Course content

The course covers manufacture of metallic products by casting and metal forming. Design of cast and metal formed components. Casting methods, mould and ingot mould. Casting of iron, steel and light metals. Melt flow, solidification, heat transfer, contraction, thermal stresses, foundry management, quality, environmental considerations and costs. General metal forming theory: Technological tests, flow stress, friction, thermal conditions.

Learning outcome

Knowledge:
In the course students will acquire knowledge about how to cast and shape metals into useful products either as final parts or as wrought products, for instance in terms of rolled rods or extruded profiles. The students are taught how by classical theory and modern FEM-analysis they can study the process conditions in casting and metal forming operations. Through the analysis approach it is possible to determine optimum conditions in industrial applications of the processes.

Skills:
The students will gain theoretical and practical skills required in connection with casting and metal forming so that in a future job they can design products for ease of manufacture. Practical skills related to laboratory work are also acquired. The students will be given skills so they will be able to use modern data assisted methods for optimization of casting and metal forming processes on the concept stage before manufacture of products.

General competence:
Upon attending the course you will acquire general competence within the casting and the metal forming technologies. More specific competence is gained so you should be able to judge what optimum conditions are when such manufacturing methods are used. The competence acquired can be described by following key words: Design of components in casting and metal forming, understanding the physics of casting and metal forming, metallurgy and mechanics of casting and metal forming, methods used, important alloys for the purpose, optimization of processes and process conditions, running of casting and metal forming companies, quality and cost control.

Learning methods and activities

Lectures, calculation- and laboratory exercises. There will be two semester projects where casting and metal forming are analysed in laboratory experiments supported by FEM-analysis using the FEM-programs DEFORM and MAGMASOFT. A mark is given for the semester projects/exercises, and this mark counts 40% when final mark is given. Lectures and exercises will be in English if some students do not speak Norwegian. If there is a re-sit examination, the examination form may be changed from written to oral.

Compulsory assignments

• Exercises

Recommended previous knowledge

Background knowledge comparable with TMM4100 Materials Technology.

Course materials

Distributed compendium. (Support literature: J. Campbell: Castings, Butterworth/Heinemann, 1993 eller 2003.)
Selected chapters from the book: Henry Valberg: Applied metal forming including FEM-analysis, Cambridge University Press, 2010.