Course Syllabus for students Autumn 2024

On completion of the course, the student should

• display knowledge of how different casting processes and equipment work
• display knowledge of the molded material microstructure in detail
• demonstrate comprehension of shape and form materials
• demonstrate comprehension of design and defects in casting

• demonstrate the ability to explain and analyze how different the cast components are manufactured and how material properties depend on manufacturing process
• demonstrate the ability to formulate heat balances for molds and setting materials
• demonstrate the ability to calculate the mold filling
• demonstrate skills of applying heat balances for mathematical relationship between heat flow and microstructure

• demonstrate the ability to compare and select the appropriate alloy / materials, proper design / design and casting process to get the right properties
• demonstrate the ability to evaluate different solutions through process simulation

The course aims to give the student basic knowledge and deepening of component production of the casting of metallic materials, including design, material properties and manufacturing processes. In each step, a scientific approach to technology both in terms of systematic approaches and mathematical language to be able to analyze and evaluate process solutions and the problems that are associated.

The course includes the following topics:
- Manufacturing of components by casting.
- Applications of heat transfer, including conduction, convection, radiation to calculate the solidification and feeding.
- Applications of fluid flow, Bernoulli's equation, the continuity equation, lamellar and turbulent flow
- Cast materials, solidification and microstructure and properties. Phase diagrams. The relation casting process, microstructure and properties of cast alloys. Sheingkage and gas porosity.
- Design for casting and cast materials
- Introduction to computer simulation of the casting process. The integration of CAD / CAM

Recorded lectures, computer based laboratory exercises and assignments. Teaching can be done both on campus as well as distance learning.

The teaching is conducted in English.

General entry requirements, Physics 2, Chemistry 1, Mathematics 3c, and completed courses in Solid Mechanics, 6 credits and Basic Thermodynamics and Transport Phenomena, 3 credits (or the equivalent) and proof of English proficiency is required.

The course is graded 5,4,3 or Fail.

The final grade will only be issued after satisfactory completion of all assessments.

Name of the Test	Value	Grading
Examination1	3 credits	5/4/3/U
Laboratory work and Assignments	3 credits	U/G

¹ Determines the final grade of the course, which is issued only when all course units have been passed.

The literature list for the course will be provided 8 weeks before the course starts.

Component Casting with Simulation, School of Engineering, Jönköping och Webbased material.

Complementary texts: J., Campbell, “Complete Casting Handbook”, D. M. Stefanescu, “Science and Engineering of Casting Solidification”, H. Fredriksson & U., Åkerlind, “Materials Processing During Casting