1. Preparation and testing of simple castings and welded joints.
2. Effect of the various solidification parameters on the produced microstructure and mechanical properties of the cast alloys.
3. An overview of Casting and welding.
4. Friction Stir Welding.

SECTION (1): CASTING

Sessions (1) & (2)  Review on the Various Casting Processes (Presentations Schedule)

SECTION (2): EFFECT OF SOLIDIFICATION PARAMETERS ON CAST STRUCTURE
 

Experiment (1)	Effect of (V/A) ratio on the cast structure and its properties.
Experiment (2) (2-sessions)	Effect of the cooling rate on the as-cast structure and metal cast ingot and its properties.
Experiment (3) (2-sessions)	Effect of adding nucleating agent and alloying on the cast structure of pure metal cast ingot and its properties.

Section (3): Casting Project (3 weeks)
Groups of three students are required to select a component to be mainly manufactured by casting, using the facilities available in the casting lab. Students are required to:

1. Design of the component
2. Design and implement all the required cast parts such as pattern, fasteners, inserts, cores, risers, vents, etc.
3. Cast the component selected in the ME workshop using the available facilities
4. Identify the defects present in the cast
5. Write a detailed technical report on the project

Experiment (4)        : Demonstration for the welding techniques available at WS
Experiment (5)        : Friction Stir Welding Process (download the lab sheet here-presentation here)

Section (5): Welding Project
Electric arc or oxyfuel gas welding methods are to be used to weld Al-Alloy sheets of different thicknesses in comparison with friction stir welding.  Microstrucutral evolution and it’s effect on the mechanical behavior of the welded joints should be characterized.  Inspection of the welded joints for the possibly present defects using destructive and non-destructive testing.

1. Lab reports are graded based on their content, format, organization, language and academic honesty. The grade distribution for the lab report is mentioned on the Standard Cover Page that you must use.

2. All the lab reports should have the same format to objectively judge its quality, depth of discussion and analysis. Always use

3. The length of the report bulk (without cover page, table of contents, appendices) should not exceed 10 pages of typed material excluding pictures, graphs and tables. In case of writing more than 10 pages, only the first 10 pages will be graded.

4. The lab report should include the following sections (each should start at a different page):

 I    Cover page: Only use the standard page Download the standard cover page here
II.   Abstract (page numbering starts here)
III   Table of Contents and figures (use headings and caption options in Word to generate them)
IV.  Introduction: maximum a page of typed material excluding pictures & comparisons tables if any.
V.   Theory: Maybe added in case of a qualitative or quantitative theory
VI.  Objective
VII. Specimen Preparation (specimen type, etching solution, heat treatment specs, magnification)
VIII.Testing (technique or device)
The above two sections can be merged together under one section called Experimental Procedures
IX.   Results (sketches, graphs, data, etc....)
X.    Discussion
XI.   Conclusion & Recommendations (if any)
XII.  References
XIII. Appendices (if any, attach graphs, sections from references, standards, etc.. (large reports))

- Make sure to obtain a notebook to take good lab notes, and please do not take the lab notes and results on the caravan!!
- No late reports except with an excuse from the OSA or Dr. Hanadi since the correct results will be posted online.
- Special attention will be paid for plagiarism, including cheating ( Academic Honesty Policy ).
- Adequate and neat hand or computer (Photoshop) drawings are required for microstructures, or you can use digital camera.