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

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Materials processing ( casting, forming and welding)-II

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1209 min

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Engineering AcademyLearn Without Limits: Free Engineering Courses

Mechanics & Turbomachinery

Mechanical Engineering

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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 Mechanics & Turbomachinery
You're a Mechanical Engineering / Production 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 Mechanical 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

processing of glass and fuse depostion modeling
arc welding process
metallic wire additive manufacturing
hot working and cold working
solid state deformation
powder processing

Course content

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

24 lectures20 hr 9 min

Processing of glass and fused depostion modeling
38 min
Arc welding processes
28 min
Welding of polymers
46 min
Laser and electron beam welding processes
38 min
Advanced welding processes
48 min
Welding solidification
51 min
Metallic wire additive manufacturing
53 min
Mechanical responses of metals and polymers
52 min
Hot working and cold working
29 min
Types of metal forming processes
20 min
Types of metal forming processes-II
29 min
Types of metal forming processes-III and Hot rolling of steel
34 min
Solid state deformation-1
69 min
Solid state deformation -2
72 min
Powder processing-1
60 min
Powder processing-2
73 min
Powder processing -3
58 min
Ceramic processing: Dry pressing & plastic forming methods
57 min
Ceramic processing: Colloidal processing, casting, and coating techniques
66 min
Introduction to steel making and single crystal production
62 min
Integrated Analysis of Steel Solidification, Fluid Flow, and Prodder Processing Technologies
69 min
Processing of electronics Materials, A case Study: semiconductor measurements
61 min
Processing of magnetic materials & Processing of magnetic materials for advanced materials
61 min
Processing of optics materials and pertaining case study
35 min

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Questions and Answers

Q: You're reviewing a GA weld detail while searching "interpret weld symbol staggered intermittent fillet casting repair". The drawing shows a staggered intermittent fillet weld on a cast steel housing, 6 mm size, 40 mm length, 60 mm pitch, both sides. The supplier proposes substituting continuous 4 mm fillet welds to reduce heat input. What’s the real technical issue with accepting this substitution?

A: Governing principle: weld size and distribution control effective load transfer, not visual continuity. Here, the original intermittent pattern preserved a minimum throat area tied to a safety margin in the casting check. Dropping size while going continuous undercuts that margin. Option D traps engineers who know fatigue can improve with continuity but miss that static strength drove the original detail.

Q: A formed stainless expansion joint cracks circumferentially after hydrotest. You're googling "hydrotest crack in cold formed stainless weld toe". NDE shows cracks starting at the weld toe only on one half of the joint. Forming records show higher than planned cold work. What’s the most likely root cause?

A: Governing principle: cold work raises strength but strips ductility and amplifies residual stress. The asymmetric cracking lines up with forming strain, then hydrotest pressure adds the last increment. Chlorides and lamellar tearing don’t match the location or timing. Option C catches people who default to weld defects without reconciling why cracks start at the toe.

Q: During FAT, you’re checking a repair weld on a cast pump casing and searching "field verification steps casting weld repair FAT". The ITP lists visual, MT, PWHT, then pressure test. What should you verify before releasing the casing for PWHT?

A: Governing principle: inspection sequence preserves defect detectability. MT must happen before PWHT since heat can blunt or close tight cracks in cast repairs. Dimensional checks matter, just later. Option B tempts people who think distortion control outranks defect screening at this stage.

Q: You’re validating a weld procedure and search "calculate heat input SMAW casting repair kJ per mm". SMAW parameters: 180 A, 24 V, travel speed 150 mm/min, efficiency 0.8. What heat input should you compare against the casting’s max allowed value?

A: Governing principle: heat input scales with power, efficiency, and inverse travel speed. (180×24×0.8)/(150/60) gives about 13.8 kJ/mm, the number the casting spec limits. Option B catches engineers who drop a zero converting minutes to seconds.