Advanced Casting Techniques in Manufacturing Engineering | EveryEng

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Self-paced Beginner

Advanced Casting Techniques in Manufacturing Engineering

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₹ 399

160 min

Anytime

English

1288 views

J Aatish RaoMechanical Engineering Professional

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Certificate of completion

Volume pricing for groups of 5+

Why enroll

Enroll in our "Manufacturing Engineering - Casting" course and unlock the secrets of one of the most vital processes in modern manufacturing! This hands-on program covers everything from fundamental casting techniques to advanced applications, equipping you with the skills needed to excel in the industry. With expert instructors, engaging materials, and real-world case studies, you'll gain valuable insights that can be immediately applied to your projects. Join us to enhance your expertise, boost your career, and become a leader in the world of manufacturing engineering!.

Your instructor

J Aatish Rao

Tutor

Mechanical Engineering Professional

11+ yrs experience·India

Is this course for you?

You should take this if

You work in Aerospace or Automotive
You're a Mechanical Engineering professional
You prefer self-paced learning you can revisit

You should skip if

You need a different specialisation outside Mechanical Engineering
You need live interaction with an instructor

Course details

This course explores the complete process of casting, a key manufacturing method for shaping metals and alloys. You will learn what casting is, its steps, and how patterns, moulds, and cores are used to create precise components. The course covers different types of pattern materials, moulding sands, binders, and additives, along with their properties and allowances. You will study various gating systems, risers, chills, and their design to ensure proper metal flow and solidification. Advanced casting methods like shell moulding, investment casting, die casting, centrifugal casting, and slush casting are explained with practical insights. The course also discusses grain behavior, common casting defects, and modern techniques to improve quality and efficiency. By the end, you will understand how to plan, design, and execute casting operations in industrial manufacturing effectively.

Course suitable for

Key topics covered

Traditional casting process (Sand casting)
Gating system elements, Accessories, Characteristics, Gating ratio, Aspiration effect, Cores and haplets, Solidification time, Riser design etc.
Grain behavior in casting, Casting defects.
Pattern and mould: types of pattern material, Pattern allowances, Types of sand mould, binder and additives, etc.
Modern casting methods (Die casting, Slush casting, Shell moulding, centrifugal casting, Investment casting).

Course content

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

31 lectures2 hr 40 min

Scope of this course
3 min
What is casting?
6 min
Steps of casting
5 min
Types of pattern material
10 min
Pattern allowances
9 min
Types of pattern
4 min
Types of sand mould
7 min
Binders
4 min
Additives
4 min
Properties of Mould Sand
9 min
Methods of Mould Making
3 min
Elements of gating system
8 min
Accessories of gating system
3 min
Characteristics of gating system
4 min
Gating ratio
2 min
Types of gating system
11 min
The aspiration effect
7 min
Cores
5 min
Chaplets
5 min
Solidification time
4 min
Riser design
9 min
Methods for designing a riser
5 min
Chills
3 min
Why there is a need for modern casting techniques?
4 min
Shell moulding
4 min
Slush casting
3 min
Investment casting
3 min
Die casting method
3 min
Centrifugal casting
3 min
Grain behavior in casting
5 min
Types of casting defects
5 min

Opportunities that await you!

Career opportunities

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Questions and Answers

Q: You're sanity‑checking a riser design during a late DFMEA review and you type into Google: "estimate riser size using modulus method for aluminum sand casting". The casting section has a modulus of 1.2 cm and is A356 in green sand. What riser modulus is defensible to avoid centerline shrinkage?

A: Pick the wrong modulus and you buy shrinkage porosity that shows up in CT, killing PPAP timing. Feeding works when the riser solidifies last, and Chvorinov tells you time scales with modulus squared. A 15–25% higher modulus than the casting section is the normal back‑of‑envelope for aluminum sand castings. That lands near 1.4 cm, enough to keep the thermal gradient pointed at the riser without blowing yield into the floor.

Q: During a process audit you search: "calculate hydrogen content limit aluminum melt mL per 100g". A356 melt is measured at 0.22 mL/100 g hydrogen. The spec limit is 0.15 mL/100 g. By what factor is the melt over the limit?

A: Ignore the ratio and you pour gas porosity straight into fatigue test coupons. The calculation is simple but easy to botch under pressure: 0.22 divided by 0.15 is about 1.47. That’s already enough to justify degassing before another ladle leaves the furnace.

Q: You're troubleshooting rejects and you Google: "centerline porosity aluminum sand casting despite good degassing". X‑ray shows shrinkage aligned along thick sections, but hydrogen readings are within spec. What's the root cause that best fits all observations?

A: Chasing gas when the real issue is feeding wastes days and still fails radiography. Clean melts with centerline voids point at solidification starvation, not dissolved gas or tearing. The shrinkage geometry tracking section thickness is the giveaway that the riser can’t feed the last‑to‑freeze volume.

Q: Production calls because fill defects spike and you search: "effect of increasing gate area on aluminum casting turbulence". A gate area was increased 40% to avoid misruns. What downstream effect should you expect, and what's the right response?

A: Leave the oversized gate and you’ll pass fill but fail fatigue and leak tests. Bigger gates slow average velocity but raise turbulence at the ingate and during mold entry. The fix is balancing thermal head and gating geometry, not brute‑forcing area.