process parameters, specific applications. Electron Beam Welding: The interaction of electron beam with matter, mode of heat generation, mode of energy losses, details of the equipment, product design for EBW, case studies. Ultrasonic Welding: Propagation of ultrasonic waves in matter, mode of joint formation, joint types and design of product for ultrasonic welding, details of equipment and case studies, cutting and gauging, flame cutting, plasma arc welding, laser assisted cutting.

UNIT - II

Heat flow in welding: Significance, theory of heat flow, cooling rate determination, selection of welding parameters based on heat flow analysis, residual stresses and distortion. Joint design, analysis of fracture and fatigue of welded joints. Automated welding systems.

UNIT - III

Investment casting, shell moulding, squeeze casting, vacuum casting, counter-gravity flow - pressure casting, directional and mono crystal solidification, squeeze casting, semisolid metal casting, rheocasting.

UNIT - IV

Solidification, Gating and Rising, Nucleation and grain growth, solidification of pure metals, short and long freezing range alloys. Gating and riser design calculations, Fluidity and its measurement.

UNIT - V

CAE of Welding and Casting: Design of weldment, application of finite element method in welding – determination of distortion in weldments, modeling of temperature distribution - case studies. Design for casting, application of finite element method in casting - determination of hot spots, location of turbulence and other defects, modeling of flow in molds, modeling of heat transfer in castings – case studies.

TEXT BOOKS:

• 1. Metal Casting: Computer Aided Design and Analysis by Ravi B, Prentice Hall, 2005.
• 2. Welding and Welding Technology by Richard L Little, Tata McGraw Hill, 2004.
• 3. Casting Practice by John Campbell, Elsevier Science Publishing Co., 2004.
• 4. Welding: Principles and Applications by Larry Jeffus, Delmar Publishers, 2004. R19 M.Tech. Production Engineering

REFERENCE BOOKS:

• 1. Casting by John Campbell, Butterworth Heinemann, 2003.
• 2. Welding Processes Handbook by Klas Weman, 2003.
• 3. Modern Welding Technology by Howard B Cary, Prentice Hall, 2002.
• 4. Welding for Collision Repair by Larry Jeffus, Delmar Publishers, 1999.
• 5. Casting, ASM Hand Book, ASM International, 1998. R19 M.Tech. Production Engineering M. TECH. I Year II Sem. (PRODUCTION ENGINEERING)