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Production of Castings from Non-ferrous Metals
Major: Computer-integrated technologies of art and jewelry casting
Code of subject: 6.136.03.O.034
Credits: 4.00
Department: Department of Materials Science and Engineering
Lecturer: Dr.Sc., Kulyk Volodymyr Volodymyrovych
Semester: 7 семестр
Mode of study: денна
Завдання: Formation of professional competencies:
? FC 2 - critical understanding of scientific facts, concepts, theories, principles and methods, necessary for professional activity in the field of metallurgy.
? FC 5 - the ability to apply scientific and engineering methods, as well as computer software to solve typical and complex tasks of foundry production, including under conditions of uncertainty.
? FC 6 - the ability to define and investigate a problem in the field of computer modeling and development of artistic and jewelry casting technologies, as well as to identify limitations, in particular those related to issues of sustainable development, environmental protection, health and safety and risk assessments.
? FC 9 - the ability to identify, classify and describe the effectiveness of systems, components and processes in metallurgy based on the use of analytical and modeling methods.
? FC 11 - the ability to implement concepts of lean production and general principles of reducing production costs in metallurgy, as well as to introduce resource-saving technologies that allow accumulating resources aimed at achieving goals in all areas of activity of metallurgical and foundry enterprises.
? FC 12 - awareness of the requirements for activities in the field of foundry production, determined by the need to ensure sustainable development.
? FC 13 - the ability to solve typical engineering tasks of foundry production, in particular with the use of modern computer modeling tools.
? FC 14 - awareness of the characteristics of specific materials, equipment, processes and products of foundry production.
? FC 15 - the ability to apply the best world practices, standards of activity in metallurgy with the specialization of computer-integrated technologies of artistic and jewelry casting.
? FC 16 - the ability to manage complex actions or projects in foundry production to ensure the achievement of the set goal, taking into account all aspects of the problem being solved, including those related to production, operation, maintenance and disposal.
? FCS 1.1 - the ability to rationally choose materials, typical technological processes, equipment and tools for the manufacture of metal products, including using modern CAD/CAM/CAE systems, in order to ensure the specified properties, required quality indicators, minimum cost and impact on the environment with high technical and economic indicators of production.
? FCS 1.2 - awareness of the main stages of designing the technology of the casting mold, the properties of materials for the manufacture of model devices, the properties of molding and core materials, the ability to calculate sprue systems for the manufacture of castings from various alloys, to develop the necessary technological documentation taking into account the type of production.
? FCS 1.5 – the ability to calculate the amount of foundry equipment and its layout in the production areas of the foundry, determine the operating modes of the foundry, its ventilation and lighting systems, calculate the amount of casting material according to the technology for manufacturing a given number of castings, and propose basic measures for fire safety and labor protection.
Learning outcomes: ZN 2 - knowledge and understanding of the engineering sciences that underlie the specialization, at the level necessary to achieve other program outcomes, including sufficient awareness of their latest achievements.
ZN 3 - advanced knowledge in the field of metallurgy and, in particular, computer-integrated technologies of artistic and jewelry casting.
ZN 5 - understanding of the characteristics of the materials used, equipment and tools, engineering technologies and processes, as well as their limitations in foundry production.
ZN 8 - Understanding of the best global practices and standards of activity and the skills to apply them in the metallurgical industry of Ukraine.
UM 1 - the ability to identify, formulate and solve typical and complex and unpredictable engineering tasks and problems of foundry production, which includes collecting and interpreting information (data), selecting and using appropriate equipment, tools and methods, applying innovative approaches and specialized software.
UM 4 - the ability to develop, design and model foundry processes and systems that meet the established requirements, assuming awareness of non-technical (society, health and safety, environment, economy) aspects, to select and apply adequate design methodologies, including computer-aided design tools.
UM 5 - the ability to select and use management systems and organization of foundry production in the field of artistic and jewelry casting.
UM 15 - the ability to apply the concepts of lean production and general principles of reducing production costs in metallurgy.
COM 1 - the ability to communicate, including oral and written communication, in Ukrainian and one of the foreign languages ??(English, German, French).
Required prior and related subjects: Construction Materials Technology
Theoretical Fundamentals of Foundry Production
Physical and Chemical Fundamentals of Metal Production
Foundry Mold Technology
Theoretical Fundamentals of Forming
Summary of the subject: The discipline studies the structure of the technological process of melting and casting of non-ferrous metals and alloys.
While studying the discipline, the student becomes familiar with the composition and classification of non-ferrous metals and alloys, the basics of their theory and technology of melting, the basics of the technology of producing castings from non-ferrous metals and alloys by various casting methods, the main types of defects in castings from these metals and alloys, the causes of their occurrence and prevention and removal
Опис: Introduction. Furnaces for melting non-ferrous metals and alloys.
General characteristics and classification of non-ferrous metal castings.
Composition and properties of primary aluminum. Composition and properties of aluminum alloys
Features of melting aluminum alloys. Production of aluminum alloy castings
Composition and properties of primary magnesium. Composition and properties of magnesium alloys. Features of melting magnesium alloys. Production of magnesium alloy castings
Composition and properties of copper. Composition and properties of copper alloys
Features of melting copper and copper alloys. Technology of melting copper alloys.
Production of copper alloy castings
Composition and properties of nickel and nickel alloys. Features of melting nickel alloy. Production of nickel alloy castings
Composition and properties of titanium and titanium alloys. Features of melting titanium alloys. Production of castings from titanium alloys
Properties of refractory metals and features of their melting. Composition and properties of zinc, tin, lead and cadmium alloys and features of their melting
Features of the technology for the production of shaped castings from low-melting alloys. Composition and properties of gold, silver, platinum and palladium alloys and production of castings from alloys of noble metals
Assessment methods and criteria: 1. Interview and admission to laboratory work.
2. Defense of laboratory work, including those performed on individual assignments.
3. Examination control with written and oral components.
Критерії оцінювання результатів навчання: - written reports from laboratory work, oral questioning (40%);
- final control (60%, test): written-oral form.
Recommended books: 1. Дан Л. О. Ливарне виробництво : навчальний посібник для студентів металургійних спеціальностей / Л. О. Дан, Л. О. Трофімова ; М-во освіти і науки України, ПДТУ. Каф. технології і комп`ютерізації ливарного виробництва. – Маріуполь : ПДТУ, 2013. – 207 с.
2. Пахаренко В.Л. Матеріалознавство та технологія конструкційних матеріалів (металургія, ливарне виробництво): навчальний посібник / В. Л. Пахаренко, М.М. Марчук . – Рівне: НУВГП, 2009. –179 с.:іл.
3. Energy and Resource Efficiency in Aluminium Die Casting. – Springer, 2016. – 263 p.
4. Reikher A. Casting: An Analytical Approach / A.Reikher , M. R. Barkhudarov. – London: Springer, 2007. – 177 p.
5. Campbell F.C. Elements metallurgy and engineering alloys / F.C. Campbell. – ASM International, 2008. – 645 р.
6. Chakrabarti A.K. Сasting technology and cast alloys / A.K. Chakrabarti. – PHI Learning Pvt. Ltd., 2005. – 288p
7. Campbell J. Complete Casting Handbook. 2nd Edition: Metal Casting Processes, Metallurgy, Techniques and Design . Elsevier / J. Campbell: Butterworth-Heinemann, 2015. – 1054p.
8. Sahoo M. Principles of Metal Casting / M. Sahoo, S. Sahu. – Third Edition 3rd Edition, MsGraw-Hill Education, 2014. –795 p.
Auxiliary
1. Campbell F.C. Elements metallurgy and engineering alloys / F.C. Campbell. – ASM International, 2008. – 645 р.
2. Chakrabarti A.K. Сasting technology and cast alloys / A.K. Chakrabarti. – PHI Learning Pvt. Ltd., 2005. – 288p
3. Campbell J. Complete Casting Handbook. 2nd Edition: Metal Casting Processes, Metallurgy, Techniques and Design . Elsevier / J. Campbell: Butterworth-Heinemann, 2015. – 1054p.
Information resources
1. http://www.sciencedirect.com/science/book/9780750