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Fundamentals of Manufacturing Materials, Processes & Systems

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This course provides an introduction to the manufacturing processes that are used in industry to manufacture products that are widely used in daily life. Introduction to Manufacturing: Types of manufacturing industries, materials used in manufacturing and properties of materials, different processing operation. Sand Casting:Introduction: Sand casting, molding, heating, pouring, solidification, and cooling.

Pattern: making, material, types, construction, pattern allowances. Core: making, types, sand conditioning, testing of the sand, molding process, tools and equipment, molding machines, different types of casting, cleaning and finishing of castings, an inspection of castings. Permanent Mold Casting (PMC): Introduction, types of PMC, gravity die casting, and its types.

Pressure die casting, Centrifugal casting, and their types. Furnaces used in PMC. Metal Forming:Fundamentals, Types, hot, warm, and cold working.

Bulk Deformation Processes:Rolling; rolled products, rolling types: flat, shape, thread, gear, ring rolling, and rolling mill configurations. Forging; open die, impression die, press, upset, roll, net shape, isothermal forging and swaging. Extrusion; solid & hollow shapes, direct & indirect, hot & cold, continuous & discrete, impact extrusion, hydrostatic.

Drawing; bar, wire, tube drawing and its types tike tube sinking, fixed mandrel, floating plug. Other metal forming processes; roll extrusion, riveting, staking, peening, coining, hubbing, burnishing. Sheet metal forming processes: Shearing operations: slitting, blanking, piercing, cutoff, parting, dinking, slotting, perforating, notching, semi-notching, lancing, nibbling, trimming, shaving, fine blanking.

Bending operations: V bending, edge bending, flanging, curling, hemming, seaming. Drawing operations like deep and shallow drawing, embossing. Welding Processes: Classification, Fusion welding and its types such as oxyfuel gas welding and oxygen torch cutting, arc welding (shielded metal, flux-cored, gas metal, submerged, gas tungsten, plasma, stud welding, Arc cutting), resistance welding (spot, seam and projection.

Heating, pressure, current control and power supply for resistance welding). Solid-state welding and its types include diffusion welding, friction welding, and ultrasonic welding. Other welding processes: Forge, Roll, Friction, Explosion, Thermic, Electron beam, Laser welding and cutting, Brazing and Soldering.

Fabrication of Plastics: Casting, Blow molding and its types, Compression molding, Transfer molding, Cold molding, Injection molding: Injection molding machine, mold design, and construction, types of mold, cooling and ejection of mold, Reaction injection molding, Welding of plastics. In the end, there are videos that are videos related to the course for better understanding. Course OutlineIntroduction to Manufacturing: Lecture 1Introduction to Manufacturing ProcessesWhat is manufacturingManufacturing IndustriesManufacturing ProductsProduction Quantity and Product varietyMaterials in ManufacturingManufacturing Processes (Processing operations and Assembly operations)Sand Casting:Lecture 2Overview of casting technologiesDifference between casting and moldingAdvantages and Disadvantages of casting processesCasting Processes (Expendable mold casting and permanent mold casting)Lecture 3Sand casting and Engineering analysis of sand casting y sandPouring and Engineering Analysis of PouringFlow rate and time required to fill the moldFluiditySolidification and CoolingLecture 4Solidification of pure metals and alloys (Alloys and Eutectic Alloys)Solidification time and ShrinkageDirectional SolidificationLecture 5Riser Design with Exercise Problems.

Lecture 6Pattern for castingMaterials used for patternTypes of patternMold making and Classification of sand moldsWhat is foundry sand? Lecture 7Buoyancy ForceMetal casting processesShell moldingAdvantages and Disadvantages of Shell moldingVacuum moldingAdvantages and Disadvantages of Vacuum moldingExpanded Polystyrene CastingAdvantages and Disadvantages of Expanded Polystyrene CastingInvestment castingPlaster and Ceramic Mold castingPermanent Mold Casting (PMC): Lecture 8Types of pattern allowance (Shrinkage and contraction allowance, Draft allowance, Machining allowance, and Distortion allowance)Permanent mold casting and its Applications. Slush castingLow-pressure castingVacuum permanent mold castingDie casting (Hot and cold chamber die casting)Advantages and LimitationsCentrifugal casting and Semi centrifugal castingLecture 9FurnacesCupolas FurnaceDirect Fuel Fired FurnaceCrucible FurnaceElectric Arc FurnaceInduction FurnaceMetal Forming:Lecture 10Fundamentals of metal formingTypes of deformation processes of metalBulk deformation (Rolling, Forging, Extrusion, Wire Drawing)Sheet metal workingStress-Strain CurveDerivation of the relation between stress and strainFlow stress and Average flow stressThe temperature in metal forming (Cold working and Hot-working)RecrystallizationIso thermal forming (recovery and Grain growth)Strain rate SensitivityLecture 11Introduction of rollingShapes used for rollingTypes of rollingWorking of the rolling processAnalysis of the rollingRolling millsNo-Slip Point for rollingFlatness control and rolling defectLecture 12Numerical Problems related to the rolling processLecture 13Introduction to forgingClassification of forgingTypes of forgingAnalysis of the forgingBarreling effect in forgingOpen Die forging and its practicesImpression Die forging and its practicesAdvantages and Limitations of Impression Die forgingFleshless forgingForging Press and Forging HammersLecture 14Numerical Problems related to the forging processLecture 15Introduction to the extrusion processClassification of extrusionDirect and Indirect extrusionHot and Cold extrusionDirect and Continuous extrusionAnalysis of the extrusion processEffect of friction on extrusionExtrusion Dies and OrificeExtrusion press and other extrusion processesLecture 16Numerical Problems related to the extrusion processIntroduction to DrawingDifference between drawing and wire drawingBar DrawingWire DrawingFeatures of Draw DiePreparation of the workAnalysis of the drawing processSheet metal forming processes: Lecture 17Introduction to sheet metal cutting processCharacteristics of EdgesTypes of sheet metal cuttingShearingBlanking and PunchingClearance in Sheet metal cuttingAnalysis of sheet metal cutting processesNumerical Problems related to the sheet metal cutting processLecture 18Introduction of sheet metal bending processTypes of sheet metal bendingAnalysis of the sheet metal bending processNumerical Problems related to the sheet metal bending processSpring BackLecture 19Introduction to the drawing processMechanics of drawingStages of deformationAnalysis of the drawing processTests of Drawing FeasibilityBlank force and blank size determinationNumerical Problems related to the drawing processLecture 20Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)Defects in DrawingThe operation performed with metal toolingIroningCoining & EmbossingLancing & TwistingThe operation performed with flexible Rubber toolingGuerin and Hydro forming processLecture 21Numerical Problems related to the other drawing processesWelding Processes:Lecture 22Fundamentals of weldingDifference between joining and weldingAdvantages and Disadvantages of WeldingHistory of weldingTypes of the welding processComponents used for welding process (Filler material, Flux, and Electrolyte)Consumable and Non-consumable electrolyteWelding positionsWelding Electrode NomenclatureType of Weld Joints (Butt joint, Corner Joint, Lap joint, Tee Joint, Edge Joint)Types of Weld (Filler Weld, Groove Weld, Plug weld or slot weld, Spot and Seam weld, Flange and Surface Weld)Features of Fusion Welded JointsPhysics of welding (Power Density and Numerical of Power Density)Heat Balance in Fusion WeldingWelding as Commercial OperationAutomation in Welding (Machine, Automatic and Robotic)Welding SafetyLecture 23Welding Categories (Fusion Welding, Solid State Welding, Soldering and Brazing)Arc WeldingArc ShieldingThe power source in Arc weldingTypes of Arc Welding (Shielding metal arc welding, Gas Metal Arc Welding, Flux Cored Arc Welding, Submerged Arc Welding,Gas Tungsten weldingPlasma arc weldingLecture 24Oxyfuel arc weldingOxyacetylene weldingResistance weldingSpot WeldingResistance seam weldingResistance projection weldingEnergy beam welding (Electron beam welding, Laser beam welding)Numerical Problems related to the welding processesLecture 25Numerical Problems Related to the welding processesLecture 26Solid-state weldingTypes of solid-state welding(Diffusion welding, Friction welding, and Ultrasonic welding)Welding Defects of Solid State WeldingBrazing and SolderingFabrication of Plastics:Lecture 27PlasticsType of PlasticsProperties of polymer melt (Viscosity and Viscoelasticity)Extrusion process for Plastics in detailExtruder ScrewFeed SectionCompression SectionMetering SectionProcess ParametersSolid and Hollow ProfilesWire and Tube coatingDefects in the extrusion processLecture 28Injection molding for Plastics in detailClampingInjectionCoolingEjectionApplication and MaterialAdvantages and DisadvantagesLecture 29Blow MoldingExtrusion Blow MoldingInjection Blow MoldingStretched Blow MoldingCompression MoldingTransfer Molding (A pot transfer molding and B plunger-type transfer molding)OZIS Academy is the best platform for struggling students and professionals who want to improve their skills for the workfield as it provides a large no of quality and detailed courses.

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Getting ready for the journeyman electrician exam can feel stressful. The test covers a lot: electrical theory, NEC code rules, wiring methods, equipment, special locations, and job site safety. Reading the code book alone is not enough. You also need to practice answering real exam-style questions under time pressure.This course gives you that practice. It is built as a complete set of journeyman electrician practice tests and mock exams, so you can find your weak spots, fix them, and walk into the test room with confidence.Every question is written to match the style and difficulty of the real licensing exam. You will see calculation problems, code lookup questions, and situation-based questions like the ones you will face on test day. After each question, you get a clear explanation that shows why the right answer is right and why the other choices are wrong. You do not just memorize answers. You learn how to think through them.The questions are grouped into six key areas: electrical theory and testing, general code requirements and plan reading, wiring methods and protection, equipment for general use, special occupancies and special equipment, and electrical safety and professional practice. Together, they cover the topics most often seen on journeyman electrician certification exams.Many people fail the electrician exam for the same reasons. They run out of time. They do not know where to find rules in the NEC. They make small math mistakes on voltage drop or conductor sizing. This course helps you fix all three. You will practice with timed mock exams, learn faster ways to move through the code book, and get plenty of repetition on the math problems that trip people up.The course is updated for 2026 exam preparation. Rules and exam content change over time, so be sure to check which NEC edition your state or local area uses. The practice questions help you build strong habits that work no matter which edition you are tested on.This is a good fit if you are an apprentice finishing your hours, an electrician who has been working in the field and needs to prepare for the test, or someone who failed the exam once and wants a better plan. You can study at your own pace, repeat the tests as many times as you like, and track your progress as your scores go up.By the end, you will know the exam topics better, answer faster, and feel ready to earn your journeyman license. If you want solid exam preparation with real test questions and clear answers, this course is built for you.What You’ll LearnSolve Ohm’s Law and Watt’s Law problems quickly and correctlyTell the difference between AC and DC circuits, and understand impedance and power factorWork through three-phase power and voltage drop calculationsChoose the right test method and troubleshoot electrical problemsFind rules in the NEC faster and understand the code languageRead blueprints, riser diagrams, and panel schedulesSize conductors, apply ampacity and derating, and figure out box fillPick the right wiring method, raceway, or cable, and know support spacing rulesUnderstand overcurrent protection and equipment rules for panels, motors, lighting, and HVACHandle questions on hazardous locations, health care facilities, solar PV, and emergency systemsApply lockout/tagout, arc flash boundaries, and PPE rulesManage your time and stay calm during the real examCourse FeaturesFull-length practice exams that feel like the real licensing testRealistic exam questions on theory, code, calculations, and safetyDetailed explanations for every answer, right or wrongUpdated for 2026 exam preparationSelf-paced learning, so you can study any time, on any deviceRetake the tests as often as you want to build confidenceQuestions sorted by topic so you can focus on your weak areasBuilt for journeyman electrician certification prepCourse StructureElectrical Theory, Principles and TestingThis section covers the math and science behind electrical work. You will practice Ohm’s Law and Watt’s Law, AC and DC circuits, impedance, power factor, three-phase power, and voltage drop. It also includes questions on testing methods and troubleshooting, so you can find faults the way the exam expects.General Code Requirements and Plan InterpretationHere you build your NEC skills. You will practice questions on the purpose and language of the code, the authority having jurisdiction, working space and clearances, key definitions, and enclosures. You will also work on reading blueprints, riser diagrams, and panel schedules.Wiring Methods, Materials and ProtectionThis is one of the biggest parts of the exam. You will practice conductor sizing and ampacity, derating, and box fill. You will also work on choosing raceways and cables, picking the right wiring method, following support interval rules, and applying overcurrent protection.Equipment for General UseThis section covers the everyday equipment electricians install. Topics include switches, receptacles, switchboards, panelboards, luminaires, appliances, space heating, motors, and air-conditioning equipment.Special Occupancies, Special Equipment and ConditionsThese questions test your knowledge of harder code areas. You will work on hazardous locations, health care facilities, solar photovoltaic systems, fire pumps, emergency and standby systems, and energy storage.Basic Electrical Safety and Professional PracticesSafety matters on the exam and on the job. You will practice creating an electrically safe work condition, lockout and tagout, arc flash and shock boundaries, personal protective equipment, job site hazards, and good professional habits.Who This Course Is ForApprentice electricians getting ready for the journeyman examWorking electricians who want to test for their licenseAnyone who failed the exam before and wants to try again with a better planElectrical students finishing a trade school or training programHelpers and wiremen moving up to a licensed positionElectricians moving to a new state who need to pass a new licensing testAnyone who wants a quick review of NEC rules, theory, and safetyRequirementsBasic knowledge of electrical work or some time in an apprenticeshipA copy of the NEC code book (check which edition your exam uses)A simple calculator that is allowed on your examWillingness to practice and review your mistakesNo special software needed, just a phone, tablet, or computerWhy Take This CoursePassing the journeyman exam is a big step. It moves you from apprentice to licensed professional, and it can mean better pay, more trust on the job, and more choices for your future.Reading alone does not prepare you for how the test feels. Practice questions show you how the exam asks things, where you lose points, and how to manage your time. Each explanation fills a gap in your knowledge, so you improve with every test you take.This course saves you time. Instead of guessing what to study, you get questions organized by topic. You can see right away which areas need work and spend your study hours where they matter most.Exam Preparation StrategyPractice exams are one of the best ways to pass a licensing test. Here is how to use this course for the best results:Start with a timed practice test. Do it before you study much. This shows you where you stand.Review every answer. Read the explanations, even for questions you got right. Sometimes you guess correctly without knowing why.Study by topic. If you miss several voltage drop questions, spend a few days on that and then test again.Practice using your code book. Learn to flip to the right article fast. Tabs and highlights can help if your exam allows them.Retake the tests. Repeating the exams helps your memory and builds speed.Do a final timed mock exam. A few days before the real test, take a full practice exam in one sitting to build stamina.Students who follow this plan feel less nervous on test day because the questions already feel familiar.Career BenefitsA journeyman electrician license opens many doors. Licensed electricians can work on their own jobs, lead crews, and take on larger projects. Many employers will only hire or promote licensed people.Demand for electricians stays strong. Homes, factories, hospitals, and solar and energy storage projects all need skilled workers. Knowing the latest code rules makes you more valuable.A license also builds toward bigger goals. It is the step before the master electrician license, and from there you can start your own contracting business. Even if you stay a journeyman, you will often earn more, get steadier work, and have better job security.DisclaimerThis course is an independent study resource and is not affiliated with, endorsed by, or sponsored by any licensing board, testing company, or the National Fire Protection Association (NFPA). NEC is a registered trademark of NFPA. Practice questions are created for study purposes and do not guarantee a passing score on any official exam. Always check your local licensing board for the exam rules and code edition that apply to you.Rest assured, these aren't leaks. They are custom-developed practice questions, specifically engineered using advanced research tools to match the 2026 exam standards.

Characterization Techniques for Solid Materials

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Characterization Techniques for Solid Materials provides a comprehensive introduction to the fundamental principles, methodologies, and applications of modern techniques used to investigate and analyze solid materials. The course focuses on understanding material structure, composition, morphology, crystallinity, defects, and physical properties from the atomic scale to the macroscopic level.The course begins with the fundamentals of material characterization and its importance in materials science, solid-state physics, chemistry, engineering, nanotechnology, and related fields. It introduces major categories of characterization techniques, including structural characterization, microscopy, and spectroscopy.Structural characterization techniques such as X-Ray Diffraction (XRD), Neutron Diffraction, and Electron Diffraction are explored for determining crystal structures, phase composition, lattice parameters, crystallinity, atomic arrangements, crystal orientation, and structural defects.The microscopy section covers Optical Microscopy, Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), Atomic Force Microscopy (AFM), and Scanning Tunneling Microscopy (STM). These methods are used to examine surface morphology, grain structure, particle size, microstructure, defects, interfaces, and nanoscale or atomic-scale features.The course also introduces important spectroscopic techniques, including Energy Dispersive X-ray Spectroscopy (EDS/EDX), X-Ray Photoelectron Spectroscopy (XPS), Auger Electron Spectroscopy (AES), and Fourier Transform Infrared Spectroscopy (FTIR) for investigating elemental composition, chemical states, surface chemistry, and molecular bonding.For each technique, emphasis is placed on its basic principle, working mechanism, instrumentation, information obtained, advantages, limitations, and practical applications. The course also highlights how different characterization techniques complement one another to provide a comprehensive understanding of material properties and performance.This course is designed to establish a strong conceptual foundation for students, researchers, and professionals interested in the characterization and analysis of solid materials.

Electrical Properties of Solids

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Ever wondered why metals like copper conduct electricity effortlessly, while rubber completely blocks it? Or how some materials can generate electricity just by being pressed or heated? Welcome to Electrical Properties of Solids, a comprehensive course that explores the fascinating ways materials interact with electricity!In this course, you’ll dive deep into:Conductors, Insulators, and Semiconductors: Understand how different materials allow—or block—the flow of electricity and why semiconductors are the backbone of modern electronics.Dielectric Materials: Learn how insulators store electrical energy and play a crucial role in capacitors, transformers, and electronic devices.Piezoelectric Materials: Discover materials that generate electricity under mechanical stress and their applications in sensors, medical devices, and energy harvesting.Superconductors: Explore materials with zero electrical resistance at low temperatures, powering MRI machines, maglev trains, and futuristic energy systems.Thermoelectric Materials: See how heat can be converted into electricity, opening doors for waste heat recovery, solid-state cooling, and self-powered devices.Through clear explanations, real-world examples, and easy-to-understand visuals, this course will give you a solid foundation in the electrical properties of solids and their technological applications. Whether you’re a physics student, engineer, or tech enthusiast, this course will equip you with the knowledge to understand and innovate with advanced materials.By the end of the course, you’ll know how electricity flows through materials, why some materials are perfect for modern electronics, and how cutting-edge materials like superconductors and thermoelectrics are shaping the future of technology.Unlock the secrets of materials that power our world—enroll now and take your understanding of electricity in solids to the next level!

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Fundamentals of Manufacturing Materials, Processes & Systems

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