Metal Casting Engineering Design, Processes, Calculations

This book covers all main aspects of metal-casting processes and practices, including mold/gating-system design, melting of metal, solidification, QC/QA, safety, economic, and environmental considerations. The flow and solidification of metal is presented with reference to Bernoulli’s Law, Fick’s 2nd law, and Chvorinov’s rule, with detailed mathematical analyses and calculations. Foundry practices involving mold design, molding sand characteristics, melting furnaces, testing/NDT, and QC are explained, including both conventional casting processes and recent advances in casting technologies. There are around 120 diagrammatic illustrations, which have been properly labelled to enhance the understanding of readers. One of the salient features of the book is the inclusion of an industrially-oriented project; the key solution of the project is presented with the aid of mathematical analysis and diagrams. The metal-casting design project cultivates managerial skills enabling the reader to work effectively as an engineer/manufacturing manager in an industry.

Introduction.- Melting and Solidification of Metals.- Solidification Behavior in Metal Casting.- Melting Furnaces in Foundry Practice.- Cold Blast Cupola.- Sand Casting Design and Processes.- Worked Casting-Design Project.- Shell Mold Casting and Lost Wax Casting Processes.- Investment Casting Process.- Basic Permanent Mold Casting and Die Casting Processes.- Centrifugal Casting Process.- Inspection, Casting Defects, and Quality Assurance.- Safety Economic and Environmental Considerations in Foundry.

Dr. Zainul Huda is a Professor emeritus of Manufacturing/Mechanical Engineering, King Abdulaziz University, Jeddah, Saudi Arabia. He has worked as a full Professor in good standing at reputed/world-ranking universities for 17 years (Feb 2007–May 2024). Professor emeritus Zainul Huda possesses 42 years’ academic experience in manufacturing/mechanical/ metallurgical engineering. His teaching interests include Foundry/Manufacturing Technology, Metallurgy, Fracture Mechanics, and Mechanical Behavior of Materials. He has supervised-to- completion several PhD and Masters’ theses in the field of manufacturing/materials engineering.

Professor emeritus Z. Huda is the single/first author of 9 books and over 100 research articles in the field of metallurgical/materials/manufacturing engineering published by reputed journals/publishers from the USA, Canada, UK, Germany, France, Poland, Switzerland, Pakistan, South Korea, Malaysia, and Singapore. His research work has been cited over 1350 times with h-index of 15 and i-10 index of 29. He (as a PI) has attracted nine (9) research grants, with a total worth of US$ 0.16 million.

Prof. emeritus Zainul Huda has hands-on experience in metal casting. He has worked as a manager/engineer /metallurgist in various manufacturing companies, including Pakistan Steel Mills Corporation Ltd., Karachi. He is a registered professional engineer (PE) registered under the Pakistan Engineering Council. He has also successfully completed 20 industrial consultancy projects in the areas of failure analysis and manufacturing. He is the developer of Toyota Corolla cars' axle-hub's manufacturing procedure first ever implemented in Pakistan (through Indus Motor Co., Karachi).

Prof. emeritus Z. Huda earned a PhD in Materials Engineering/Metallurgy from Brunel University, London, UK, in 1991. He is also a postgraduate in Manufacturing Engineering. He obtained a BS (Metallurgical Engineering) from the University of Karachi, Pakistan, in 1976. He has delivered guest lectures on metallurgy/mechanical engineering in the United Kingdom, South Africa, Malaysia, Pakistan, and Saudi Arabia.