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Metalcasting for Automotive Parts

* Exchange students do not have to consider this information when selecting suitable courses for an exchange stay.

Course Unit Code618-1415/02
Number of ECTS Credits Allocated8 ECTS credits
Type of Course Unit *Compulsory
Level of Course Unit *First Cycle
Year of Study *Second Year
Semester when the Course Unit is deliveredWinter Semester
Mode of DeliveryFace-to-face
Language of InstructionCzech
Prerequisites and Co-Requisites Course succeeds to compulsory courses of previous semester
Name of Lecturer(s)Personal IDName
LIC03doc. Ing. Petr Lichý, Ph.D.
KRO226doc. Ing. Ivana Lichá, Ph.D.
Summary
1st Overview of castings for the automotive industry. Technological flow
production in the foundry.
2nd Casting the single sand molds. Moulding Materials -
grog, binders.
3rd Moulding Materials I-IV. generation. Properties of molding and
core mixtures, testing.
4th Technology of production of sand molds and cores. Production of precision
automotive castings. Shell formation, the use of lost and
odpařitelného model.
5th Metal casting molds. (Gravity, pressure, low pressure,
centrifugal).
6th The flow of molten metal in the gating system, the fluidity of metal, static
and the dynamic effect of the metal form.
7th Solidification and crystallization of the metal. Gases in metals and in shape.
8th Volumetric shrinkage of metal and its consequences. Heat units and their
Disposal
9th Linear shrinkage in castings. The emergence of tensions in the castings.
10th Development of technological process of casting. Casting defects.
11th Materials for castings. Cast iron - structure, formation of graphite, basic
metal compound. Mechanical properties of cast iron.
12th Metallurgy of cast iron - vaccination and modification
13th Automotive castings of nonferrous metals. Aluminum alloys and
magnesium.
14th Metallurgy of Al and Mg.
Learning Outcomes of the Course Unit
Student will be able to analyse and compare basic methods of mould- and core-making;
Student will be able to describe basic processes during forming a casting from pouring it up to metal cooling;
Student will be able to explain the formation of the most important casting defects;
Student will be able to describe material and foundry properties of cast materials for automotive industry.
Course Contents
Lectures:
1. Foundry industry in the Czech republic and in the world, statistics, possibilities and limits of casting production. Procedure of casting production from a design to the dispatch department
2. Applied processes and techniques in foundries. Production of castings using permanent metal mold and lost sand mold
3. Molding materials, sand, binders, mold and core making technologies, molding mixtures making and testing
4. Sand reclamation techniques – dry, wet, thermal reclamation
5. Melt flow in molds,castability, running system design and calculation
6. Static and dynamic action of the melted alloys on molds and cores. Gases in metals and molds
7. Castings crystallization and solidification
8. Solidification shrinkage – feeding (risers)
9. Linear contraction of the casting, hot tearing, cold cracking, residual stresses
10. Materials for casting production, cast steel
11. Cast irons - types, structures, mecanical properties
12. Cast iron – melting, secondary metallurgy, innoculation
13. Non ferrous alloys for casting - metallurgy, properties
14. Terminal consultation
practices
1. Refractory materials for mold and core making, silica and non silica sands, organic and inorganic binders
2. Molding mixtures making and testing -– test report
3. Mold and core making technologies, split pattern, simple and complex mold, core making by compactin or hardening
4. Molding and pouring the own AlSi alloy casting
5. Visit of a cast iron foundry and its pattern shop
6. Casting design, axonometric drawing
7. Calculation of metalostatic pressure and buoyancy
8. Casting designing- parting line, scarfs, working allowance
9. Visit of a hight pressure die casting aluminium alloys foundry
10. Running system design and calculation (program)
11. Calculation of the riser volume ( program)
12. Cast irons, steels, standards, properties, metallografy
13. Seminary Rapid prototyping , computer simulations
14. Final seminary, credit
Recommended or Required Reading
Required Reading:
[1] SCHLEG, Frederick P. a Frederick H. KOHLOFF. Technology of metalcasting. Des Plaines: American Foundry Society, c2003. ISBN 0-87433-257-5.
[1] JELÍNEK, Petr. Slévárenství. 5. vyd. Ostrava: VŠB - Technická univerzita Ostrava, 2007. ISBN 978-80-248-1282-3.
[2] MICHNA, Štefan a Iva NOVÁ. Technologie a zpracování kovových materiálů. Prešov: Adin, 2008. ISBN 978-80-89244-38-6.
[3] HAMPL, Jiří. Metalurgie slévárenských slitin: studijní opora. Ostrava: Vysoká škola báňská - Technická univerzita Ostrava, Fakulta metalurgie a materiálového inženýrství, 2014. ISBN 978-80-248-3585-3.
[4] SCHLEG, Frederick P. a Frederick H. KOHLOFF. Technology of metalcasting. Des Plaines: American Foundry Society, c2003. ISBN 0-87433-257-5.
Recommended Reading:
[1] CAMPBELL, John. Castings. 2nd ed. Oxford: Elsevier Butterworth-Heinemann, 2003. ISBN 0-7506-4790-6.
[1] CHRÁST, Jaroslav. Slévárenská zařízení. Brno: Akademické nakladatelství CERM, 2006. ISBN 80-7204-455-9.
[2] CAMPBELL, John. Castings practice: the 10 rules of castings. Oxford: Elsevier Butterworth-Heinemann, 2004. ISBN 0-7506-4791-4.
Planned learning activities and teaching methods
Lectures, Seminars, Tutorials, Experimental work in labs, Project work
Assesment methods and criteria
Task TitleTask TypeMaximum Number of Points
(Act. for Subtasks)
Minimum Number of Points for Task Passing
Credit and ExaminationCredit and Examination100 (100)51
        CreditCredit30 16
        ExaminationExamination70 35