CITS Foundryman Trade Syllabus

Overview

The CITS Foundryman trade is a one-year program designed to train instructors to teach foundry techniques and casting processes in ITIs. Divided into two semesters, the course covers Trade Technology (theory and practical), Training Methodology, Engineering Drawing, Workshop Calculation & Science, and Soft Skills. It aligns with NSQF Level 5 standards, emphasizing advanced casting methods, quality control, and effective teaching methods. The syllabus adheres to the latest DGT guidelines for outcome-based learning.

Semester 1 Syllabus

Trade Technology - Theory

• Introduction to CITS and Foundryman Trade: Role of instructors, scope of the foundry industry, and trends (e.g., automation, eco-friendly casting).

• Safety and Standards:

  • Advanced foundry safety: Risk assessment, PPE usage, and handling molten metal.

  • Compliance with IS, ISO, and environmental standards for foundry operations.

  • Fire safety and emergency procedures in foundry environments.

• Foundry Materials:

  • Properties of metals and alloys: Ferrous (iron, steel) and non-ferrous (aluminum, copper).

  • Sands and binders: Types, properties, and testing.

• Molding and Core Making:

  • Advanced molding techniques: Green sand, dry sand, and shell molding.

  • Core making: Design, assembly, and core coating.

• Melting and Pouring:

  • Types of furnaces: Cupola, electric arc, and induction furnaces.

  • Melting processes and pouring techniques for defect-free casting.

• Pattern Making:

  • Advanced pattern design: Allowances, shrinkage, and draft angles.

  • Materials for patterns: Wood, metal, and plastic.

• Foundry Tools and Equipment:

  • Use and maintenance of ladles, crucibles, and molding machines.

  • Calibration of testing equipment (e.g., pyrometers, sand testers).

• Quality Control: Inspection of castings for defects (e.g., porosity, shrinkage) and compliance with standards.

Trade Technology - Practical

• Implement advanced safety protocols in the foundry workshop (e.g., PPE, ventilation).

• Prepare and test molding sands for strength and permeability.

• Create complex molds using green sand and shell molding techniques.

• Design and assemble cores for casting applications.

• Operate furnaces (e.g., induction, cupola) for melting metals.

• Perform pouring operations to produce defect-free castings.

• Construct patterns with accurate allowances and draft angles.

• Inspect castings for defects using visual and non-destructive testing methods.

• Document foundry processes and quality control findings.

Training Methodology

• Instructor Role: Lesson planning, teaching strategies, and student evaluation techniques.

• Communication Skills: Clear verbal and non-verbal communication for effective training.

• Classroom Management: Engaging diverse learners and ensuring discipline.

• Instructional Aids: Using projectors, digital tools, and e-learning platforms.

• Practical Training: Demonstrating foundry tasks, guiding practice, and providing feedback.

Semester 2 Syllabus

Trade Technology - Theory

• Advanced Casting Processes:

  • Investment casting, die casting, and centrifugal casting.

  • Continuous casting and vacuum casting techniques.

• Computer-Aided Foundry Technology:

  • Simulation software: Use of MAGMASoft or ProCAST for casting design.

  • CAD for pattern and mold design.

• Defect Analysis and Correction:

  • Common casting defects: Causes and remedies (e.g., blowholes, misruns).

  • Non-destructive testing (NDT): Radiography, ultrasonic, and magnetic particle testing.

• Foundry Automation:

  • Automated molding and pouring systems.

  • Robotics in foundry operations (e.g., mold handling, finishing).

• Sustainable Foundry Practices:

  • Energy-efficient melting and waste recycling.

  • Emission control and use of eco-friendly binders.

• Foundry Management:

  • Production planning, inventory control, and cost estimation.

  • Quality assurance and process optimization.

• Entrepreneurship:

  • Starting a foundry or casting business: Business plans, budgeting, and marketing.

  • Client acquisition and industry networking.

• Industry 4.0 in Foundry:

  • IoT for real-time monitoring of furnaces and molds.

  • AI-based defect prediction and process optimization.

• Legal and Ethical Issues: Environmental regulations, labor laws, and ethical foundry practices.

Trade Technology - Practical

• Produce castings using advanced techniques (e.g., investment casting, die casting).

• Simulate casting processes using software (e.g., MAGMASoft, if available).

• Analyze and correct casting defects in a lab setup.

• Perform NDT methods (e.g., ultrasonic, dye penetrant) on castings.

• Operate automated foundry equipment (e.g., molding machines, if available).

• Implement sustainable practices: Recycle sand and reduce emissions.

• Plan and execute a small-scale foundry production run.

• Develop a business plan for a foundry or casting service.

• Document compliance with environmental and safety regulations.

Training Methodology

• Advanced Teaching Techniques: Micro-teaching, flipped classrooms, and blended learning.

• Assessment and Evaluation: Designing tests, practical assessments, and grading systems.

• Digital Tools: Using Learning Management Systems (LMS), virtual labs, and e-learning modules.

• Mentoring: Supporting trainees in skill development and career planning.

• Project-Based Learning: Guiding trainees to complete foundry projects (e.g., casting production).

Additional Components

Workshop Calculation & Science

• Calculations: Metal volume, mold cavity sizing, and furnace efficiency.

• Science: Metallurgy, thermodynamics of melting, and sand properties.

Engineering Drawing

• Drawing Basics: Detailed casting and pattern drawings.

• Schematics: Mold designs, core assemblies, and furnace layouts.

Soft Skills & Employability Skills

• Communication: Client consultations, report writing, and technical presentations.

• Leadership: Managing foundry teams and production workflows.

• Time Management: Meeting production and project deadlines.

Assessment

• Internal Assessment: Continuous evaluation through assignments, practicals, and tests.

• Final Examination: Theory and practical exams conducted by NCVT at year-end.

• Project Work: Complete a foundry project (e.g., producing a casting component) and a teaching demonstration.