ME664A - Fundamentals of Casting & Solidification

1. Introduction to Casting Problem: Principles of solidification, introduction to fluid flow and microstructure in a casting process.

2. Solidification Transnort Phenomena in Casting: Solidification of pure metals and alloys; Nucleation and growth; Natwe of solic VI liquid interface; Constitutional under cooling; Dendritic growth; Directional solidification. Mathematical treatment of solidification transport phenomena involved in a casting process (mass and heat transfer, fluid dynamics, mushy zone); Mathematical analysis of re-distribution of solute during solidification, micro and macro segregation.

3. Defects: Casting defects (compositional, micro structural, mold filling, shrinkage and other flow and heat transfer related defects), their causes and remedies; Understanding the role of transport phenomena in the formation of these defects.

4. Case Studies of Some Selected Casting Processes: Mold, die and investment casting; Direct chill casting; Ingot casting; Directional solidification, Micro casting. Manipulation and control of casting structure, properties and defects through advanced casting processes Inoculation practices, rheo-casting, thixo-casting, multi-physics casting processes involving magnetic fields.

5. Casting Design by Controlling the Accompanied Heat Transfer 2 Fluid Flow and Solidification: Mathematical treatment of solidification rates exact and approximate methods; mold casting heat transfer. Riser design, feeding distance, mold filling and their relation with temperature distribution and dimensional design of the casting.