Course Handout

SE Production (2015 Course)

Welding and Foundry (211103)
Name of Faculty: Prof. S. B. Sangle
Teaching Scheme Theory: 04 hrs
Insem Exam: 50 Marks (1hr)
(Online)
Examination Scheme
Oral Exam: 50 Marks
(Lab)
Practical: 02hrs/Week
Endsem Exam: 50 (2 hr)
(Paper)
Term work: 00 Marks
(Lab+ Theory)

Date of Commencement: 15/06/2019

Date of Conclusion: 16/10/2019
Practical/ Oral Exam: 18/10/2019 to 5/11/2019
Theory Exam: 14/11/2019 to 7/12/2019

Continuous Assessment Policy

(Term work marks of 50 will be awarded based on following policy)
Description Weightage Evaluation criteria
Attendance in theory class 10 Marks Attendance between 95 and above --10marks
10 Marks Attendance between 91 to 95 % --- 8marks
Attendance between 86 to 90 % --- 6marks
Attendance in laboratory Attendance between 81 to 85 % --- 4marks
work Attendance between 75 to 80 % --- 2marks

Timely Checking of laboratory 10 Marks Each experiment / assignment will get 10

work marks for timely submission.
Late submission will be valued as 0 in totality.
Average of all experiments / assignments will
be converted into 10
Performance in Class test 10 Marks At actual on the scale of ten

Performance in homework 10 Marks Each homework assignment will get 10 marks

Assignments for timely submission.
Late submission will be valued as 0 in totality.
Average of all homework assignment will be
converted into 10

Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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 Teaching Plan
Unit Topics to be explored Completion of
No topic : Date
Unit Introduction & classification of welding processes, Basic electrical – 03/07/2019
01 Electrodes – coding of electrodes – Electrode efficiency, Welding symbol.
Physics of welding – arc structure, characteristics and power – chemical
heat source- contact resistance heat source- heat flow characteristics-
cooling of weld Arc welding processes- carbon arc, submerged arc,
Tungsten inert gas (TIG), Metal Inert gas (MIG), Plasma arc, stud welding-
Theory, comparison on merits, limitations and applications.
Fluxes used in arc welding. (8 hrs)
Unit GAS welding: - processes and equipment used, type of flames, adjustment 27/07/2019
02 of flames, oxyacetylene welding, gas cutting –merits, limitations and
applications. Electric resistance welding- processes and equipment used,
spot, seam, projection, butt, percussion welding, resistance tube welding,
- merits, limitations and applications. (8 hrs)
Unit Pressure welding, diffusion welding, ultrasonic, friction, explosive, forge, 14/08/2019
03 thermit welding, laser, electron beam welding- equipment used- merits,
limitations and applications of above processes. Brazing, braze welding and
soldering processes. Inspection and testing of welding: - visual inspection,
destructive & non-destructive testing. Estimation of welding cost. Protection
and safety in welding. (8 hrs)
Unit Sand casting processes, Principles of casting, steps involved in casting, 31/08/2019
04 Introduction of sand casting. Patterns, Pattern materials, pattern allowances
and design. Core prints and core seats. Mould strength, Ingredients of moulding
materials and their effect on mould strength-testing of mould strength, testing
of moulding sand. Melting and pouring of metals: - melting furnace- types,
Cupola, electric arc furnace, Induction furnace- Construction, operations and
zones, cleaning, finishing of casting. (8 hrs)
Unit Special casting processes Pressure and gravity die casting (hot and cold 18/09/2019
05 chamber), shell moulding, centrifugal casting, continuous casting, investment
casting, - their typical applications, merits and limitations. Casting defects-
defects, Inspection- analysis of casting defects- Quality control. Foundry
mechanization and automation. (8 hrs)
Unit Casting Design, Metal pouring, Gating system- design of gating system, 05/10/2019
06 solidification time, riser design, Principles of gating, risering and their design
methods. Progressive and directional solidification, casting design
consideration, Chvornov‟s rule, numerical on casting, defects in casting.
Fluidity- method of measuring fluidity of metal by spiral technique. Computer
applications in casting design and software (8 hrs)

Text Books:
1. Rao P.N., “Manufacturing Technology, Foundry, Forming and welding”, 2ed., Tata
McGraw-hill publishing, 2006, ISBN 0-07-463180-2.
2. Khanna O.P., “Welding Technology”, Dhanpat Rai& sons, 1996.
3. Khanna O.P., “Foundry Technology”, Dhanpat Rai& sons, 1999.
4. Parmar R.S., “Welding Process and Technology”, 2ed.,Khanna Publishers, 1997.
Reference Books:
1. KalpakjianSerope and Schmid Steven, “Manufacturing Engineering & Technology”, 2004.

Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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 Text Books:
2. Degarmo E.P. and Black J.T., “Materials &Processes in Manufacturing”, 9ed., Prentice hall of India
Pvt.Ltd., 2002.
3. Little Richard., “Welding & Welding Technology”,Tata Mc-graw hill Publishing, 1992, ISBN 0-07-
099409-9.

Schedule of Site visits

Visit no. Week / Date Actual date of visit Name of industry visited
proposed
1 Last week of August Aditya foundries, Nashik
Schedule of Expert lectures
Week / Actual date of Name of speaker Topic of Lecture
Date conduction
proposed
First week Somnath Avhad, Quality Investment
of engineer, OK ferm, Sinnar Casting
September
Schedule of submission
(The assessment with final index signature is to be closed on or before five days of conclusion of
teaching)
Ex 01 To find out grain fineness number by using sand sieve shaker test.
Ex 02 Permeability testing of green sand.
Ex 03 Green compression test for molding sand.
Ex 04 Fluidity testing of any metal using fluidity spiral.)
Ex 05 Study of TIG/MIG welding process parameters for ferrous and nonferrous metals.
Ex 06 Tensile test on a welded specimen.
Ex 07 Impact test on a welded specimen.
Ex 08 Non-destructive test on a weldment- dye penetrant test.
Ex 09 Non-destructive test on a weldment- magnaflux test.
Ex 10 Industrial visit to any foundry.

Exp.No Batch Date of Assessment Assessment In case

Performance starts on completes ,assessment
on postpones,
next date of
completion
1 S3 24/06/2019 25/06/2019 01/07/2019 08/07/2019
S4 25/06/2019 26/06/2019 02/07/2019 09/07/2019
S2 28/06/2019 29/06/2019 05/07/2019 12/07/2019
S1 29/06/2019 30/06/2019 06/07/2019 13/07/2019
2 S3 01/07/2019 02/07/2019 08/07/2019 22/07/2019
S4 02/07/2019 03/09/2019 09/07/2019 23/09/2019
S2 05/07/2019 06/07/2019 12/07/2019 26/07/2019
S1 06/07/2019 07/07/2019 13/07/2019 27/07/2019
3 S3 08/07/2019 09/07/2019 22/07/2019 06/08/2019
Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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 S4 09/07/2019 10/09/2019 23/09/2019 19/08/2019
S2 12/07/2019 13/07/2019 26/07/2019 10/08/2019
S1 13/07/2019 14/07/2019 19/07/2019 11/08/2019
4 S3 22/07/2019 23/07/2019 06/08/2019 29/07/2019
S4 23/09/2019 24/09/2019 19/08/2019 25/09/2019
S2 26/07/2019 27/07/2019 10/08/2019 01/08/2019
S1 27/07/2019 28/07/2019 11/08/2019 02/08/2019
5 S3 05/08/2019 06/08/2019 29/07/2019 26/08/2019
S4 18/09/2019 19/08/2019 25/09/2019 27/09/2019
S2 09/08/2019 10/08/2019 01/08/2019 30/08/2019
S1 10/07/2019 11/08/2019 02/08/2019 31/08/2019
6 S3 29/07/2019 30/07/2019 26/08/2019 10/09/2019
S4 18/09/2019 19/09/2019 27/09/2019 04/09/2019
S2 01/08/2019 02/08/2019 30/08/2019 07/09/2019
S1 02/08/2019 03/08/2019 31/08/2019 08/09/2019
7 S3 26/08/2019 27/08/2019 10/09/2019 24/09/2019
S4 27/09/2019 28/09/2019 04/09/2019 25/09/2019
S2 30/08/2019 31/08/2019 07/09/2019 28/09/2019
S1 31/08/2019 01/09/2019 08/09/2019 30/09/2019
8 S3 09/09/2019 10/09/2019 24/09/2019 01/10/2019
S4 03/09/2019 04/09/2019 25/09/2019 02/10/2019
S2 06/09/2019 07/09/2019 28/09/2019 05/10/2019
S1 07/09/2019 08/09/2019 30/09/2019 06/09/2019
9 S3 23/09/2019 24/09/2019 01/10/2019 16/09/2019
S4 24/09/2019 25/09/2019 02/10/2019 16/10/2019
S2 27/09/2019 28/09/2019 05/10/2019 19/09/2019
S1 28/09/2019 30/09/2019 06/09/2019 06/09/2019
10 S3 30/09/2019 01/10/2019 07/10/2019 14/10/2019
S4 01/10/2019 02/10/2019 08/10/2019 15/10/2019
S2 04/10/2019 05/10/2019 11/10/2019 18/10/2019
S1 05/10/2019 06/09/2019 12/10/2019 19/10/2019

Join the Virtual classroom of Welding and Foundry on Edpuzzle platform

SE Production (Soft Skill) with Santosh Sangle
It's free and it takes under a minute to sign up!
Instructions for students and parents
1. Visit www.edmodo.com from your phone or computer.
2. Click on the "Join a group" button and enter the code, ciklike
3. Follow the instructions to create an account and get started on Edpuzzle!
4. Watch the informative video and attempt quizzes.

Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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Schedule of Online tests (Weightage of this test is 10 marks)
Instruction for Online test:
1. Link of the test will be share on your what’s app group.
2. You have to log in with your name as username and Password is sbs3

Test No Syllabus Date of Internal Test Date of Declaration

of Marks
Test 01 Unit 01 25/06/2019 26/06/2019
Test 02 Unit 01 03/07/2019 04/07/2019
Test 03 Unit 02 17/07/2019 18/07/2019
Test 04 Unit 02 25/07/2019 26/07/2019
Test 05 Unit 03 03/08/2019 04/08/2019
Test 06 Unit 03 14/08/2019 16/08/2019
Test 07 Unit 04 23/08/2019 23/08/2019
Test 08 Unit 04 31/08/2019 01/09/2019

Course Handout: SE Production (2015 course) Welding and Foundry AY:2019-20 (Sem-I)
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