Technology (Metallurgy, Welding, Casting) (FSI-WTC-A)

Academic year 2020/2021

Supervisor:	prof. Ing. Milan Horáček, CSc.
Supervising institute:	ÚST	all courses guaranted by this institute
Teaching language:	English
Aims of the course unit:
The aim is to obtain the knowledge about the following technologies: metallurgy, foundry and welding of ferrous and non-ferrous materials. In each of these technologies is the attention devoted to the kind of raw materials, semi-product, melting furnaces, machinery, quality and control of processes and also to the final product.
Learning outcomes and competences:
The course gives the possibility to obtain the knowledge about the following technologies: metallurgy, foundry and welding of ferrous and non-ferrous materials. In each of these technologies is the attention devoted to the kind of raw materials, semi-product, melting furnaces, machinery, quality and control of processes and also to the final product. The graduate obtains the possibility of an orientation in the present (contemporary) production technologies of metals.
Prerequisites:
Universal knowledge and foundation knowledge of mathematics, physics and chemistry from secondary school
Course contents:
Metallurgy of the iron alloys. The basic technical information about production of iron from ores in the coke blast furnaces. The present production of steel in the oxygen converter and in electrical arc and induction furnaces. The main technologies used in a steel production. The continuous casting and ingot casting. The technology of grey, ductile and malleable cast irons. The furnaces used to the steel and cast iron production. Metallurgy of the non-ferrous alloys. Types of foundry moulds. Moulding materials, moulding methods both for making moulds and cores. Non-permanent moulds according to the binders used - 1st - 3rd generation. Technology of permanent moulds. Pouring, solidification and cooling of the metals. Finishing operations and heat treatment of the castings. Quality control and simulations used in casting production. Additive technologies in foundry processes. Welding and weldability of materials. The welding technologies, manual, automatic and arc welding, additional materials. The welding of ferrous metals and non-ferrous metals and alloys. The repair welding. The defects in metallurgical, foundry and welding processes.
Teaching methods and criteria:
The course is taught through lectures explaining the basic principles and theory of the discipline. Teaching is suplemented by practical laboratory work.
Assesment methods and criteria linked to learning outcomes:
Condition for awarding the course unit credit: Having done all the assigned topics in exercises. Examination has a written and an oral part .
Controlled participation in lessons:
Compulsory attendance at exercises. Absence from exercises is resolved individually.
Type of course unit:
Lecture	13 × 2 hrs.	compulsory
Laboratory exercise	13 × 1 hrs.	optionally
Course curriculum:
Lecture	1. Technology of cast iron production in coke blast furnace, steel production in oxygen converter and in electrical furnaces.The continuous and ingot casting technologies 2. Technology of grey, ductile and special cast irons production. Metallurgy of the non-ferrous alloys. Trends in mettalurgy of foundry alloys 3. Introduction into history of casting technologies. basic principles of making castings. 4. Categories of foundry moulds. Non permanent moulds according to the binders used (1st - 3rd generation) 5. Technology of pouring into permanent moulds 6. Metal pouring, gating systems. Casting solidification and cooling. 7. Volumetric changes during solidification. Elimination of hot spots in casting. 8. Simulation of the foundry processes. Additive technologies in foundries. 9. Finishing operations and heat treatment of castings 10. Welding technologies: manual, automatic 11. Thermal cutting technologies and additive materials 12. Weldability of steels, irons and non-ferrous materials 13. Reclamation welding. Metallurgical, foundry and welding defects. Classification systems.

Laboratory exercise	1. Exercise to: cast iron production in coke blast furnace, oxygen converter and electrical furnaces. 2. Exercise to: metallurgy of the ferrous and non-ferrous alloys. 3. Exercise to: basic foundry technologies 4. Exercise to: non-permanent moulds - examples 5. Exercise to: pouring into permanent moulds 6. Exercise to: gating systems 7. Exercise to: hot spots in casting and their elimination 8. Exercise to: simulation of foundry processes. 9. Exercise to: casting quality control 10.Excercise to: welding technology, mechanical properties of welds and tesing 11. Exercise to: cutting by oxygen and plasma 12. Exercise to: weldability of different materials 13. Exercise to: classification systems of the welding defects.

Literature - fundamental:
1. TURKDOGAN, R. T. ,Fundamentals of Steelmaking.The Institute of Materials, London 1996.
2. FLEMINGS, M.C.,Solidification Procesing. McGraw - Hill Book Company.
3. PILOUS, V. – STRÁNSKÝ, K. Structural Stability of Deposits and Welded Joints in Power Engeneering. Gambridge International Science Publishing, Gambridge 1998.
Literature - recommended:
1. LEVÍČEK, P. – STRÁNSKÝ, K. Metalurgické vady ocelových odlitků. SNTL, Praha 1984.
2. RUSÍN, K. Teorie slévárenských procesů. SNTL, Praha 1990.
3. HRIVŇÁK, I. Teória zvárania kovových materiálov. Veda, Bratislava 1989.