ITI's which provides courses for Foundaryman

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Occupational Safety & Health Importance of housekeeping & good shop floor practices.

Soft Skills: its importance and Job area after completion of training. I

2

Sieve sand mix and Temp

History of foundry Industry-Development of foundry in India.

3

Carry out the different tests such as – moisture content, clay content: strength: permeability & sand grain fineness no. etc. of moulding sand.

Sand testing – Different methods of moisture content test; permeability test clay content test – strength test, sand grain fineness test; refractoriness test of moulding sand.

4

Wood Working – Marking: sawing and planning on wood.

Brief description: specification and use of various wood working hand tools.

5

Making important joints on wood and prepare simple pattern.

Methods of repairing the patterns & core boxes. Induction hardening of S G Iron casting.

6

Ramming Practice in moulding boxes with hand Rammers to obtain desired Green hardness

Safety precautions-General while moulding and core making pouring and fettling operation

7

Use hand Tools : cut channels on rammed boxes with cross section such as square : semicircular ; Trapezoid and Triangular and finish with double enders ; cleaners etc.

Name : specification and their application of various hand tools used in foundry

8

Prepare unit sand: prepare mould for block such as square: Rectangular & Round.

Difference between natural and Synthetic moulding sand-principle ingredients in moulding sand & their effect on physical properties-special additives in moulding sand & their effect.

9

Prepare facing and Backing sand Prepare simple moulds with Top run gates.

Facing sand: Backing sand and unit sand – composition of various moulding sand

10

Prepare mould with self leaving core pattern by using parting line gates.

Definition: advantages and disadvantages of “Green sand mould” Skin dry sand mould – Loam sand mould and cement bonded sand mould.

11

Prepare Green sand mould by using split pattern for alminium casting use natural moulding sand Melt aluminium in pit furnace and pour the same into moulds, fettle aluminium casting.

Construction, operation and maintenance of “Pit furnace” name

12

Level the floor with spirit level and straight edge and prepare open sand mould.

Moulding process-Bench moulding – different methods, advantages, disadvantages and their application.

13

Prepare Bedded in mould

Moulding process – floor moulding – different methods: advantages: disadvantages and their application.

14

Prepare moulds with vertical core print.

Core - uses and types – composition of various cores sand mixtures.

15

Prepare moulds for copper and copper base alloy’s melts copper alloy in pit furnace or oil fired furnace & pour

Construction: operation & maintenance of oil fired furnace. Pattern – Pattern Materials.

16

Prepare mould with drawback method and false cheek method.

Pattern – Types of patterns- Allowances on pattern colouring of pattern as per I.S. 1513-1959 – care & maintenance of pattern.

17

Prepare “Stack mould” and “Snap flask mould”

Gating system – various types of Top run gate, Part line run gate & Bottom run gate

18

Prepare mould with Loose piece patterns & core with Loose piece core box.

Pre-requisites of gating system – Risers : Feeders & directional solidification – chills: chaplets: Denserners & Exothermic matetials

19

Prepare Cupola for charging chipping and doubling – prepare metal & slag spout; Tap hole and slag hole; sand bed; Lining of ladle.

Cupola – construction – parts of cupola and their functions – cupola zones – calculation of melting capacity of cupola.

20

Metal Working – Marking and sawing on straight line –chipping and Filling to desired size on diff. metals.

Description specification and use of common, marking, measuring; sawing; chipping and filing instruments used in metal work.

21

Prepare induction furnace for charging. Prepare charges for charging, operate and melt aluminum/magnesium and pour aluminum/magnesium into the mould and identify defects.

Induction furnace: Types- construction, operation and maintenance.

Sem. II

Trade Practical

Trade Theory

1

Prepare Dry sand mould for cast iron with odd sided pattern.

Brief description: types; advantages & disadvantages of ‘Die casting’ – centrifugal casting and ceramic moulding process.

2

Prepare simple “Loam sand mould” for simple pan/bell shape casting.

Brief description: advantages; disadvantages and use of ‘Investment casting process’. Binderless dry sand (Full mould) process; Plaster of Paris moulding process.

3

Prepare Pit mould on foundry floor

Slush casting process; Continuous casting process Permanent mould casting process; Nishiyama process (by using ferrosilicon powder) Common casting defects appearance – causes and remedies – salvaging of castings.

4

Prepare simple CO2 mould. Prepare simple CO2 core; assemble in CO2 mould & cast by cast iron.

Fettling of casting – knock out and removal of casting from mould- removal of gates and risers; Fins and unwanted projection – surface cleaning – trimming and finishing.

5

Prepare mould for setting “Balancing core” and set balance core in mould with the help of chaplets.

Binders-common binders used in foundry and their application and their grades as per I.S. Common “Facing materials” used in foundry and their application and their grades as per I.S. Casting Design - Functional Design, Simplification of foundry practice, Metallurgical Design, Economic consideration.

6

Prepare mould to assemble “Hanging core” and set hanging core in mould.

Common “Fluxes” used in foundry and their application

7

Prepare mould for using “Chills”: Denseners and fix chill and denseners in mould.

Difference between “Metal and Non-metal” –Difference between ferrous metal and non-ferrous metal.

8

Prepare core halves; Bake and join by different methods.

Iron ore – pretreatments of iron ore - pig iron –manufacturing process – grades as per I.S. and use cast iron – manufacturing process; grades as per I.S. and use.

9

Prepare mould with “pencil gate”; Finger gate and cast it by Aluminium.

Common cast iron

10

Prepare mould with wedge gate and ring gate and cast it by copper base alloy.

Effect of elements normally present in ferrous metals

11

Prepare mould with Branch gate mould with match plate pattern and cast it by cast iron.

Steel manufacturing process classification – common steel alloys and use.

12

Prepare mould with relief sprue gate; skin bob gate and cast it by cast iron.

Wrought iron – manufacturing process – use. Copper manufacturing process – properties & uses

13

Prepare mould with Horn gate and mould with stepped gate.

Manufacturing process, properties and use of Aluminium, Tin, Zinc, Lead.

14

Prepare mould for extra thick casting with large feeder heads and cast it by cast iron.

Manufacturing process of copper base alloys, Aluminium base alloys and magnesium base alloys.

15

Reline the pit furnace.

Brief information about Blast furnace, Electric furnaces such as Arc furnace & Induction furnace.

16

Reline the oil fired furnace.

Brief information about open hearth furnace, Air furnace, Rotary furnace, Paddling furnace and convertors.

17

Reline the cupola furnace

Heat treatment of casting Hardening, Tempering, Annealing, Normalising, Quenching, Nitriding Cyaniding etc.

18

Prepare simple oil sand core by using linseed oil and IVP oils.

Calculation of ferrostatic pressure calculation of weight required on a mould

19

Prepare simple regular shape mould without pattern. (By cutting practice).

Calculation of molten metal requirement for different size mould (A1, Brass, Copper, C.I. etc.)

20

Prepare simple casting by gravity die casting process

Cost estimation of simple castings of different metals.

21

Prepare simple casting by Investment casting process and binderless dry  and process

Foundry mechanization – layout of a small foundry – List of material handling equipments and their use

Project Work