ITI's which provides courses for Moulder

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Introduction the trainee to the institution

Explaining the course objective & introduction to trg. Necessity of safety fire fighting equipment’s. Safety in Foundry shop.

2

Sand sieving mixing & tempering by shovel and mixer Muller. Sieving the sand by an auto riddle or sieve shaker screen vibrator etc. Sand sampling by Quartering method

Occurrence of moulding sand in India- common types of natural and synthetic moulding sand IS specs. For natural moulding sand IS: 3343-1965. Importance of sand sieving and grain fineness analysis

3

Ramming practice in moulding boxes with hand rammers obtaining desired green hardness such as 60, 70, 80, and 90 on green hardness tester.

Importance of hardness. Various mould hardness required for various metals, to be cast, ingredients in moulding sand.

4

Use of hand tools cutting of channels on rammed boxes with cross sections such as square cross section semi circular, trape zoid and triangular and finishing with double enders clearerns etc.

Various terms used in foundry & use of IS glossary of foundry practice. Use of various channels in gating and necessity of practice to cut them. Name of hand tools their construction use & manipulation.

5

Preparing backing sand and facing sand for CI ramming a box and cutting a cube cavity without the use of pattern.

Hand tools continued ingredients of moulding sand, sand grains, clay & water additives of moulding sand

6

Preparation of sand bed on floor. Preparation of open mould & mould with block gates.

Chemical composition of natural moulding sand. Advantages and disadvantages of natural moulding sand & synthetic moulding sand.

7

Levelling of floor with spirit level and straight edges.

Parts of a mould parting line gating system basic principle of risering.

8

Preparation of closed moulds with natural moulding sand in two boxes melting of aluminium in crucible furnace and pouring the same into moulds.

Equipment uses for moulding. Crucible furnace and melting of aluminium in a crucible furnace. Basic material handling equipment as related to foundry shop.

9

Prepare moulds with self’s cored Patterns preparation of moulds with split patterns

Types of patterns their constructions and use patterns materials colouring and marking system of pattern equipment’s (ISI 1513-1971)

10

Preparation of moulds with simple split pattern having vertical & horizontal core prints.

Cores and their composition on reinforcing of cores.

11

Preparation moulds forecast iron preparation & operation of pit type/ tilting oil fired furnace and melting cast iron and pour the same in moulds

Cast iron types, melting procure of CI in crucible furnaces, construction of crucible type furnace.

12

Preparation of moulds with draw back methods. Preparation of moulds in 3 boxes.

Moulding joints, loose pieces, draw backs, draw back plates stop off pieces.

13

Metal working: Sawing & filing of different metals.

Hacksaw frame. Hacksaw blades specifications get used. Files their types specs.

14

Grinding of different metals chipping & hammering of different metals.

Grind wheels preparation–specs. Selection of grind wheels for a particular metal

15

Handling of crucible ladle melting in crucible by pits, tilting furnace, ladle lining lifting of crucibles by lifting tongs & ladle carrier.

Types of ladle, lining, methods crucibles IS specs. Capacity as per 1748-1961. Types safety on crucibles use. Safety while handling metals.

16

Moulds making with special gating and obtaining moulds hardness for preparing aluminium casting.

Aluminium foundry practice fluxing & degassing. Use of hexo-chlorothene in degassing. Type of plungers used in degassing.

17

Repairing of furnaces, relining and patching of tilting/ pit furnace preparation of ladle lining by fire clay mixture and CO2 sand.

Method of lining of pit and tilting type furnace types of ladles and lining methods of ladles various refractory mixtures for furnace lining.

18

Preparation of charges for cupola. Preparation of metal spout preparation of cupola such as slag, chipping, daubing & relining of cupola.

Cupola parts function preparation & operation of cupola. Calculation and melting losses & gains in cupola Fuel and air requirement in cupola.

19

Fettling of CI casting knocking chipping cutting cleaning grinding working by hand fettling tools and power pneumatic tools.

Fettling tools & equipment and methods. Types of chisels, hand power and pneumatic tumbling shot plasting and wheel brator.

20

Preparation of moulds with stack Moulding methods. Preparation dry sand moulds -use of cover core and bottom gate

Moulding, types stack moulding sweep moulding, moulds with core assembly methods. Special types of cores. Types of pouring basins and their application in various moulds

21

Preparation of moulds forecast iron. Preparation of various grades of cast iron in cupola and other furnaces. Preparation of fluidity spiral moulds and chill test wedges.

Types of fuels used in foundry such as solid, liquid and gaseous fuel metal ratio in cupola various grades. Cast iron as per Indian Standard (IS) various test on metal such as chill test and fluidity test.

22

Preparation of moulds with odd side method. Setting of vertical cores and horizontal cores in mould and getting dimensional accuracy in casting.

Foundry equipment. Types of melting tools furnaces and metal hadling and storing equipment such as receiver and metal holders conveyors and their types.

23

Preparation of a pit mould and large sand mould on floor with sinder bed and vent pipes.

Flooring moulding advantages and dis advantages pit moulds construction advantages & dis advantages material used for constructing large pit moulds.

24

Preparation of moulds with iron gate, preparation of mould with pencil gate spray gates etc.

Various types of gating system bottom gating spray gating. Step gating- block gating, risering and feeding breaker case.

25

Preparation of moulds sand and mould for copper base alloys such as casting melting of copper alloys such as brass gun metal and bronze in pit type/tilting type crucible furnace

Copper- copper base alloys foundry techniques copper base alloys. Procedure of melding fluxing and use of covering flux and alloying.

26

Preparation of moulds in snap flasks. Preparation of core with various types of core boxes.

Types of moulding boxes sanp flask and special types of moulding boxes, Specification moulding boxes as per IS : 1280-1958 specifications

27

Preparation of moulds with loam sand preparation mould with sweep methods.

Loan sand composition materials used process of loam.

28

Making mould with different mould joints straight joint stepped joint tapered joint and pattern with irregular joint.

Types of pig iron as per IS cast iron elements of cast iron effect of elements in cast iron.

29

Operation of reverbratory skelnar for furnace melting of cast iron inskelnar furnaces making a batch of particular grade cast iron.

Principle of reverbratory melting Advantages melting in reverbratory type furnaces over cupola and other furnaces, rotary furnace, induction furnace, arc furnace.

30

Lining of reverbratory furnace preheating and melting on reverbratory furnace.

Reverbratory furnace. It’s application for Grey iron melting. It’s advantages in the present day shortage of fuel and making particular grade of casting.

31

Preparation of special moulds by full mould process (use of expanded polysterene/thermocole pattern). Making mould with ferrosilicon of Nishiyama process.

Advantages & disadvantages of fuel mould process. Nishiyam process Antioch process. Air setting binders used for moulding.

32

Making of mould with special moulding process investment casting process (Lost wax process) etc.

Advantages & disadvantages of graphite mould, investment casting process – shaw process magnetic moulding - slush casting die (gravity and pressure) casting vacuum and continues casting V process.

33

Preparation of moulds with co2 process. Preparation of core with co2 process.

Co2 process for moulds and core making sodium silicate preparation types of sand and grain size requirement of co2 types of probes used for gasing reclamation of co2 sand.

34

Grading, inspection, and gauging checking accuracy of a casting by gauges & measuring tools carrying out visual inspection of casting detecting the defect and identifying defects in casting.

Inspection of casting destruction and non destructing test radio graphy test Gamma Ray and X ray ultra sonic testing etc.

35

Preparation of mould in a hand moulding machine. Use of pneumatic rammer and air compressor.

High pressure moulding machine types moulding machines types hand operated and power operated sand slinger power hydraulically operated machine

36

Preparation of mould for application of chills and den seners

Solidification of metal directional solidification use of chills and denseners.

37

Preparing moulds with step gating and bottom gating.

Step gating bottom gating feeding risering nasic concept of design of gates and risers.

38

Preparation of moulds for setting cores with chaplets setting of cores in a mould with balancing core.

Chaplets types’ calculation of chaplet requirement. Calculation of core print area required.

39

Preparation of black washing mixtures (plumbago) – bott clay and ladle lining mixtures)

Types of facing materials coating of facing materials bott clay composition and shape and size for effectiveness ladle lining procedure mixtures monolithic and brick lining.

40

Making a casting in a gravity die or permanent mould casting preparation setting of cores for permanent mould.

Permanent mould cores in permanent mould gating of permanent mould coating of permanent moulding and casting alloys

41

Preparation of plaster moulds and ceramic moulds.

Materials used in plaster moulds and ceramic moulds.

42

Preparation of moulds for steel casting coating of non carbonaceous materials on moulds placing exorthermic compounds or sleeves on moulds.

Types of steel casting annealing casting foundry techniques gating and risering for steel casting steel melting furnaces and their types.

43

Preparation of moulds for malleable iron S.G. iron etc.

Malleaaable cast iron types black heart white heart.

44

Repairinga casting grooving gouching welding pluging depositing metal by thin layers by metallising filling up of unwanted cavities by cold setting metal compounds.

Solvaging of casting, preparation of casting for solvaging welding metalising cold setting metal resin compounds thermit welding burning on process etc.

45

Making of different types of core by using different types of cores with different core binders and baking then in oven and other methods.

Core binders baking oven baking method die electric core oven. Materials used to increase collapsibility of coress.

46

Making a mould with multiple gating systems, making a mould with side riser and blind riser.

Advantages of multiple gating system. Use of blind risers williams core and side risers gate with shrink box.

47

Identifying casting defects from CI casting aluminium casting and suggesting remedy for them

Casting defects causes, remedies. Factors related to casting defects. Method of avoiding casting defects.

48

Preparation of special moulds for calculating metallostatic pressure acting on mould upward thrust downward side way thrust.

Force acting on moulds and cores metallostatic pressure on moulds. Calculation of metalostatic pressure on mould walls.

49

Making a mould with wedge gate for light metals and cast irons melting and pouring the moulds fettling the thin casting

Foundry mechanisation and lay out

50

Revision of major skills of the trade.

Revision of major knowledge portion of the trade.