Mahi Sahoo Books

About Dr. Mahi Sahoo and Suraja Consulting


We specialize in process development and optimization (especially in non-ferrous alloys) and casting defect analysis to solve your casting problems and produce premium quality castings. With over 35 years of research and development experience in casting technology, Dr. Mahi Sahoo and Suraja Consulting focus on improving your productivity and your competitive advantage in a challenging market environment. To implement these solutions, we advise on business development plans, budgeting, project management, revenue generation and management of people so your next project exceeds expectations and stands out among the competition.

Books by Dr. Mahi Sahoo

Principles of Metal Casting 

Third Edition Hardcover – Jun 4 2014

Available at
Published by McGraw-Hill, 2014. This 795-pages book with 14 chapters will meet the expectations of undergraduate and graduate students, research scientists, and those in the metal casting industry. The book contains the latest information on casting and solidification technology involving ferrous (steel and cast iron) and non-ferrous (copper, aluminum, magnesium and zinc) metals and alloys, casting processes, solidification characteristics, casting process simulation, gating and risering design, and quality evaluation (non-destructive testing).
Book description: Written by prominent industry experts, Principles of Metal Casting, Third Edition, addresses the latest advances in the field such as melting, casting processes, sand systems, alloy development, heat treatment, and processing technologies. New chapters cover solidificationmodeling, casting defects, and zinc and zinc alloys. Detailed photographs, illustrations, tables, and equations are included throughout. Ideal for students and researchers in metallurgy and foundry science as well as foundry industry professionals, this authoritative guide provides all of the information needed to produce premium-quality castings.

Comprehensive coverage includes:

  • Patterns
  • Casting processes
  • Solidification of metals and alloys
  • Gating and risering of castings
  • Casting process simulation
  • Aluminum and aluminum alloys
  • Copper and copper alloys
  • Magnesium and magnesium alloys
  • Zinc and zinc alloys
  • Cast irons
  • Steel castings
  • Cleaning and inspection
  • Casting defects

Casting Copper-Base Alloys

Hardcover – June 1984

By M. Sahoo, S. Sahu, L. V. Whiting and K. Sadayappan (Technical Editors)

Available at

Published by the American Foundry Society, 2016, 341 pages. The book addresses cutting edge technology required to stay competitive in today’s market. Established practices and new concepts on classification of copper-base alloys, casting processes and materials, melting equipment, melt control, solidification characteristics, properties and applications of commercial alloys, gating and risering design, quality control and health and safety aspects, and lead-free plumbing alloys have been addressed in this book.

Technology for Magnesium Castings: Design, Products & Applications

Paperback – 2011

Available at
Published by the American Foundry Society, 2011, 314 pages. Magnesium is a structural material with low density and very high strength to weight ratio. As a result, it will reduce vehicle weight and in turn reduce greenhouse gas emissions and increase fuel economy. Valuable information is provided on alloys and their physical metallurgy and solidification behavior, melt control, process control, heat treatment, materials selection and various casting processes. The book is of interest to those in the metal casting industry, especially design and process engineers, and students of metallurgy, materials science, and metal casting.
Book description: The publication of this book is very timely in view of the important role magnesium contributes to the transportation industry and other industrial applications using the latest casting and processing technologies. Being a structural material with low density and a very high strength-to-weight ratio, magnesium can reduce vehicle weight and in turn reduce greenhouse gas emissions and increase fuel economy. In Technology for Magnesium Castings, valuable information is provided on melt control, process control, casting and solidification, heat treatment, materials selection and various casting processes such as sand, permanent mold, high pressure die, lost foam, ablation ad semi-solid casting. This publication will be of great interest to many individuals involved in the metal-casting industry, especially the casting designer and process engineer. It will also be an invaluable tool for students of metallurgy, materials science and metal-casting. The 18 chapter authors are world-class scientists, professors and engineers with countless years of industrial and laboratory experience. The knowledge gained from their work, research and teaching has been incorporated to provide only the latest information to the reader. Each chapter was reviewed by qualified metallurgists/materials engineers from the metal-casting industry, academia and research laboratories to ensure that only the highest quality information was accepted for publication.