Sand Casting: Sand Mould, Sand Properties, Core Making – Patterns: Types, Materials, allowances – Types of Melting furnaces, Solidification and Cooling, Special casting processes: Shell - investment - Ceramic mould -Pressure die casting - Centrifugal Casting – Fettling -Defects in Sand castingSimulation of casting. Gas welding -Types -Flame characteristics - Manual metal arc welding -Gas Tungsten arc welding - Gas metal arc welding – Types of Special Welding Processes – Electron Beam welding and Friction Stir Welding – Brazing, soldering and Adhesive Bonding - Weld defects – Simulation of Welding - Applications.

Mechanical working of Metals- Plastic deformation theory – Principles - Hot working and cold working of metals: Forging-Types - Operations, rolling – Flat and Shape rolling, Extrusion – Direct & Indirect, Drawing processes – Tube, Wire - Defects. Sheet metal Processes and characteristics– shearing - bending and drawing operations. special forming Processes : Types - Rubber pad forming - Explosive forming - peen Forming

Mechanics of chip formation - single point cutting tool - forces in machining - Types of chip - cutting tools -nomenclature – orthogonal, oblique metal cutting - thermal aspects - cutting tool materials - tool wear - tool life - surface finish - cutting fluids and Machinability. Centre lathe - constructional features - specification - operations -taper turning methods - thread cutting methods - special attachments - machining time and power estimation - Capstan and turret lathes

Types of operations–drilling - reaming - boring - tapping -milling operations –types of milling cutter. Gear manufacturing: Gear milling and Hobbing -Gear shaping and finishing process. Abrasive processes -grinding wheel - specifications and selection -types of grinding process- cylindrical grinding -surface grinding -centreless grinding and internal grinding -Typical applications – broaching – operations – applications

Need for NDT -laser beam machining - electron beam machining - electric discharge machining - wire cut – waterjet & electro chemical machining-equipment - applications - advantages and limitations. Introduction to Powder metallurgy – applications. Surface modification – methods-CVDPVD-Electroplating- shot blasting – application to electronic components manufacturing