Introduction: Basics, Primary and secondary manufacturing processes, types, and examples. (3 hours)

Metal Casting: Conventional and advanced casting processes, including brief mentions of solidification techniques, their significance, and practical control of cast structure. This also encompasses both conventional and advanced casting processes, including sand casting, investment casting, die casting, centrifugal casting, full mold casting, and others with use advantages and drawbacks. (12 hours)

Metalworking: Fundamentals of metalworking, difference between hot and cold deformation, forging, rolling, wire drawing, extrusion – basic concepts and applications. (5 hours)

Powder metallurgy: Basic concept and applications in the metallurgical field, advanced powder processing techniques. (3 hours)

Metal Joining: Principle, theory and classification of welding process, details for each type of welding metallurgy of carbon and alloy steels cast irons, stainless steels, Al and Cu based alloys, weldability and heat affected zones (HAZ); Hardfacing: Basic concept and applications, Difference between both the processes, consumables used, methods of brazing, fluxes used, their purposes and flux residue treatment, Brazing of similar and dissimilar materials, different grad of filler materials, without filler materials, alloys with applications. (12 hours)

Product Quality: Possible defects and their detection, assessment, and remedy, to be discussed along with each manufacturing process (5 hours)

To understand the principle of different manufacturing process including Metal joining, Casting, Metal Working, Powder Metallurgy

To study the Possible defects in different manufacturing technology and their detection, assessment and remedy.

Students will be able to understand different metal working techniques like forging, rolling, wire drawing, and corresponding parameters and process up-gradation.

Comprehension of the principle of welding, soldering, brazing techniques, and different process attributes. Students will be able to understand conventional and advanced casting processes and their respective structure. Comprehension of powder metallurgy as manufacturing process, applications of powder metallurgically prepared products and advancement in the powder metallurgy field.

The student will be able to understand the difference between primary and secondary manufacturing processes and to understand the basic principles of secondary manufacturing processes such as Metal Casting, Metal joining, Metal Working, and Powder Metallurgy.

The student will be able to understand the scientific rationale behind the casting methodology adapted in foundry practice with a focus on the basics of sand casting, die casting, investment casting, etc., the solidification process, and major defects.

The students will be able to understand the mechanisms and applications of major metalworking processes like forging, rolling, extrusion, and drawing.

The students will be able to understand the principles and applications of powder metallurgy processes.

The students will be able to understand the principles of metal joining processes, classification, similar and dissimilar combinations, and will be able to choose the right joining technique depending on the material and application.

The students will be able to understand defect types, possible detection mechanisms, with remedies.

J. Beddoes, M. J. Bibby, Principles of Metal Manufacturing Processes, Elsevier, Butterworth-Heinemann, 1999

R. W. Hein, C. R. Loper and P. C. Rosenthal, Principles of Metal casting, Mc Graw Hill, 1976

G. E. Dieter, Mechanical Metallurgy, McGREW-HILL

P. R. Beeley, Foundry Technology, Newnes-Butterworths

J. F. Lancaster, Metallurgy of Welding, Allen

R. M. German, Powder Metallurgy Science, Metal Powder Industries Federation

R. H. Todd, D. K. Allen, L. Alting, Fundamental Principles of Manufacturing Processes, Industrial Press, Inc.1994

K. Weman, Welding Processes Handbook (2nd Edition), Woodhead Publishing, 2011

G. S. Upadhyaya, Powder Metallurgy Technology, Cambridge International Science Publishing