iti 12 April 2025

ITI Foundryman Technician Trade Syllabus 

The ITI "Foundryman Technician" trade is a one-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This course equips trainees with skills in preparing molds, melting metals, casting components, and maintaining foundry equipment for producing metal parts used in industries like automotive, machinery, and construction. The syllabus integrates theoretical knowledge, practical foundry skills, and employability training to prepare students for roles such as foundry technicians, mold makers, or casting operators in foundries, manufacturing units, or as self-employed professionals.

Course Overview

  • Duration: 1 year (2 semesters, each 6 months)
  • NSQF Level: Level 4
  • Eligibility: Minimum 10th grade pass (or equivalent)
  • Objective: To train individuals in foundry techniques, mold preparation, and metal casting to produce high-quality metal components that meet industrial standards.

Detailed Syllabus Breakdown 

1. Trade Theory (Theoretical Knowledge)

Covers foundational concepts in foundry operations and metal casting.

  • Semester 1
    • Introduction to Foundry Technology
      • Overview of the foundry industry: scope, applications, opportunities.
      • Role of a foundryman technician: mold making, metal casting, quality control.
      • Types of foundries: ferrous (iron, steel), non-ferrous (aluminum, copper).
    • Materials and Properties
      • Metals and alloys: cast iron, steel, aluminum, bronze – properties, uses.
      • Sand types: silica, zircon, chromite – properties for molding.
      • Binders and additives: clay, resin, molasses – role in mold strength.
    • Tools and Equipment
      • Foundry tools: shovels, riddles, trowels, rammers, sprue cutters.
      • Equipment: furnaces (cupola, electric arc), ladles, molding machines.
      • Maintenance: cleaning, lubricating, and inspecting foundry equipment.
    • Mold and Core Making
      • Types of molds: green sand, dry sand, shell, investment casting.
      • Core making: core sand preparation, core baking, core setting.
      • Pattern making: types (solid, split), materials (wood, metal), allowances.
    • Melting and Pouring
      • Melting processes: cupola furnace, induction furnace operations.
      • Metal treatment: degassing, fluxing for quality casting.
      • Pouring techniques: ladle pouring, temperature control, safety measures.
    • Safety and Hygiene
      • Workplace safety: handling hot metals, furnaces, heavy tools.
      • Personal protective equipment (PPE): gloves, aprons, safety glasses.
      • Environmental safety: managing dust, fumes, waste disposal.
  • Semester 2
    • Advanced Casting Techniques
      • Special casting methods: die casting, centrifugal casting, continuous casting.
      • Casting defects: shrinkage, porosity, misrun – causes, remedies.
      • Quality control: inspection, testing (visual, ultrasonic, X-ray).
    • Furnace Operations
      • Furnace types: crucible, reverberatory, electric induction – working principles.
      • Charge calculation: determining metal, scrap, and flux quantities.
      • Energy efficiency: optimizing fuel, power usage in melting.
    • Finishing and Inspection
      • Fettling: removing runners, risers, and excess material.
      • Surface finishing: grinding, shot blasting, polishing castings.
      • Non-destructive testing: dye penetrant, magnetic particle testing.
    • Foundry Metallurgy
      • Alloying: effects of additives (carbon, silicon, nickel) on metal properties.
      • Heat treatment: annealing, quenching, tempering for castings.
      • Metal analysis: spectrometry, hardness testing for quality assurance.
    • Professional Skills
      • Entrepreneurship: starting a small foundry or casting workshop.
      • Team coordination: working with molders, melters, and inspectors.
      • Industry trends: demand for lightweight alloys, automation in foundries.

2. Trade Practical (Hands-On Skills)

Focuses on practical foundry operations and casting techniques.

  • Semester 1
    • Mold Preparation
      • Preparing green sand molds: mixing sand, clay, water for molding.
      • Making simple molds: single-piece, split patterns for castings.
      • Setting cores: aligning, securing cores in molds for hollow castings.
    • Pattern Handling
      • Using patterns: wooden, metal patterns for mold creation.
      • Applying allowances: shrinkage, draft, machining allowances.
      • Maintaining patterns: cleaning, repairing for reuse.
    • Melting and Pouring Practice
      • Operating furnaces: charging, igniting cupola or electric furnaces.
      • Melting metals: aluminum, cast iron in small-scale setups.
      • Pouring molten metal: using ladles into prepared molds safely.
    • Sand Testing
      • Testing sand properties: moisture content, permeability, strength.
      • Mixing sand: preparing molding sand with binders, additives.
      • Recycling sand: cleaning, reusing foundry sand for molds.
    • Safety Drills
      • Using PPE: wearing heat-resistant gloves, aprons, face shields.
      • Practicing emergency protocols: handling spills, furnace malfunctions.
      • Maintaining hygiene: cleaning work areas, managing dust.
    • Project Work
      • Casting a simple component (e.g., gear, bracket) using green sand mold.
      • Documenting mold preparation, melting, and pouring processes.
  • Semester 2
    • Advanced Mold Making
      • Preparing complex molds: multi-part molds, shell molds for precision.
      • Making cores: baking, assembling cores for intricate castings.
      • Using special sands: resin-bonded, sodium silicate for high-strength molds.
    • Casting Operations
      • Casting complex shapes: components with undercuts, thin sections.
      • Performing special casting: investment casting, die casting simulations.
      • Correcting defects: repairing minor casting flaws during fettling.
    • Finishing and Inspection
      • Fettling castings: cutting runners, grinding rough surfaces.
      • Inspecting castings: checking dimensions, surface quality visually.
      • Testing castings: performing dye penetrant tests for cracks.
    • Furnace Management
      • Operating advanced furnaces: induction, crucible for non-ferrous metals.
      • Calculating charges: determining metal, flux ratios for melting.
      • Monitoring furnaces: controlling temperature, ensuring safety.
    • Quality Control
      • Measuring castings: using calipers, gauges for dimensional accuracy.
      • Identifying defects: analyzing shrinkage, gas holes in castings.
      • Preparing reports: documenting casting quality, process improvements.
    • Project Work
      • Producing a complex casting (e.g., pump housing, automotive part).
      • Presenting a portfolio with mold designs, casting outcomes, and quality checks.

3. Workshop Calculation and Science

Provides mathematical and scientific support for foundry tasks.

  • Semester 1
    • Arithmetic: calculating sand quantities, metal weights, mold volumes.
    • Measurements: estimating pattern dimensions, shrinkage allowances.
    • Science: properties of metals, thermal expansion, sand bonding.
  • Semester 2
    • Calculations: determining furnace charges, casting costs, yield percentages.
    • Geometry: designing mold cavities, calculating gating system dimensions.
    • Science: metallurgy basics, heat transfer, solidification processes.

4. Engineering Drawing

Focuses on technical drawing for foundry patterns and molds.

  • Semester 1: Sketching patterns, mold layouts, gating systems.
  • Semester 2: Preparing detailed drawings for complex castings, core assemblies.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1
    • Communication skills: coordinating with foundry teams, reporting issues.
    • Time management: completing mold preparation, casting on schedule.
    • Basic IT skills: recording production data, quality reports.
  • Semester 2
    • Entrepreneurship: planning a small-scale foundry business.
    • Teamwork: collaborating with melters, inspectors, and supervisors.
    • Problem-solving: addressing casting defects, equipment issues.

Assessment and Certification

  • Examinations: Conducted semester-wise with theoretical and practical components.
  • Certification: Successful candidates receive the National Trade Certificate (NTC) from NCVT, recognized nationally and internationally.
  • Evaluation: Based on foundry skills, casting quality, theoretical knowledge, and project work.

Career Opportunities

  • Employment: Foundry technician, mold maker, casting operator in foundries, automotive, or machinery manufacturing units.
  • Self-Employment: Starting a small casting workshop or mold-making service.
  • Further Studies: Diploma in Foundry Technology, Metallurgy, or Mechanical Engineering.

Note

  • This syllabus aligns with the latest NCVT guidelines and may vary slightly based on institutional or state-specific requirements.
  • For the most current version, refer to the Directorate General of Training (DGT) or consult your local ITI.

Trade Type

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