Materials processing ( casting, forming and welding)-I | EveryEng

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Materials processing ( casting, forming and welding)-I

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960 min

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Why enroll

Participants join Materials Processing (Casting, Forming, and Welding) to gain a solid understanding of the core manufacturing processes that underpin most mechanical and industrial products. The course enables learners to understand how raw materials are transformed into usable components and how processing methods influence microstructure, mechanical properties, quality, and service performance.

Many participants are motivated to develop practical knowledge of casting, forming, and welding techniques that are widely used across industries such as automotive, aerospace, construction, heavy engineering, and energy. The course helps learners make informed decisions regarding process selection, material suitability, defect prevention, and cost-effective manufacturing, which are critical skills for production, design, and quality roles.

Participants also join to strengthen their technical foundation for advanced studies, research, or professional certification in manufacturing and materials engineering. By linking theoretical principles with real-world applications, the course supports career growth for students, practicing engineers, and professionals seeking to enhance their competence in materials processing, fabrication, and manufacturing technology.

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Is this course for you?

You should take this if

You work in Manufacturing & Industrial or Mechanics & Turbomachinery
You're a Manufacturing Engineering / Mechanical Engineering professional
You have 3+ years of hands-on experience in this field
You prefer self-paced learning you can revisit

You should skip if

You're new to this field with no prior experience
You need a different specialisation outside Manufacturing Engineering
You need live interaction with an instructor

Course details

Materials Processing (Casting, Forming, and Welding) deals with the fundamental principles and practical techniques used to convert raw materials, particularly metals and alloys, into functional engineering components with desired shapes, dimensions, and properties. The course provides a comprehensive understanding of how material behavior, process parameters, and manufacturing conditions influence the quality, performance, and reliability of finished products.

The course begins with casting processes, focusing on the science of melting, pouring, solidification, and cooling of metals. Topics include sand casting, die casting, investment casting, and continuous casting, along with mold materials, gating and riser design, solidification defects, and methods for improving casting quality. Emphasis is placed on understanding microstructure evolution during solidification and its impact on mechanical properties.

Metal forming processes are then explored, covering both bulk deformation and sheet metal forming techniques such as rolling, forging, extrusion, drawing, bending, and deep drawing. The course examines material flow, stress–strain behavior, plastic deformation, forming loads, lubrication, and formability limits. Process design considerations, defect prevention, and the role of temperature in hot and cold working are also discussed.

The welding and joining section focuses on permanent joining processes used in manufacturing and fabrication. Various welding techniques, including arc welding, resistance welding, gas welding, and advanced welding processes, are introduced. Topics include weld metallurgy, heat-affected zones, residual stresses, welding defects, and quality inspection methods. The course highlights the relationship between welding parameters, joint design, and structural integrity.

Overall, the course integrates theoretical concepts with practical insights to help participants understand the selection, design, and optimization of casting, forming, and welding processes. It prepares learners to address real-world manufacturing challenges, improve product quality, and make informed decisions in materials processing and fabrication applications.

source: NPTEL [youtube]

Course suitable for

Key topics covered

materials and microcture evolution
basics of heat conduction
basics of fluid flow
solidification processing
casting and welding
material forming

Course content

The course is readily available, allowing learners to start and complete it at their own pace.

26 lectures16 hr

Materials and microcture evolutions-1
45 min
Materials and microcture evolutions-2
46 min
Materials and microcture evolutions-3
27 min
Basics of heat conduction-1
30 min
Basics of heat conduction-2
34 min
Basics of heat conduction-3
35 min
Basics of heat conduction-4
30 min
Basics of fluid flow-1
31 min
Basics of fluid flow-2
36 min
Solidification processing-1
55 min
Solidification processing-2
54 min
Casting and welding-1
63 min
Casting and welding-2
43 min
Casting and welding-3
35 min
Casting and welding-4
44 min
Material forming
68 min
Material forming: Numerical problem
29 min
Processing of metal: Casting Process- I
41 min
Processing of metal: Casting Process- II
30 min
Processing of polymer: Thermoplastic and thermosets
23 min
Processing of polymer: Extrusion
31 min
Processing of polymer: Injection molding
29 min
Processing of polymer: Blow molding
22 min
Processing of polymer: Thermosets
25 min
Processing of ceramics - I
24 min
Processing of ceramics - II
30 min

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Questions and Answers

Q: You're checking a foundry trial and typing into Google: "Chvorinov rule solidification time casting calculation for steel riser". A steel casting uses a sand mold with mold constant C = 4.5 min/cm². The casting has V/A = 1.8 cm. The riser must freeze last with a 20% safety margin on solidification time. What minimum V/A should the riser have?

A: A feels small, but it respects the physics. Chvorinov ties time to (V/A)², so the margin belongs on time first, then you work back to modulus. B is the trap people fall into when they forget why risers exist at all. C sounds tidy, but adding margin to modulus instead of time underestimates the riser because of the squared relationship. D looks conservative, yet double-counting margin kills yield and doesn't match the design intent.

Q: On the shop floor you're searching: "welding WPS verification steps before production run". A supplier proposes a filler metal substitution that slightly lowers impact toughness, eating into the original safety margin. The drawing references AWS D1.1:2010, but that standard has been superseded. Before approving the weld, what should you verify first?

A: A slows things down for a moment, but it prevents rework later. Contract language decides which code applies, not what's newest. B feels practical, yet testing without knowing the governing code leaves you exposed during audit. C is common in the field, but codes don't replace contract terms by default. D protects safety emotionally, not technically, and ignores that margins are sometimes intentionally adjusted with proper approval.

Q: You Google: "hot cracking in aluminum welds high silicon magnesium". An aluminum casting with ~7% Si and 0.4% Mg shows centerline cracks after repair welding. What's the dominant mechanism?

A: A matches the alloy chemistry and timing. The cracks form during solidification, not later. B sounds familiar from steels, but aluminum doesn't behave that way. C applies to rolled plate with inclusions, not cast aluminum. D needs service exposure and time, neither of which fits a post-weld observation.

Q: Design review search phrase: "casting process selection thin wall steel component". You need to produce a thin-walled steel housing, 4 mm nominal wall, moderate volume, good surface finish, and minimal machining. Which process fits best?

A: A lines up with the constraints even if procurement winces at the tooling quote. B can make the shape, but the wall thickness and finish will fight you every run. C works for aluminum and zinc; steel makes the die life unacceptable. D helps with symmetry and density, not complex housings.