Manufacturing Processes

  1. Formative Processes: Casting
    1. Fundamentals of Metal Casting
      1. Solidification Process
        1. Nucleation Mechanisms
          1. Crystal Growth
            1. Solidification Time
              1. Cooling Curves
                1. Chvorinov's Rule
                2. Fluid Flow in Casting
                  1. Bernoulli's Equation
                    1. Continuity Equation
                      1. Mold Filling Time
                        1. Turbulence Effects
                        2. Heat Transfer in Casting
                          1. Conduction
                            1. Convection
                              1. Radiation
                                1. Thermal Analysis
                                2. Pattern Design and Construction
                                  1. Pattern Materials
                                    1. Wood Patterns
                                      1. Metal Patterns
                                        1. Plastic Patterns
                                        2. Pattern Allowances
                                          1. Shrinkage Allowance
                                            1. Draft Allowance
                                              1. Machining Allowance
                                              2. Types of Patterns
                                                1. Single Piece Patterns
                                                  1. Split Patterns
                                                    1. Match Plate Patterns
                                                      1. Cope and Drag Patterns
                                                    2. Mold Materials and Properties
                                                      1. Sand Properties
                                                        1. Grain Size and Distribution
                                                          1. Clay Content
                                                            1. Moisture Content
                                                              1. Permeability
                                                                1. Strength Properties
                                                                2. Binders and Additives
                                                                3. Core Making
                                                                  1. Core Materials
                                                                    1. Core Binders
                                                                      1. Core Making Processes
                                                                        1. Core Assembly
                                                                        2. Gating System Design
                                                                          1. Sprue Design
                                                                            1. Runner System
                                                                              1. Gates
                                                                                1. Risers and Feeders
                                                                                  1. Venting Systems
                                                                                2. Expendable Mold Casting
                                                                                  1. Sand Casting
                                                                                    1. Green Sand Molding
                                                                                      1. Sand Preparation
                                                                                        1. Molding Procedures
                                                                                          1. Flask Design
                                                                                          2. Dry Sand Molding
                                                                                            1. No-Bake Sand Molding
                                                                                              1. Shell Molding Process
                                                                                              2. Investment Casting
                                                                                                1. Wax Pattern Production
                                                                                                  1. Shell Building
                                                                                                    1. Dewaxing Process
                                                                                                      1. Metal Pouring
                                                                                                        1. Shell Removal
                                                                                                        2. Lost Foam Casting
                                                                                                          1. Foam Pattern Making
                                                                                                            1. Coating Application
                                                                                                              1. Sand Packing
                                                                                                                1. Metal Pouring
                                                                                                                2. Plaster Mold Casting
                                                                                                                  1. Ceramic Mold Casting
                                                                                                                  2. Permanent Mold Casting
                                                                                                                    1. Gravity Die Casting
                                                                                                                      1. Mold Design
                                                                                                                        1. Mold Materials
                                                                                                                          1. Process Steps
                                                                                                                          2. Pressure Die Casting
                                                                                                                            1. Hot Chamber Die Casting
                                                                                                                              1. Cold Chamber Die Casting
                                                                                                                                1. Die Design Considerations
                                                                                                                                  1. Process Parameters
                                                                                                                                  2. Low Pressure Casting
                                                                                                                                    1. Vacuum Casting
                                                                                                                                      1. Squeeze Casting
                                                                                                                                        1. Centrifugal Casting
                                                                                                                                          1. True Centrifugal Casting
                                                                                                                                            1. Semi-Centrifugal Casting
                                                                                                                                              1. Centrifuge Casting
                                                                                                                                            2. Casting Defects and Quality Control
                                                                                                                                              1. Surface Defects
                                                                                                                                                1. Misruns
                                                                                                                                                  1. Cold Shuts
                                                                                                                                                    1. Surface Roughness
                                                                                                                                                      1. Fins and Flash
                                                                                                                                                      2. Internal Defects
                                                                                                                                                        1. Porosity
                                                                                                                                                          1. Gas Porosity
                                                                                                                                                            1. Shrinkage Porosity
                                                                                                                                                            2. Inclusions
                                                                                                                                                              1. Sand Inclusions
                                                                                                                                                                1. Slag Inclusions
                                                                                                                                                                2. Hot Tears and Cracks
                                                                                                                                                                3. Dimensional Defects
                                                                                                                                                                  1. Dimensional Inaccuracy
                                                                                                                                                                    1. Warping and Distortion
                                                                                                                                                                    2. Defect Prevention and Remedies
                                                                                                                                                                      1. Casting Inspection Methods
                                                                                                                                                                        1. Visual Inspection
                                                                                                                                                                          1. Dimensional Inspection
                                                                                                                                                                            1. Non-Destructive Testing
                                                                                                                                                                              1. Destructive Testing

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                                                                                                                                                                          3. Measurement and Quality Assurance

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                                                                                                                                                                          5. Formative Processes: Bulk Deformation