Casting Processes and Applications (MATE401) Ders Detayları

Course Name	Corse Code	Dönemi	Lecture Hours	Uygulama Saati	Lab Hours	Credit	ECTS
Casting Processes and Applications	MATE401	7. Semester	2	2	0	3	6

Pre-requisite Course(s)
MATE 316, consent of the department

Course Language	İngilizce
Course Type	Compulsory Departmental Courses
Course Level	Lisans
Mode of Delivery
Learning and Teaching Strategies	.
Course Coordinator
Course Lecturer(s)
Course Assistants
Course Objectives	To introduce the students of Materials Engineering to the liquid state shaping processes emphasizing on shape casting processes and related metallurgical issues
Course Learning Outcomes	The students who succeeded in this course; Ability to cite casting fundamentals, classification of metal casting processes, castability index of metal alloys, factors effecting casting process selection, basic foundry process sequences. Understandig of melting furnaces and melting shop practice, charge calculation as per required alloy composition. Ability to cite molding types, sand molding practice; cores and core-making; patterns and pattern-making; Understanding of properties of molding sand and the effects of other mold constituents, standard tests for molding sand, Understanding of principles of gating and risering design Ability to cite, determine, calculate and comment on problems and casting defects encountered in foundry practice, techniques for their detection and casting quality control.
Course Content	Introduction to casting processes, permanent and expendable mold casting, molding sands and sand casting; refractoriness test; mold making practice; CO2 molding, core and mold making with organic binders, heat curing binders, core oils and core resins, methyleneblue test; gating and feeding principles and methods; cast metal alloys, production of

Weekly Subjects and Releated Preparation Studies

Week	Subjects	Preparation
1	Metal Castings, Turkish Foundry Industry and Classification of Casting Processes, Melting Furnaces
2	Metal Casting Design, Pattern Design, Rapid Prototyping
3	Sand Casting Processes-Sand size distribution, Strength of Green sand, Temperature dependence of Green Strength
4	Sand Casting Processes-Chemically Bonded Molding and Core Sand
5	Reclamation of Foundry Sand, Sand Life Cycle, Reclamation Systems
6	Other Casting Processes- Cosworth process, Rheocasting and Thixiocasting, Lost Foam Casting, Die Casting, Squeeze Casting, Investment Casting
7	Fluid Flow and Gating Design, Bernoulli’s Law, Determination of Mold Filling Time
8	Number of Gates in the system, Fluidity of Molten metals
9	Shrinkage and Riser Design, Calculation of Modulus of Riser and Casting; d
10	Location, Size, Shape and Number of Risers, Casting Yield
11	Additives to Molten Metal, Finite Element Analysis of Solidification
12	Issues in Cast Irons, Cast Steel, Cast Aluminum alloys and Cast Copper alloys
13	Defects in Castings, and use of NDT for flaw detection; Homogenization of Castings
14	Environmental Concerns in Metal Casting
15	Overall Review
16	Final Exam

Sources

Course Book	1. Foundry Metallurgy, P. BEELEY, 2E, Butterworth-Heinemann, 2001.
	2. Castings, 2E, J. CAMPBELL, Butterworth-Heinemann, 2003.
	3. Casting Practice, J. CAMPBELL, Butterworth-Heinemann, 2004.
Other Sources	4. Fundamentals of Metal Casting, R.A. FLINN, Addison-Wesley, 1963.
	5. Analysis of Casting Defects, American Foundry Society, 1974.

Evaluation System

Requirements	Number	Percentage of Grade
Attendance/Participation	-	-
Laboratory	-	-
Application	-	-
Field Work	-	-
Special Course Internship	-	-
Quizzes/Studio Critics	-	-
Homework Assignments	5	20
Presentation	-	-
Project	1	20
Report	-	-
Seminar	-	-
Midterms Exams/Midterms Jury	1	25
Final Exam/Final Jury	-	-
Toplam	7	65

Percentage of Semester Work	65
Percentage of Final Work	35
Total	100

Course Category

Core Courses
Major Area Courses	X
Supportive Courses
Media and Managment Skills Courses
Transferable Skill Courses

The Relation Between Course Learning Competencies and Program Qualifications

#	Program Qualifications / Competencies	Level of Contribution
#	Program Qualifications / Competencies	1	2	3	4	5
1	An ability to apply knowledge of mathematics, science, and engineering					X
2	An ability to design and conduct experiments, as well as to analyze and interpret data					X
3	An ability to design a system, component, or process to meet desired needs					X
4	An ability to function on multi-disciplinary teams				X
5	An ability to identify, formulate and solve engineering problems					X
6	An ability to use the techniques, skills, and modern engineering tools necessary for engineering practice					X
7	An understanding of professional and ethical responsibility					X
8	An ability to communicate effectively					X
9	An understanding the impact of engineering solutions in a global and societal context and recognition of the responsibilities for social problems					X
10	A knowledge of contemporary engineering issues					X
11	Skills in project management and recognition of international standards and methodologies					X
12	Recognition of the need for, and an ability to engage in life-long learning					X

ECTS/Workload Table

Activities	Number	Duration (Hours)	Total Workload
Course Hours (Including Exam Week: 16 x Total Hours)
Laboratory
Application
Special Course Internship
Field Work
Study Hours Out of Class
Presentation/Seminar Prepration
Project
Report
Homework Assignments
Quizzes/Studio Critics
Prepration of Midterm Exams/Midterm Jury
Prepration of Final Exams/Final Jury
Total Workload			0