IME 4550- Advanced Metal Castomg
Catalog Data (2001/2003) :
| The identification of causes for cast metal variability (melt, mold and fill) through the use of instrumentation, data gathering, and analysis techniques. Strategies for establishing process control and process capability in metal casted parts. Lecture/Lab: (2-3), Credit: 3 hrs., Prerequisites: IME 352. |
Textbooks :
| None Required |
References :
| ASM Metals Handbook, Volume 15, Casting; Class Handouts; Internet. |
Objectives :
Based on the above stated course description, at the conclusion of the semester the student should be able to,
| 1. | To understand the importance of die casting in an industrial society. (j) |
| 2. | Identify and model the conditions of 3-D solidification simulations. (a, b & f) |
| 3. | To understand the quality control aspects of the die casting industry. (c & k) |
| 4. | Work safely in teams and solve die casting related problems. (e & f) |
Topics :
Non-traditional and innovative metal casting processes : Squeeze Casting
Investment Casting
V-Process
Continuous Casting
Semi-Solid Molding
Spray Casting
Specialized alloys : Super Alloys
Ductile Cast Iron (Nodular or SGI) (Austempered DI)
Magnesium
Cast Metal Matrix Composites (CMMC)
Chemical Sand Binder Systems : Organic
Plant Tours (6 week)
Inorganic
3D Solidification (4 week)
Specialty and Alternative Molding Media : Casting Design : Computer Modeling
Finite Element Analysis
Solidification Simulation Analysis
Preventing Fatigue Failures
Gating System Design : Requirements
Ferrous versus Non-Ferrous Designs
Types
Friction
Pouring Time
Choke
Design Principles for sprue, runner, gate, pouring basin, and wells.
Junction Design : Risering System Design : Requirements
Metal volume change patterns
Selection of risering method
Casting Finishing and Coating : Painting
Plating
Anodizing
Hot dipping
Polishing and buffing
Shot peening
Sealant impregnation
Corrosion protection coating
Hard face coating
Phosphate coating
Process Control : Temperature Monitoring
Melt Chemistry
Thermal Distortion Curves
Sand Control (Squeeze pressures)
Defect Recognition
Clean Metal Technologies : Filtration
K-Bar Test
Qualiflash/SNIF/Sonics Test
Rapid Prototyping : Environmental issues in the foundry :
Evaluation :
1. Exams and Quizzes 40% 2. Homework 10% 3. Lab assignments 15% 4. Projects 10% 5. Attendance, Participation 25%
Performance Criteria :
The student should demonstrate proficiency to,
Objective 1:
| 1. | To identify the non-traditional processes in the foundry industry. (1 & 4) | ||
| 2. | To be familiar with the current research literature in the metal casting field. (5) | ||
| 3. | To identify the new material being used in the foundry industry. (5) | ||
| 4. | To understand the environmental issues in the foundry industry.. (5) | ||
| 5. | To understand the theory of solidification. (1-9) | ||
Objective 2:
| 1. | Identify defects found on metalcastings. (3, 6, 7 & 9) | |
| 2. | To understand process control in the foundry industry. (6-9) | |
Objective 3:
| 1. | Demonstrate the safe operation of die casting equipment. (6-9) | |
| 2. | To understand gating and risering procedures used in the foundry industry. (1, 2, 3, 4 & 5) | |
| 3. | Generate computer files to analyze and interpret a three dimensional solidification simulation models, using AFSolid 2000 software. (1, 2, 3, 4 & 5) | |
Grading :
| Projected Score | Grade | ||
| 90-100% | A | Lab #1 (Sand squeeze pressures) | 5% |
| 85 - 89.9% | BA | Lab #2 (CMMC vs. A356) | 5% |
| 80 - 84.9% | B | Lab #3 (Matchplate casting) | 10% |
| 75 - 79.9% | CB | Lab #4 (Gating/Solid. of "Final Project") | 15% |
| 70 - 74.9% | C | Course Work (Assignments) | 30% |
| 65 - 69.9% | DC | Attendance & Field Trips | 10% |
| 60 - 64.9% | D | Mid Term Exam | 10% |
| BELOW 60% | E | Comprehensive Final | 15% |
Prepared by :
1. Letter in parenthesis refers to the ABET-TAC criteria.
2. Number in parenthesis refers to the evaluation method.
Revision Date: Fall 2002