Manufacturing Processes - Casting and Joining

By Prof. Sounak Kumar Choudhury   |   IIT Kanpur
Learners enrolled: 2632
This course is intended to introduce the characteristic features of casting and welding processes.Process characteristics, analysis, and design criteria of various casting and welding processes will be discussed in detail with examples and video clips from industries. Typical numerical examples will be discussed to help the students understand the theory in a better way. The course is designed for undergraduate engineering students as a part of the core course on Manufacturing Technology as well as for practicing engineers.

UG students; practicing engineers
INDUSTRIES  SUPPORT     : Machine Tool industries; Automobile manufacturing industries; Foundry industries.
Course Status : Ongoing
Course Type : Core
Duration : 4 weeks
Start Date : 18 Jan 2021
End Date : 12 Feb 2021
Exam Date : 21 Mar 2021
Enrollment Ends : 01 Feb 2021
Category :
  • Mechanical Engineering
  • Manufacturing Processes and Technology
  • Product Design
Level : Undergraduate

Course layout

Week 1:Casting: Introduction; Classification of casting processes; Advantages and drawbacks; Historical background; Foundry practice on video; Casting of BMW car wheels on video; Patterns; Shrinkage and Mechanical allowances; Moulds; Gating system; Properties of moulding sand; Gating design; Vertical gating: aspiration effect; Optimum riser design;
Week 2:Solidification of pure metal and alloy; Solidification time: Chvorinov’s rule; Categories of metal casting processes; Steps in sand casting; Mould properties and characteristics; Shell moulding; Investment casting: Process characteristics, Process to show through video, Advantages and disadvantages; Multiple mould casting, Steps in permanent mould casting; Die casting: Hot and Cold Chamber die casting; Centrifugal casting; Continuous casting; Cost analysis of casting; Casting defects; Product design considerations in casting;
Week 3: Joining Processes: Preamble, classification of joining processes; Welding: advantages and limitations; Joints in welding; Fusion welding processes; Heat density; Comparison among welding processes; Features of a Fusion Welded Joint; Typical Fusion Welded Joints; Heat Affected Zone; Solidification of Weld; Solid-State (Phase) Welding: Forge welding, butt welding, friction welding, explosion welding, resistance welding;
Week 4:Ultrasonic welding: process characteristics and applications; Electron beam welding; Laser beam welding; Plasma arc welding; Arc welding: characteristics; Consumable and non-consumable electrodes; Power source; Shielded metal arc welding: Principles and applications; Gas metal arc welding; Gas Tungsten Arc Welding; Tungsten-Inert Gas Welding (TIG); Submerged Arc Welding; Gas Welding: Principles, types of flames; Brazing and Soldering: Process capabilities; Welding defects;

Books and references

1. A.Ghosh and Asok Mallik - Manufacturing Science
2. G.K.Lal and S.K.Choudhury - Fundamental of Manufacturing Processes
3. Richard Flinn - Fundamentals of Metal Casting
4. Kalpakjian and Schmid - Manufacturing Processes for Engineering Materials,

Instructor bio

Prof. Sounak Kumar Choudhury

IIT Kanpur
I have completed my Ph.D. in Mechanical Engineering from Moscow, Russia in 1985 followed by post-doctoral at the same university till 1986. From 1986 I am involved in teaching and research in the Mechanical Engineering Department of Indian Institute of Technology Kanpur. My areas of specialization are conventional and non-conventional machining, automatic control, hydraulic control, machine tools and manufacturing automation.

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: 21 March 2021 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.


Average assignment score = 25% of average of best 3 assignments out of the total 4 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Kanpur .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team

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