Name:- Arslan Ahmed

Roll No: 20IN027

Department:- Industrial Engineering and Management
Subject:- Manufacturing Process
Assignment Teacher:- Sir Ali Arsalan Siddiqui
Topic:- Coating and It’s types (CLO 1) And 2 topic :-
Casting (CLO-2)
Coating and it’s types:-
A coating is a covering that is
applied to the surface of an object,usually referred to
as the substrate.
• The purpose of applying the coating may be
decorative, functional, or both.
• The coating itself may be an all-over coating,
completely covering the substrate, or it may only
cover parts of the substrate.
• An example of all of these types of coating is a
product label on many drinks bottles one side has
an all-over functional coating (the adhesive) and the
other side has one or more decorative coatings in an
appropriate pattern (the printing) to form the words
and iimages.
• Paint and polishes are that mostly have dual uses of
protecting substrate and being decorative.
• A major consideration for most coating processes is
that the coating is to be applied at a controlled
thickness,and a number of different processes are in
use to achieve this control.
• Many industrial coating processes involve the
application of a thin film of functional material to a
substrate,such as paper, fabric,film foil, or
sheetstock.
• Coating may be applied as liquids,solids ,Gasses.
• Different types of industrial coating have different
chemical and physical properties Corrosion
resistance, performance when exposed to UV, etc.
But no coating provide all the protection a structure
needs.
• Industrial coatings appear everywhere. They protect
a diverse array of products from corrosion, wear and
tear and decay, as well as bringing an aesthetic and
colorful appearance to the coated surface or
product. With OEM applications ranging from:
• Building products.
• Outdoor structures and equipment.
• Sports and play equipment.
• Cars, boats and planes and related accessories.
• All other types of transportation equipment.
• Appliances and machinery.
• Construction and agricultural equipment.
• Safety and security equipment.
 • Well-chosen industrial coatings make manufactured
products last longer and look better. The variety of
possible coated surfaces is huge: All types of metals,
wood, plastics and composites, rubber, glass,
leather, and more. Almost any material used to
manufacture an OEM product is a candidate for a
protective industrial coating.
• Manufacturers usually apply industrial coatings
during the later stages of production. The finishing
process, using the formulated coating material,
protects and strengthens their valuable OEM
product.

• We have compiled a short list of some commonly

used types of higher performance polymers in OEM
industrial coatings. These polymers are available to
be formulated in modern, low solvent or waterborne
systems, as needed.
=>We describe some benefits each brings to
application.
Polyurethane Coatings:-
• Manufacturers use polyurethane coatings in a wide
array of environments, often as a protective final
 coat over other custom formulated industrial
primers. Polyurethanes resist abrasion, and can
enhance durability to withstand wear and tear and
abuse.
• These coatings maintain color and can have an
attractive, high-gloss finish, if desired. Aliphatic
polyurethane coatings have good UV and
environmental durability. Such coatings are a good
choice for outdoor applications.
• Aromatic polyurethane products resist degradation
in wet conditions or underwater, but they tend
toward fading when exposed to UV light. These
coatings can work well in interior environments.
• Two component polyurethanes do require
protection for workers when applied, as with many
other types of chemical processes.
• Most often, polyurethanes are chosen as the topcoat
of a total protective coating system.
• For example, polyurethane might be applied as a
topcoat above a zinc-rich primer and epoxy
intermediate coat on a highway bridge.
• Polyurethane Coatings used as a topcoat on the
concrete walls and floors of a nuclear power plant.
Advantages:-
• Abrasion resistant
• High gloss and color retention.
• Aliphatic polyurethanes perform well against
weathering and UV light.
• Aromatics perform well when submerged.
• Low VOC formulations available.
Disadvantages:-
• Contains isocyanate (-NCO) ,a harmful carcinogen.
• Skilled workers and protective equipment are
necessary for application
• Higher priced than epoxies.

Epoxy Coatings:-
• coatings normally consist of an amine curing
agent blended with an epoxy polymer. Think of the
doubletubes of epoxy glue you might use to secure a
strong adhesive bond of one material to another.
• Formulators can alter the mix ratios (and
ingredients) of epoxies to create a wide variety of
characteristics. This gives users a unique coating to
meet the demands of numerous environments.
 • Epoxy coatings bond well to many different
surfaces.
• Epoxies resist weathering and abrasion
extremely effectively.

COSTING:- (CLO-2)

=>Definition:-
• Casting manufacturing is a process in which liquefied
material, such as molten metal, is poured into the
cavity of a specially designed mold and allowed to
harden.
• solidification, the workpiece is removed from the
mold to undergo various finishing treatments or for
use as a final product.
• Casting methods are typically used to create
intricate solid and hollow shapes, and cast products
are found in a wide range of applications, including
automotive components, aerospace parts,etc.
=>There are many types of casting.
• Although casting is one of the oldest known
manufacturing techniques, modern advances in
casting technology have led to a broad array of
specialized casting methods.
1:-Sand Casting:-
• Sand casting typically relies on silica-based materials,
such as synthetic or naturally-bonded sand. Casting
sand generally consists of finely ground, spherical
grains that can be tightly packed together into a
smooth molding surface.
• Sand casting involves several steps, including
patternmaking, molding, melting and pouring, and
cleaning.
• The pattern is the form around which the sand is
packed, usually in two parts, the cope and the drag.
• After the sand is compacted enough to replicate the
pattern, the cope is removed and the pattern
extracted.
• Then, any additional inserts called core boxes are
installed and the cope is replaced.
 2.Investment Casting
Investment, or lost-wax, casting uses a disposable
wax pattern for each cast part. The wax is injected
directly into a mold, removed, then coated with
refractory material and a binding agent, usually in
several stages to build up a thick shell.
Multiple patterns are assembled onto common
sprues. Once the shells have hardened the patterns
are inverted and heated in ovens to remove the wax.
Molten metal is then poured into the remaining
shells where it hardens into the shape of the wax
patterns. The refractory shell is broken away to
reveal the completed casting. Investment casting is
often used to manufacture parts for the automotive,
power generation, and aerospace industries, such as
turbine blades. Some of the central advantages and
disadvantages of investment casting include:
• A high degree of accuracy and precise dimensional
results.
• The ability to create thin-walled parts with complex
geometries.
• The capacity for casting both ferrous and nonferrous
materials.
• Relatively high-quality surface finish and detail in
final components.

3.Plaster Casting:-
Plaster casting is similar to the sand casting process,
using a mixture of gypsum, strengthening
compound, and water in place of the sand. The
plaster pattern is typically coated with an
antiadhesive compound to prevent it from becoming
stuck against the mold, and the plaster is capable of
filling in any gaps around the mold. Once the plaster
material has been used to cast the part, it usually
cracks or forms defects, requiring it to be replaced
with fresh material. The advantages offered by
plaster casting include:

4.Die Casting (Metal Casting Process):-

Die casting is a method of molding materials under
high pressure and usually involves non-ferrous
metals and alloys, such as zinc, tin, copper, and
aluminum. The reusable mold is coated with a
lubricant to help regulate the die’s temperature and
to assist with component ejection. Molten metal is
 then injected into the die under high pressure, which
remains continuous until the workpiece solidifies.
This pressurized insertion is rapid, preventing any
segment of material from hardening before being
cast. After the process is completed, the component
is taken out of the die and any scrap material is
removed. A few of the major advantages provided
by die casting include.
• Close size and shape tolerances.
• High component dimensional consistency and
uniform design.

5.Permanent Mold Casting

Permanent mold casting shares similarities with die
casting and centrifugal casting, notably the use of
reusable molds.
These can be made of steel, graphite, etc. and are
generally used to cast materials such as lead, zinc,
aluminum and magnesium alloys, certain bronzes,
and cast iron.
• It is a low-pressure process with pouring usually
done by hand using multiple molds on a turntable.
As the molds rotate through the various stations
 they are successively coated, closed, filled, opened,
and emptied.
• One such method is known as slush casting, where
the mold is filled but emptied before the metal fully
hardens. Molten metal is dumped from the casting
to produce a hollow, cast shell.
• A similar idea is used in the molding of hollow
chocolate products such as Easter bunnies. The use
of metal molds induces faster heat transfer through
the mold, allowing the shell to harden while the core
remains liquid