UNIT I :  METAL CASTING PROCESSES
Sand Casting – Sand Mould – Type of patterns – Pattern Materials – Pattern allowances – Molding sand Properties and testing – Cores –Types and applications – Molding machines – Types and applications – Melting furnaces – Principle of special casting processes- Shell, investment – Ceramic mould – Pressure die casting – low pressure, gravity- Tilt pouring, high pressure die casting- Centrifugal Casting – CO2 casting –- Defects in Sand casting process-remedies

UNIT II:  METAL JOINING PROCESSES
Fusion welding processes – Oxy fuel welding – Filler and Flux materials-–Arc welding, Electrodes, Coating and specifications – Gas Tungsten arc welding –Gas metal arc welding – Submerged arc welding – Electro slag welding– Plasma arc welding –– Resistance welding Processes -Electron beam welding –Laser beam Welding Friction welding – Friction stir welding – Diffusion welding – Thermit Welding, Weld defects – inspection &remedies – Brazing – soldering – Adhesive bonding.

UNIT III : BULK DEFORMATION PROCESSES
Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – cold forging- Characteristics of the processes – Typical forging operations – rolling of metals – Types of Rolling – Flat strip rolling – shape rolling operations – Defects in rolled parts – Principle of rod and wire drawing – Tube drawing – Principles of Extrusion – Types – Hot and Cold extrusion. Introduction to shaping operations.

UNIT IV :  SHEET METAL PROCESSES
Sheet metal characteristics – Typical shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes – Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning – Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming – Incremental forming.

UNIT V  : MANUFACTURE OF PLASTIC COMPONENTS
Types and characteristics of plastics – Molding of thermoplastics & Thermosetting polymers– working principles and typical applications – injection molding – Plunger and screw machines – Compression molding, Transfer Molding – Typical industrial applications – introduction to blow molding – Rotational molding – Film blowing – Extrusion – Thermoforming – Bonding of Thermoplastics- duff moulding.