Metal Casting Methods Training Program
Course Introduction
The Metal Casting Methods training program is designed to provide in-depth and practical knowledge for engineers, technicians, and students in mechanical engineering and manufacturing. The course focuses on popular casting techniques such as sand casting, permanent mold casting, die casting, centrifugal casting, and modern specialized casting methods.
Training Objectives
- Equip foundational knowledge of metal casting processes, including sand casting, permanent mold casting, die casting, centrifugal casting, and special casting methods.
- Understand factors affecting castability, casting design, solidification structure, and practical applications of each method.
- Analyze technical characteristics of casting materials, melting equipment, gating systems, and casting technology procedures.
Training Duration
Theory: 48 periods
Instructor in Charge
Assoc. Prof. Dr. Nguyen Thanh Hai
Department of Equipment & Mechanical Materials Technology – Ho Chi Minh City University of Technology (HCMUT), VNU-HCM.
With years of teaching and practical experience, the instructor will accompany trainees throughout the course.
Who Should Attend?
- Mechanical engineers and technical specialists in metal manufacturing and processing.
- Final-year students in Mechanical Engineering – Machine Manufacturing.
- Enterprises seeking to upgrade the skills of their technical teams.
Benefits of Attending the Course
- Access knowledge from top experts.
- Understand and apply casting methods in actual production.
- Improve ability to analyze, detect, and handle technical defects in metal casting.
- Opportunity to network with businesses and industry experts.
Theory Training Curriculum
| No. | Content | Detailed Description | Duration (periods) |
| 1 | Overview of Casting Methods – Classification and Application | Analyzing casting method groups: sand mold, metal mold, special methods. Comparing pros/cons and applications in the manufacturing industry. | 2 |
| 2 | Casting Principles – Solidification, Metal Flow, Heat Transfer | Presenting crystallization phenomena during solidification, effects of flow and heat transfer on casting structure. Simulation of crystallization process. | 4 |
| 3 | Castability of Alloys | Defining castability, influencing factors such as fluidity, shrinkage, porosity, filling ability. Comparing castability of common alloys: cast iron, aluminum, copper, steel. | 3 |
| 4 | Casting Product Design – Pattern, Core, Gating System, Shrinkage | Guiding geometric analysis of castings, shrinkage calculation, design of pouring channels, venting systems, and removable pattern structures. | 5 |
| 5 | Metal Melting Technology and Equipment | Introduction to furnace types: resistance, induction, arc furnaces. Techniques for controlling temperature and chemical composition during melting. | 2 |
| 6 | Sand Casting Process | Steps in preparing molding materials, making patterns and cores, mold assembly, pouring metal, shakeout, and post-casting treatment. Discussion of common defects. | 4 |
| 7 | Permanent Mold Casting – Principles, Equipment, Applications | Principles of casting in metal molds, advantages in precision, mold reusability. Design of gating channels, rapid cooling, applications with aluminum and light alloys. | 3 |
| 8 | Centrifugal Casting – Applications for Rotationally Symmetric Parts | Explaining centrifugal principles, types: horizontal, vertical, semi-centrifugal. Analyzing applications for pipes, wheels, bearings, etc. | 3 |
| 9 | Die Casting – High Speed, High Volume Production | Presenting die casting processes: hot chamber, cold chamber. Advantages in precision and speed. Analyzing disadvantages and solutions. | 4 |
| 10 | Investment Casting (Lost Wax) | Process of making wax patterns, ceramic shell molds, metal pouring, and shell removal. Applications for precision, complex parts. | 4 |
| 11 | Lost Foam Casting | Principle of using foam patterns that vaporize upon metal pouring. Characteristics include time savings, flexible shaping, and reduced core assembly. | 3 |
| 12 | Thin Wall Casting and Continuous Casting – Modern Technologies | Introduction to high-speed thin-wall casting, continuous casting in the steel industry. Analyzing equipment conditions, temperature control, cross-section, and product quality. | 3 |
| 13 | Casting Defect Analysis – Causes and Remedies | Common defects: hot tearing, blowholes, slag inclusion, mold shift. Methods for identification, root causes, and prevention. | 3 |
| 14 | Theory Exam – 40 Multiple Choice & 2 Essay Questions | Evaluating comprehensive course knowledge, analyzing practical situations to assess the ability to apply knowledge in production. | 3 |
References
Main Textbooks:
- Serope Kalpakjian – Manufacturing Engineering and Technology, Prentice Hall, 2014.
- Nguyen Tien Dao – Technical Preparation of Blanks, Hanoi University of Science and Technology, 2002.
Supplementary Materials:
- Mikell P. Groover – Fundamentals of Modern Manufacturing, Wiley, 2012.
- A.Y.C. Nee – Handbook of Manufacturing Engineering and Technology, Springer, 2015.
- J. T. Black – Materials and Processes in Manufacturing, Wiley, 2011.