METE436 FOUNDRY LABORATORY II
| Course Code: | 5700436 |
| METU Credit (Theoretical-Laboratory hours/week): | 3 (2.00 - 2.00) |
| ECTS Credit: | 5.0 |
| Department: | Metallurgical and Materials Engineering |
| Language of Instruction: | English |
| Level of Study: | Undergraduate |
| Course Coordinator: | Prof.Dr. ALİ KALKANLI |
| Offered Semester: | Fall Semesters. |
Course Objectives
To understand green sand production details physical and chemical properties, applications of green sand casting, CO2 moulding applications and details of gassing, binder additives for specific casting problems. Cold and hot box core making details to meet specific strength requirement of ferrous and non ferrous casting problems. Using sand and core making principles selection of correct sand and core material combinations to meet specific casting geometry and risering conditions. Application of riser and gating design for a particular geometry to eliminate casting defect verifying simulation output
Course Content
Molding sands and sand casting, refractoriness test, mold making practice, carbon dioxide molding, core and mold making with organic binders, heat curing binders, core oils, core resins, methylene blue test.
Course Learning Outcomes
Prepare green sands with clay and water addition, find optimum green strength and permeability values to make defect free and sound castings with good surface finish;
Measure permeability, green tensile and compressive strengths of sand and core materials for both ferrous and non-ferrous castings;
Prepare the sodium silicate silica sand mixture for CO2 setting as core and mould making at optimum gassing time and with optimum binder content;
Prepare hot box cores for thin internal cavities used for complicated castings and can performe tensile and compression testings for these materials;
Draw their patters in SolidWorks and Trispectives Drawing Softwares for NovaCast Cast simulation code, calculate riser and feeding distance requirements before casting simulation
Verify and apply their casting design projects performed by using simulation tools to real foundry conditions. Performe casting trials to see consistency between simulation and experimental work after casting
Program Outcomes Matrix
| Contribution | |||||
| # | Program Outcomes | No | Yes | ||
| 1 | An ability to identify, formulate, and solve complex engineering problems by applying principles of engineering, science, and mathematics | ✔ | |||
| 2 | An ability to apply engineering design to produce solutions that meet specified needs with consideration of public health, safety, and welfare, as well as global, cultural, social, environmental, and economic factors | ✔ | |||
| 3 | An ability to communicate effectively with a range of audiences | ✔ | |||
| 4 | An ability to recognize ethical and professional responsibilities in engineering situations and make informed judgments, which must consider the impact of engineering solutions in global, economic, environmental, and societal contexts | ✔ | |||
| 5 | An ability to function effectively on a team whose members together provide leadership, create a collaborative and inclusive environment, establish goals, plan tasks, and meet objectives | ✔ | |||
| 6 | An ability to develop and conduct appropriate experimentation, analyze and interpret data, and use engineering judgment to draw conclusions | ✔ | |||
| 7 | An ability to acquire and apply new knowledge as needed, using appropriate learning strategies | ✔ | |||
| 8 | Knowledge of the scientific and engineering principles underlying the four major elements of the field; structure, properties, processing and performance related to material systems | ✔ | |||
| 9 | An ability to apply and integrate knowledge from each of the four major elements of the field to solve materials and/or process selection and design problems | ✔ | |||