Introduction to the design of components manufactured by casting

Lecturers: Prof. Ingvar L. Svensson, Prof. Magnus Wessén, School of Engineering of the Joenkoeping University [1]

The goal of the course is to give a basic understanding about engineering and industrial design of components manufactured by casting.

Overview of casting methods, usefulness and product areas. Development trends. Different manufacturing methods and their characteristics. Machine and hand-moulding, shellmoulding, lost wax methods, lost foam, high pressure die cast methods, gravity die castings, low pressure die castings, squeeze-casting and new and special casting methods.

Overview of casting materials. Phase diagrams. Solidification of casting alloys. Metallurgical treatment. Use of alloying elements in cast irons and light alloys. Relation between microstructure and properties in cast materials. Shrinkage and gas porosity formation. Casting of new materials and composites. Melting and pouring.

Introduction to calculation and simulation of:

• mould filling
• solidification time
• feeding
• residual stresses and deformations
• local material properties

Design rules, related to filling and solidification phenomena.

The course is subdivided in 19 lectures:

1. Introduction to component casting
2. Casting in permanent moulds
3. Casting in permanent moulds (2)
4. Non-permanent mould processes
5. Non-permanent mould processes (2)
6. Thermal transports at different casting methods
7. Fluid flow and mould filling
8. Heat transfer and solidification
9. Feeding of castings
10. Cast iron
11. Cast iron (2)
12. Aluminium alloys
13. Aluminium alloys (2)
14. Magnesium alloys
15. Steel and other cast metals
16. Thermal stresses
17. Design of castings
18. Rapid prototyping
19. Introduction to simulation

The course is lectured in english.

Total duration of the 19 lectures is about 8 hours and 10 minutes. The total number of slides presented in the lectures is over 500.

This course is an outcome of the European Community Lifelong Learning Programme Leonardo da Vinci project METRO - MEtallurgical TRaining On-line and it is supported by the TCN Consortium for higher education.

The METRO project has been funded with support from the European Commission. This publication reflects the views only of the Author, and the Commission cannot be held responsible for any use which may be made of the information contained therein.