Professional Documents
Culture Documents
REPORT
SUBMITTED BY:
K N S PAVAN KUMAR
MM11B026
ACKNOWLEDGEMENT
It is with deep sense of gratitude I acknowledge this golden opportunity provided to
me by the management of MISHRA DHATU NIGAM LIMITED for the Industrial
Orientation program.
I would personally thank to SRI K. GURULINGAM, Dy. Gen. Manager, Training
and Development for having permitted me to undergo Industrial Training at MIDHANI.
I am very grateful to Prof. Dr. Kamaraj, our Head of the Metallurgical and Materials
engineering department, Indian Institute of technology, Madras, for allowing me to undergo
this training as a part of academic curriculum.
My sincere thanks also go to Prof. Dr. S. Ganesh Sundara Raman, for patiently
guiding in the crediting procedures of the internship to the curriculum in the Jul-Nov, 2014
semester.
I sincerely thank the staff of various departments of MIDHANI who tirelessly
answered all our queries and doubts, whose explanations and comments helped me to
complete this internship program successfully.
INDEX
TOPIC
PAGE NUMBERS
1. INTRODUCTION................................................................... 2
2. MELT-1....................................................................................6
3. MELT-21..................................................................................5
4. TITANIUM SHOP...................................................................21
5. FORGE SHOP..........................................................................25
6. HEAT TREATMENT SHOP...................................................29
7. MACHINE SHOP....................................................................34
8. HOT ROLLING MILLS..........................................................37
9. COLD ROLLING MILLS.......................................................42
10. INVESTMENT CASTING PLANT......................................48
11. POWDER METALLURGY...................................................51
12. BAR AND WIRE DRAWING...............................................56
13. TUBE SHOP...........................................................................60
14. UTILITIES..............................................................................65
15. QUALITY CONTROL LABORATORY...............................68
INTRODUCTION TO MIDHANI
MISHRA DHATU is Sanskrit equivalent of English word ALLOY. The company
is the brain child of some renowned metallurgists of the country and scientists of adjoining
Defense Metallurgical Research Laboratory (DMRL). Mishra Dhatu Nigam Limited
(MIDHANI) is one of the modern and integrated metallurgical plants for manufacturing a
wide range of special metals and alloys meet critical requirements of strategic industries such
as Space, Nuclear Power, Defence, Aeronautics, Automobile, Electrical,
Telecommunications, Petrochemicals and general engineering industries.
The high technology plant is a government of Indias enterprise under the Ministry of
Defense. It is a modem and integrated metallurgical plant of its kind for manufacturing a
wide range of special metals and alloys under one roof. MIDHANI was incorporated in
November 1973 with a view to achieve self-reliance in some strategic alloys needed by
critical sectors such as Defense, Aeronautics, Nuclear and Space. After a lengthy debate
about desirability and viability of such plant, go ahead for the project was given in
February 1976 and the plant was set up in collaboration with world leaders like Creusot-Lorie
and Pechiney-Ugine-Kuhlamann of France and Krupp-Kloeckner AG of Germany and was
commissioned progressively between 1980 and 1982.
Midhanis product range includes super alloys, titanium, molybdenum, special
purpose steels and other special alloys. It is a unique in concept and is probably the only plant
of its kind where integrated facilities are available for the manufacture of such a diverse
range of special metals and alloys in a wide variety of KANCHAN ARMOUR PLATE
PROJECT.
QUALITY CONTROL & LABORATORY forms, such as bars, sheets, strips, rods
and wires. A wide variety of products and testing equipment has been installed to test
numerous types of alloys produced to stringent specification of different customers.
Super alloys.
High technology special purpose steels.
Heat resistance alloys.
Powder metallurgy products.
Titanium and titanium alloys.
Soft magnetic alloys.
Control expansion alloys.
Super Alloys:
Super alloys are family of iron, nickel, cobalt base alloys used primarily for high
strength in long term exposure to working temperature of 500-1100oc, corrosive environment
4
are encountered. At Midhani, many of these alloys are melted under controlled conditions in
vacuum induction melting to produce metallurgical cleanness and low gas contents. Now find
extensive application in space, nuclear, chemical and petrochemical, power generation and
furnace industries.
Midhani manufactures:
Nickel based alloys
Iron based alloys
Cobalt based alloys
Resistance alloys:
These are basically nickel-chromium and nickel-chromium-iron alloys for heating
elements in electrical furnaces in various atmospheres. These alloys find usage in heaters,
dryers and other heating appliances.
Manufacturing Facilities:
Midhani has acquired the latest and most modern equipment for the manufacturing of these
alloys and converting them into various mill forms such as ingots, forges bars, hot rolled
sheets and bars, cold rolled sheets, strips and drawn bars.
Computerized Forging:
Midhani has a 1500 T capacity computer controlled press operating with two rail
bound manipulators for forging ingots to close tolerances.
Hot Rolling:
2-Hi 2 stand and 3-Hi strip mills, 3-Hi 3 stand bar mill and 7 stand wire rod mill
make up the hot rolling facilities along with the heat treatment, leveling and straightening of
sheets and strips.
Titanium facility:
Midhani has vacuum arc re-melting furnace for the production of titanium ingots up
to 6.5T for electrode preparation a 3000 T capacity compacting press and a plasma arc
welding unit is available. High vacuum furnace is available for annealing, and a vacuum arc
skull melting furnace for titanium castings is also available.
Melt shop-I
Introduction:
Melt shop is the main production unit of Midhani. Various types of super alloys,
stainless steels, soft magnetic alloys, are produced here. For the production of these alloys
electrically operated furnaces are installed in this shop. Especially electric furnaces are
located because they have so many technological advantages when compared to other steel
melting practices.
Depending upon certain factors like control of composition certain alloys will be
produced in electrical furnaces. Some are in air-conditioning furnaces a few are in vacuum
refining furnaces. There are some alloys that are produced by double melting techniques.
Ingots produced by any one of the above techniques are re-melted in vacuum are re-melting
furnace or in an electro slag refining furnace.
The shop has following major equipments in which the melts or refining of the
molten metal or alloys are carried out.
EQUIPMENTS:
MAJOR EQUPIMENTS:
1.
2.
3.
4.
AUXILLARY EQUIPMENTS:
1. Bottom pouring ladles.
2. Bottom type charging buckets.
3. Additive preheating oven.
4. Ladle pre-heaters.
5. Mold preheating oven.
6. Stopper rod preheating furnace.
7. Ingot molds.
8. Transfer trolleys.
9. Electrically operated cranes.
10. Simple cutting machine.
This is also includes one stage control laboratory in which the analysis of different
elements is carried out.
SHOP DESCRIPTION:
This shop has been divided into three bays:
8
1. AB Bay
2. BC Bay
3. CD Bay
AB Bay:
This bay is provided mainly for scrap. In this bay two cranes are present; each crane
has 5 tons capacity. The raw materials stored here are:
1. MS scrap
2. Limestone
3. Pure iron
4. Iron ore
5. Return scrap
6. Mixed skull
7. Scrap consolidation electrodes
8. D-phosphate
9. Graphite powder
10. Fluorspar.
BC Bay:
This bay is provided mainly for bricks, refractory work. The raw materials stored
here are:
1. Fluorspar
2. Chrome pellets
3. Graphite powder
4. Iron ore
5. Low carbon Ferro chrome
6. Aluminum powder
7. Ferronickel
8. Ferro molybdenum
9. Ferro vanadium
10. Ferro silicon
11. High carbon Ferro nickel
This bay has one crane of six ton capacity.
CD Bay:
This bay is purely production oriented. The equipments present are:
1.
2.
3.
4.
The Furnace body which consists of spout, door, hearth, walls, shell etc.
The refractory lined roof and lifting arrangement.
Gear furnace body movement.
Electrode and their holders.
Electrical equipment.
Cooling water system.
10
Furnace body:
Spout:
The spout is located diametrically opposite to the charging door. This spout is
welded to the shell so that it makes 10-12o with the horizontal and is lined with fire clay
bricks.
Door:
This is located directly opposite to the top hole and additives are made through the
door, and also used for slag removal. A hydraulic system serves for lowering and raising the
door; and is lined with fire clay bricks.
Furnace shell:
It contains the furnace lining and forms the melting space. The furnace shell rests on
the cradle. This when tilted 45o forward, tapping is done and tilted 15o backwards for slag.
Furnace roof:
This closes the melting space from the above. The arched roof with an aperture for
the electrodes rests on water cooled roofing. This ring rests on the shell rim. There are guide
studs which fit into the sockets ensuring that the roof will always be lowered into position
properly.
Electrodes:
There are three electrodes of graphite and are of 200 mm and the method of
electrode control is by electro-hydraulic automatic electric regulator with provision for
manual control. The electrode speed of rising is 60 mm/ second and for lowering is 40
mm/second.
Electric equipment:
The electric energy is taken from a high voltage network through a circuit breaker
and resulting transformer. The reactor coil is ahead of a transformer on the primary side and
serves to reduce the current during starting.
Cooling system:
11
Roof rims, door, spout arches, electrodes clamps, current conducting clamps and cooling
rings constitute the cooling water circuit. Water is fed to the furnace through a rubber hose.
Hoses are employed on the furnace itself where components under voltage must be
electrically circuited. The return water is collected in an open funnel permitting visual
inspections.
Virgin process:
The charge required is M-S scrap, alloying elements which are added in the form of
Ferro alloys or pure metals:
(a) CHARGING:
Charging is done from the top with the buckets. Charging is done in two stages:
1. Initial stage.
2. Final stage.
If the charging is low in carbon, graphite is added.
(b) TAPPING:
12
After attaining the tapping temperature electrodes are raised to clear the bath. After
the power is put down, the tap hole is opened and the furnace is tilted so that molted metal is
drained into the ladle. The second process is return scrap process.
Technical data:
Capacity
5.5 tons.
Shell
Roof
Furnace lining:
Furnace reactor:
Rating
Primary voltage
11 KVA.
Secondary voltage
85-215 V.
Cooling
Efficiency
Furnace reactor:
Rating
750 KVA.
No. of steps
3 fixed 6 variables.
Power consumption
520 KWH/ton.
400 mm.
Wall thickness
275 mm.
Method of charging
Top.
Water consumption
2liters/second.
32oc.
63oc maximum.
Mechanism for:
13
Roof lifting
oil hydraulic.
Furnace tilting
Electrode movement
water emulsion.
Electrode clamping
water emulsion.
Door operation
water emulsion.
Roof ring
water cooled.
Electrode control
40o.
20o.
15o.
Backward
20o
: 60 mm/second.
5.5 to 6 tons
Refining capacity
5 tons
Furnace lining
Current rating
500 A at 2.4 KV
Vacuum range
Tilting mechanism
hydraulic.
Backward tilt :
105o.
20o.
14 feet.
5 ton ladle.
The vacuum induction refining furnace is designed for two fold operation
1. The furnace can be hot charged with molten metal from an arc furnace
ladle. In this mode the unit has ability to maintain heat, add heat, melt and
provide stirring.
2. The furnace has capability of doing cold-charge melting without the use of
hot metal from the arc furnace.
Both the modes of operation provide for vacuum pouring into a preheated ladle or ingot mold
placed in the vacuum chamber prior to evacuation. Additional air fuming can be
accomplished by pouring through a brick lined launders.
The vacuum level used in this furnace is 100 microns to 500 microns. This is attained by
steam ejectors. Facilitates have been provided for argon bubbling and oxygen bubbling.
The chambers have refractory lining at the bottom and drive-away type lid operated
hydraulically at the top.
Charge:
The charge used for this furnace is the liquid metal from the electrode arc furnace. If
the process is refining as for melting cold charge is also done.
15
Steam injection unit used for evacuating refining unit also evacuates the mold
chamber. Special types of ladles are used for argon casting. Ladles are preheated before
tapping liquid metal for drying after refining.
Ladle capacity
2.5 tons
105o.
Mechanism
integrated hydraulic.
These furnaces work on the principle of electromagnetic effect. These are primary
melting furnaces with integrated hydraulic mechanism which uses two hydraulic cylinders.
Lining:
16
For walls high alumina refractory bricks, for bottom high alumina spiral ramming
mass (70% Al2O3 + 30% MgO) is used. A mild steel sheet is used for lining the crucible,
sintering is done to obtain the monolithic lining.
MELT SHOP II
The shop has been located in single bay, and this unit for secondary melting and
refining purpose. In this unit there are three furnaces are arranged such as vacuum induction
melting furnace, vacuum arc re-melting furnace and electro slag refining furnace. VIN is
primary melting furnace and it take cold charge as raw material, while the other furnaces are
secondary melting furnaces and take primary cast ingots as raw material. Ingots cast in melt
shop I are sent here for further refining in VAR and ESR the main products are super alloys.
To produce alloy with less amount of gases such as H2, O2 and N2.
To decrease the sulphur content by re-melting the Ingot.
To finely disperse the inclusions.
To ensure directional solidification.
Melting Capacity
Melting Power
250 kW
Frequency
150 Hz.
Vacuum Chamber
100m3.
Ultimate Vacuum UP TO
5 microns.
Vacuum Pumps
booster.
: 70% Al, 30 % Mg
Gases Levels
Melting Range
: 8 to 10 hours
Facilities
Principle:
The main principle involved in this furnace is when an high frequency alternating
current is passed through a copper coil, which acts as a primary coil and includes secondary
currents in the charge ( acts as secondary coil) contained crucible, the resistance of the metal
to flow of current generates heat, which melts the charge. The time required to melt is very
short as the heat produce from the charge only. The secondary current associates with it a
magnetic field, which provides a magnetic stirring action on the molten metal and mixes
metal uniformly.
Mechanical Boosters:
A rotary pump is an interlocking arrangement to create the vacuum by sucking the
air through the dust traps and create the initial vacuum.
There are about 5 pump sets with boosters, creating the vacuum in the whole
chamber including the Mold chamber. There are about 4 vapor boosters, the whole hydraulic
system is controlled by the hydraulic pumps.
Dust Trap:
Dust traps are used to interlocking arrangement to create the vacuum by sucking the
air through the dust traps and create the initial vacuum
Vapor Booster:
The vapor booster is mainly used to create high vacuum less than 1 micron and
functions hydraulically.
18
Description of Process:
Melting is carried out in neutral monolithic crucible in a vacuum chamber using
induction melting. Furnace coil is suitable to design and insulated to take of corona in
vacuum facilitates for charging, sampling, temperature measurement during melting or
available which facilitate these operation without breaking vacuum in, melt chamber.
Provision of Mold trolley is made for pouring in multiple molds.
Refining:
The important factor of the refining period is usually de-oxidation present in the
bath with the carbon. During this period, carbon and oxygen present in the bath gets reacted
and forming CO which is sucked off Because of the low pressure this reaction takes place
very fast and very low levels of carbon is achieved. Oxygen also gets reduced to min level
The reaction is
C+O
CO2
Degassing of hydrogen and nitrogen can be decreased via the gas face because the
solubility of these gases at constant temperature are directly proportional to their partial
pressure. The solubility of Hydrogen in atmospheric pressure is at 1600C. In Iron or Ni base
metals is in the range of 30ppm. During vacuum induction melting the hydrogen can be
removed to very low concentration.
There is no difficult in reducing the Nitrogen content to 20 ppm. When nitride
forming elements such as chromium, aluminum, vanadium, and titanium are present, the
activity of nitrogen is very low. Therefore removal of nitrogen under high vacuum is difficult
if low nitrogen contents are desired in alloys containing nitride forming elements rawmaterials should have low in nitrogen must be used.
Ni-Ca is added to remove sulphur up to some level by formation of CaS.
Misonsarc, USA
Furnace Capacity
5T
Ingot diameter
200-550 mm
Furnace design
co-axial
Ultimate vacuum
5 microns
15000 amps
Melting voltage
25 volts
by computer
by drip shot
4.5 kg/min
Principle:
The main principle in this furnace is when a high ampere low voltage direct
current is employed, for striking an arc between the consumable electrode and a pad of steel
placed in the bottom of the copper mold. The arc gap is automatically maintained.
Process:
Re-melting is carried out under fine vacuum (10-3mm level) with precise control
of melt rate by computer. It is a secondary steel melting furnace. In this process, a stud is
welded to the electrode, which is re-melted under vacuum in a water cooled crucible.
Electrode is re-melted water cooled copper crucible using arc melting principle. The metal is
progressively melted from the lower end of the electrode, forming an ingot in the mold. This
furnace is mainly used for entrapped gases and control of non-metallic inclusions from the
ingots. Melting operation is progressively carried out with constant melting rate/pool depth to
attain fine and uniform solidification structure, free from segregation in the ingot. Fine
vacuum results in low gas in volatile tramp elements. This essentially for mechanic properties
required for high performance alloys. Cleanliness of the metal is improved substantially.
Other advantages:
1.
2.
3.
4.
60%
Al2O3 :
20%
CaO
20%
Furnace details:
Manufactured
Capacity
Ingot dia
600mm
Temperature maintained
1215oc-1520oc
25000amps
Melting power
2MVA
Atmosphere control
Starting technique
solid/liquid
Slag system
Process:
Re-melting carried out under a reactive slag (flux). The preheated slag fed into the
mold and single or three phases AC or DC current is passed through the electrode and
resistance heating takes place. The heat is generated due to the electrical resistance of slag.
When the metal melts, since it is having higher density it tries to settle at the bottom and in
passing through the slag gets refined. The slag facilitates refinement in the chemical
composition and also removing sulphur and non-metallic inclusions. We can eliminate
sulphur content below 0.03% in primary melting. i.e., in EAF in order to reduce the sulphur
content up to 0.012% and to obtain a fine dispersion of the inclusion in the EAF ingots, these
21
ingots are re-melted in ESR. Melting is carried in water cooled crucible to attain sound
homogeneity, directionally solidification and segregation free ingots are obtained.
The slag ratios used for ESR refining are 3 types namely:
70:15:15, 60:20:20, 33:33:33, CaF2, CaO, and Al2O3.respectively.
Other advantages:
1. Refined metal can be obtained.
2. Good surface finish is obtained in VAR.
3. Homogeneity in production.
2.2T
Max.temperature
1600-1700oc
Electrodes
The hearth lined with magnetic bricks and the shell is rammed with graphite
powder.
capacity of the slag preheating oven is 300 kgs after this it is directly charged in the ESR
furnace.
TITANIUM SHOP
MIDHANI has established facilities for processing of Titanium and Titanium alloys
starting from Titanium sponge. Facilities for ingot melting and manufacture of mill products
including bars, sheets, wires and rods have been established in the plant. It has been
supplying different types of Titanium and Titanium alloys to numerous industries. The
prominent among them are aerospace, chemical and petro chemical etc. At Midhani,
Titanium alloys are classified as Alfa, Alfa-Beta and Beta alloys, according to the
predominant phases present.
Titanium is one of the lightest metals abundantly available. Its melting point is
1660oc. it undergoes allotropic transformation at 882.5oc. Titanium sponge is melted in
vacuum arc remelting furnace to produce ingots of size 4.0/6.5 T in weight. Primary
breakdown of ingots is carried out in a 1500 T computer controlled forge press. Subsequent
processing in different rolling mills yields a variety of mill products. The grades of
manufacture in this shop and selection of alloying addition in Midhani are given below.
TITANIUM
AND
MANUFACTURED:
TITANIUM
ALLOYS
GRADES
Visual inspection
Mixing
Compact pressing
Plasma arc welding
Dehumidification
Vacuum arc melting
Ingot turning
Titanium sponge
Master alloys viz., Al-V, Al-Mo-Ti etc.
Titanium scrap
Zirconium scrap
TiO2 powder
Virgin metallic granule i.e., cu, Al, Sn, Si.
VISUAL INSPECTION:
23
BEING
Visual inspection involves separation of any unwanted waste materials present in the
Ti sponge. The charge is passed through magnetic separator to remove Fe bearing particles.
After this inspection, it is sent to mixing.
MIXING:
The Ti sponge and the alloying elements are mixed in this mixer according to their
quantities and alloys percentage. After mixing the material, these are sent to compact
pressing.
COMPACT PRESSING:
The mixed material is compacted at a pressure of 3000 tons. The material is placed in
the die and ram is released to make compacts 620 x 170 mm2.
Furnace capacity
860 mm .
Max. Current
30000A
Melt voltage
20-35 V
Vacuum created
1x10-3.
Principle:
The welded compacts from plasma electrode welding are melted in VAR furnace to
produce sponge Ti and other alloys into uniform solid solution. The main principle in this
furnace is, Arc is generated using low voltage; high current between the consumable
24
electrode and a pad of Ti scrap is placed in the bottom of the copper Mold, droplet pass
through the hot plasma and collect in the metal pool.
Melting:
The vacuum are furnace for titanium ingot melting has two melting stations and can
produce ingots up to 860 mm diameter and 4.0/6.5 T in weight. To start the melting
operation, an electrode produced from conventional melting operation an electrode produced
from convectional air-method or vacuum-processed steel is suspended in the consumable
electrode vacuum melting furnace, the furnace is designed to ensure a coaxial
electromagnetically clean configuration of the entire circuit with in the furnace in order to
ensure interrupted melting operation and freedom from macro segregation. Due to high
vacuum in the furnace the oxygen, nitrogen, gets reduced resulting in very low content of
gases in the final product.
INGOT TURNING LATHE:
The ingots that are produced in VAR furnace are turning lathe to remove the outer
oxidized layer and to obtain better surface finish. After turning, ingots are subjected for
further processing like forge shop etc.
OTHER FURNACES IN TITANIUM SHOP ARE:
VACUUM ANNEALING FURNACE:
Annealing is done in this furnace to relieve internal stresses and also to soften the
material. It is manufactured by M/s Hendiecker Haff, WG. Its capacity is 400 kgs. Vacuum
is crated up to less than 1 annealing is done in vacuum for titanium because Ti is very
reactive and forms other compounds. Annealing temperature of Ti is 700oc.
VACUUM SKULL MELTING FURNACE:
It is similar to VAR furnace in principle and operation. But it is used to produce
castings for Titanium products. Its capacity is 130kgs. During process a skull is formed
adjacent to the furnace wall by this copper cooled crucible and is protected from melting. In
this furnace the crucible movable and it has high melting rate when compared to VAR. after
the melting temperature is attained, the crucible is turned to mold and the liquid metal is
poured in to the cavity after the solidification the required casting is obtained. All these
operations are done under vacuum, because titanium is very reactive when exposed to normal
atmosphere and reacts with oxygen and forms compounds.
VACUUM ARC FURNACE:
It is similar to VAR furnace in principle and operation. Its capacity is 250 kgs. But it
is limited to less capacity. It is used for making new products in Ti. One single compact can
be used as an electrode in this furnace.
CRUCIBLE CLEANER:
25
These are used for breaking large chips into small chips.
26
FORGE SHOP
Forging is a process of shaping the metal by application of pressure or
hammering the metal when it is in plastic state. The charge for forge shop is primary
ingots from various sections either as hot or cold metal ingots. These ingots are heated
in the furnaces up to required temperature and subjected to forging in hydraulic
pressure hammer press.
Forge shop has following equipments:
1. Hydraulic press
2. Manipulators for hydraulic Forge press
3. Hammers(Pneumatic) (I)750kg (II)1500kg
4. Mobile manipulator
5. Ingot Car
6. Turn table
7. Dies of various furnace
8. Fixed hearth furnace
9. Bogie hearth furnace
10. Auto grinding machines
11. Circular saw and saw sharpener
:
:
:
:
:
backward with the rotation of ingot. The combined capacity of the two manipulators
is about 12 rotations of ingot. The max diameter of the ingot that can be charged is
600.
HAMMER:
Manufactured by New Standards Engineering, Bombay. These are high
speed short stroke, clear space, Electro pneumatic power hammer of pull down
presses. There are two types of hammers having capacity of 1500 kg & 750 kg. The
maximum stroke of the hammer is 890mm and 85 strokes/min & 760mm and
100strokes/min respectively. These can reduce the cross section to below 140mm2,
which is not possible by hydraulic press. In this also it is required to arrange the dies
and then hammered to obtain the required cross sections/shape of the forging.
MOBILE MANIPULATOR:
A part from the two manipulators beside the hydraulic press, a mobile
manipulator is also present .This is having capacity of 2 tons and is used for assisting
the forging of ingot in hammer mill and charges the ingot or pressing.
INGOT CAR:
This is used for charging and discharging the ingot from furnaces. This is
also used to discharge hot ingots on the turntable and to remove the forged ingot from
the turntable. The capacity of this car is 6 tons.
TURNTABLE:
The capacity of the turntable is 8T .The turntable is placed in front of the
manipulator. The ingots from the furnace are brought near and positioned on the
turntable. The turntable moves to and fro motions for positioning the ingots in the
jaws of the manipulator on the turntable, so the ingot car take the forged product and
is discharged from the manipulator on the turntable, so the ingot car take the forged
product and charged in the furnace.
DIES:
These are most important and must for conducting a forging operation of the
ingot. These dies are set in the hydraulic press and hammer to obtain required shapes
of ingots. These dies are made up of nimonic (nickel based alloy)
1. Flat die
2. Swage die
3. V die
4. Spreading die
5. Upset die
REHEATING FURNACES:
28
The furnaces are used for heating the material before pressing or
hammering. In heating condition the material becomes softer and easy with low load.
The longer the section and the higher the C content. The lower is to be the rate if
heating. Alloy steels are particularly sensitive to sudden heating and that are to be pre
heated to 7500C before being exposed to higher temperatures. There are two types of
furnaces, gas fires and electrical. In gas fires furnaces the ratio of LPG and air is 1:30
i.e., 12 mm of water column. The forge shop having the following furnaces:
29
:
:
2 nos.
600030001300 mm, 140030001300
Capacity
Type
:
:
20T/chamber.
gas fired
mm
30
Following heat treatment process are done in this shop. They are:
ANNEALING:
Annealing means heating metal to a predetermined temperature, holding at
this temperature and finally cooling at very slow rate. It is done to relive internal
stresses, soften the metal and also refine grain size.
NORMALIZING:
Normalizing means heating steel to 40-500c above upper critical
temperature and holding it for proper time and then cooling in air to room
temperature. It is done mainly to uniform structure.
1. HARDENING:
Hardening means heating the metal to hardening temperature and holding at
this temperature for sufficient time followed by rapid cooling such as quenching in
water or oil. It is done to increase hardness
2. TEMPERING:
Heating hardened steel to below the lower critical temperature followed by
cooling in air is known as tempering. Removes the residual stresses and improves
ductility and toughness.
3. SOLUTION TREATMENT:
If the alloy is reheated to point to the solution treatment temperature then all
the excess will be dissolved and the structure will be homogeneous -solid solution.
The alloy is then cooled rapidly (quenched) to room temperature results in a super
saturated solution with excess trapped in solution. The quenching is usually carried
out in a cold water bath or by a water spray to minimize distortion.
4. AGEING:
The alloy which is quenched is a super saturated solid solution and in an
unstable state. The excess solute will tends to come out of solution. The excess solute,
which comes out precipitates at a rate depending upon temperature. At the low
temperature the diffusion rate is slow that no appreciable precipitation occurs. At the
low temperature the diffusion rate is slow that no appreciable precipitation occurs. At
31
high temperature such as about 250C hardening occurs quickly due to rapid
diffusion. These alloys in which precipitation takes place at room temperature are
known as natural-ageing alloys. The alloys, which require reheating to elevated
temperature, are called as artificial ageing alloys. The actual cause of age hardening is
due to the uniform distribution of finely dispersed particles with coherent stress fields.
Which increase hardness and strength of the alloy by precipitation of carbides.
i.
FURNACE :
a) Electrically heated furnaces
b) Gas fired furnace
ii.
MECHANICAL EQUIPMENT :
a) Roller straightener
b) Horizontal straightening press
iii.
COOLING EQUIPMENT :
a) Water quenching tanks
b) Oil quenching tanks
c) Pedestal fans
iv.
AUXILIARY EQUIPMENT :
a) Heat exchangers and agitation pumps
b) Hardness testing machine
c) Material handling equipment
v.
CUTTING EQUIPMENT :
a) Ecomix machine
b) Abrasive cut off machine
c) Cobra saw
FURNACES:
Electrical furnace:
There are 4 furnaces, which are electrically heated, of different sizes,
capacity.
Ludwig Furnace:
Furnace Details:
Maximum load capacity in tones
25T
Maximum temperature
975C
Size
+/- 5C
FeCrAl
Capacity
15T
HBB-3 Furnace:
Furnace Details:
1100C
+/- 5C
HBB stand for Hindustan Brown Boveri from Baroda. This is bogie hearth
furnace, the capacity of furnace is 15T and the maximum operating temperature is
1100C. Strip type heating elements are positioned on all six surfaces inside the
furnace thereby eliminating the recirculation fans. Single zone is divided into 4 zones
of individual control with temperature controllers and indicators. 4 duplex and 4
simplex thermocouples made of platinum & platinum rhodium is used as temperature
sensors.
HBB-4 Furnace:
Furnace details:
Size of the furnace
Capacity
10T
Refractory
.Face
.
800C
Maximum temperature
Pyromaster Furnace:
Furnace details:
Maximum Temperature
: 1000C
33
Capacity
: 2 Tons
Size
The maximum temperature attainable here are 950C and the capacity is 2 T.
Two fans are provided at the roof for circulation of hot air.
Capacity
25 tons
Max Temperature
1200C
Heating rate
Thermocouples
Fuel
Accuracy of temperature
+/-5C
MECHANICAL EQUIPMENT:
There are equipments chiefly employed for removing distortion,
straightening of the bars and rods etc after heat treatment.
Roller straighteners:
There are two roller straighteners. They are:
Roller Straighteners 1:
Capacity
Length
Speed
Capacity
6000 mm
Speed
Roller Straighteners 2:
34
The bars are passed in between the two-dial speed rollers of concave and
convex shapes. Which are driven by power in opposite direction at angle of 5-15 to
the axis of their mounting. Hydraulic and pneumatic arrangement is provided for
charging and discharging of bars in to inlet and outlet troughs of machine. The
distance between rolls can be adjusted depending upon the diameter of the bars.
: 75 to 250 mm diameter
Cooling Equipments:
Equipment Details:
Capacity of tank
: 40 KL
Oil used
Quenching Tanks:
Cooling is an important operation in heat treatment to attain the properties.
The shop is equipped with two water tanks for quenching. The capacity of tanks is
40KL. Oil used is servo quench 107 grade. The flash point is 175C. Servo 107 oil is
low sulphur base mineral oil, having excellent oxidation and thermal stability, high
fluidity and low volatility.
Auxiliary Equipment:
Heat exchangers and agitation pump:
These heat exchangers are employed for bringing down the oil temperature
when hot stock is quenched from high temperature.
Cutting Equipment:
These are used for to cut the samples from heat treatment products.
35
CAPACITY
HBB4
4
10 T
800
HBB3
4
25 T
1100
LUDWIG
3
25 T
PYROMASTER
1
2 T
WELMAN
3
25 T
975
950
1200
MACHINE SHOP
Various products from different sections and shops are sent to this shop to
obtain accurate sizes, dimensions, and surface finishing etc to according to customer
requirements. Various machines are available for cutting, grinding, and milling,
smoothening and drilling the products in order to get correct sizes. The various
machines are:
1. Portable grinding machine
2. Bar peeling machine
3. Behringer band saw
4. Ecomix
5. 3mts, 4mts Beco lathe machine
6. Heller cutting machine
7. Kirloskar milling machine
8. Radial drilling machine
9. Center less grinding machine
10. Horizontal milling machine
the power consume according to the size of the material thickness. Speed of the
machine is 90-100rpm.The coolant servo 68 is used as coolant oil. Maximum
diameter done on this machine is 100mm and minimum diameter is 20mm.
BEHRINGER:
This is a cutting machine. The blades used are of two varieties.
1.
2.
3.
4.
5.
ECOMIX:This is an electrical discharge cutting machine. The blade used is mild steel,
is
rotated near the ingot giving a gap of about 2-3mm. A positive charge is given
blade and negative charge is given to ingot. When the current passes through
produced between them and cutting of ingot takes place. During the process silicate is
used for improving of electrical conductivity of the job.
LATHE:
It is used for surface finishing of the material and the cutting tool is
titanium carbide and coated with tungsten carbide.
3mts lathe:
The maximum diameter can feed
: 900mm
: 2.7-2.8mts
4mts lathe:
The maximum diameter can feed
: 900mm
Beco lathe:
The maximum diameter can feed
37
: 400mm
: 2-7mts
38
The angles of the bits have facet of cutting 60 & 90.90 bits is used for
softer material and the 60 bits is used harder material.
CENTERLESS GRINDING:
The center-less grinding is a method of grinding exterior cylindrical,
tapered and formed surface on the work piece. Both wheels rotate in the same
direction and the work job is placed upon the work rest. Center-less grinding may be
done at 3 stages through feed, end feed and in feed the machine has a capacity to take
up to a maximum of 140mm thick and minimum of 10mm. The maximum and
minimum length of the job is 6mts and 3mts.
place. Hot worked components have poor surface finish and close tolerances and
dimensions cannot be maintained. The cost of rolling and handling is high but it is a
rapid process.
The main objective of rolling is to decrease the thickness of the materials.
Ordinarily little increase in width occurs so that the decrease in the thickness results in
an increase in length. The raw materials for HRM are forge billets and slabs. These
come from forge shops and processed to strips, sheets, bars and wires etc., on various
machines.
Hot rolling mill consists of the following bays:
1. Conditioning bay
2. Hot rolling bay
a) Heating furnaces
b) Roller hearth furnace
c) Fixed hearth furnace
d) Rolling of heated products
3. Dispatch bay
CONDITIONING BAY:
This bay consists of various machines, which are used to prepare the job for
rolling. The major equipments are
1. Band saw
2. Beco lathe
3. Swing frame grinding
4. Behringer and Ecomix
5. Shot blasting machine
BAND SAW:
This machine is supplied by the industrial tools to cut the job of maximum
diameter 650mm and if it square, 1000mm is maximum width. The coolant used is
servo 63.
40
BECO LATHE:
This machine mainly used for facing the ingot and face
turning. The maximum diameter is 1000mm and generally used is 600mm diameter.
The maximum utilized length is 5.5m.
41
HEATING FURNACES:
ROLLER HEARTH FURNACE:
The roller hearth furnace is supplied by DREVER, UK limited, which is
used for reheating and also annealing of sheets attached to be the quenching and aircooling space. It is continuous type reheating furnace and is divided into three zones.
1. PRE HEATING ZONE
2. HEATING ZONE
3. SOAKING ZONE
It is longitudinal type furnace having 52 rollers covered with asbestos slaves.
There are about 27 burners; gas used for firing is LPG.
42
ROLLING BAY:
The quickest method of shaping steel by passing the stock through pairs if
rolls. Most of the steel produce is consumed in the form of rolled products. The hot
ingot, bloom, or billet is passed through metal rolls, which revolve in opposite
direction at same peripheral speed. The revolution results in a longitudinal force
which draws the metal through the rolls and a vertical compression force which
reduces the size of the crystals. Some of the mills are:
1.
2.
3.
4.
Sheet mill
Finishing mill
Bar mill
Wire rod mill
STRIP MILL:
Strip mill is a 3 high single stand mill with entry and exit roller table driven
by motor raised and lowered. Top and bottom rolls are driven but middle moves due
to friction. It is a reversible mill; rolls are cooled during the process of rolling by
water sprays. A hot slab is passed between two bottom rolls. Due to load applied on
the material it starts reduction in thickness but there is no change in the width.
SHEET MILL:
Specifications:
Input size
Output size
It is a two stand and two high mills consist of two rolls driven by rotating
gears. It is not continuous reduction mills like strip mill. Once the material passed
between the two rolls, again it is taken to the other side for second pass. To increase
width the slab is rotated at 900 and passed between rolls, by this we can increase the
width and length of sheet. But there is continuous reduction in thickness from each
pass. It makes sheets of size 90mm to 9mm.
FINISHING MILL:
43
It is a two high, one stand mill. If we want further reduction in sheets after
roughing mill, we go for this finishing mill. There is a roller hearth furnace which
attached to the mill at one end to heat the roughed sheet. From this furnace it is passed
between the two rolls. Reduction in thickness depends on the number of passes done
and also on strength of the metal. It makes sheets of sizes from 10mm to 3- 4mm.
BAR MILL:
Specifications:
Type
Input material
: Square and round shaped billets and size 100 sq. and
110 to 1356mm diameters bars processed to 45 sq. and 30mm diameter respectively.
Speed
80 m/min
It is a three stand, three high mills. It consists of grooved rolls and rotated by
motor. The three high mills permits high speeds because two or more pieces of steel
can be rolled simultaneously, the distance between the rolls being maintained
constant. When the metal comes through the lower pair of rolls, a tilting table to the
upper pair of rolls mechanically raises it. A similar mechanism on the opposite side
lowers the steel from the upper rolls to the next smaller pass in the lower rolls and so
on
Output material
Speed
60 to 40 m/min.
Roller speed
900 rpm.
The 7 stand 3 high wire rod mills is used for producing rods by passing hot
material of square and round shaped through the grooves of the rolls by manually to
and fro in a single stand or more stands till the required diameter rods are obtained.
DISPATCH BAY:
In this bay the rolled product i.e. strip, rod, wires etc., are cut to required
length by the following machines.
1. Shearing machine
2. Leveling machine
3. Abrasive machine
44
SHEARING MACHINE:
It is for cutting purpose. In this sheets are cut to a required size.
LEVELING MACHINE:
This machine is used for leveling the rods and strips. The strips from the
rolling bay are not of uniform level. The bars and rods thus cut to a required length
are dispatched.
ROLLING MILLS:
This section consists of
1. 4-Hi mill.
45
2. 6- Hi mill.
3. 12- Hi mill.
4. 20- Hi mill.
4- HI MILL:
Specifications:
Capacity of loading
Mill speed
0/20/30 m/min
8mm
1.5mm
This mill is a single stand four high hydraulic cold mills with automatic
gauge control is arranged for the reversible and non-reversibility operation. The
reversible operation made is providing for rolling straight length and the nonreversible is provided for rolling coils. Flat strips and coils can be rolled on this mill;
the rolls are made up of forged high carbon, high chromium steel. This mill operates
on hydraulic system. Two rolls, which are in contact with the job, are working rolls
and the rolls which are back of the working rolls, are backup rolls.
6-HI MILL:
Specifications:
Incoming size
6.35mm
0.5mm
Width
600- 1100mm
Length
1200- 2000mm
Weight
90 kgs
Rolling speed
Load capacity
800T
8mm.
46
This mill is used for rolling sheets only. This mill consists of 2 working
rolls, 2 back up rolls and 2 intermediate rolls. This mill is high electro mechanically
operated reversible type sheet mill, which produces the sheets. To prevent distortion
of the smaller working rolls in both horizontal and vertical directions four backing
bearings are used.
12-HI MILL:
Specifications:
Initial strip thickness
3mm Max
0.05mm
Width of strip
80-250mm
Coiler tension
Rolling speed
0-75/150 m/min
In this mill there are two working rolls, 2 intermediate rolls and three backup
rolls. These are rotated up on the bearing arrangement and cooling is given for
bearing arrangements. The coolant used in this is SERVO quench 107 grade. This
mill has electro mechanical screw down mechanism with automatic gauge control
system and is arranged for reversible operation to prevent the distortion of smaller
working rolls in both horizontal and vertical direction.
20-HI MILL:
Specifications:
Initial strip thickness
0.3mm Max
0.005mm
Width of strip
50-130mm
Load capacity
12T
Rolling speed
0-30/60 m/min
6-8.5m
65 kgs
Weights used
47
In this there are two working rolls, 5 and 5 intermediate rolls and 4 and 4
backup rolls. It is designed for smallest work rolls couples with highest capacity
backing bearings to permit making heavy reductions at high speeds. Strip grinding has
the facility that the de-coiler and re-cooler rotate in two directions.
ANNEALING LINES:
The purpose annealing is during cold working process the material strain
hardened and internal stresses are developed, so by the annealing process the material
soften and it is useful for further cold working operations. Annealing is a process of
heating the metal to an elevated temperature soaking at the temperature for some time
and then slowly cooling to room temperature. The purpose of annealing is to relieve
internal stresses. After annealing process ductility also improves. There are two types
of annealing in CRM. They are
11500C
Number of zones
Number of burners
Thickness
1.5-5.0mm
Width
50-250mm
Temperature regulation
+/- 50C
Rated temperature
11500C
Vacuum
11500C
11500C
BELL FURNACE:
It is batch type furnace used for annealing of coils in H2 atmosphere. These are
heated electrically. The strips are arranged in the furnace. The top, which seems to be
like a bell is conveyor and that chamber, is filled with H2 instead of normal
atmospheric air. The hydrogen atmosphere gives the annealed product of a clean and
shining surface.
11500C
Number of zones
Thickness
0.1-1.50mm
48
Width
80-250mm
Capacity
Muffle
0.420mm
Furnace length
3.5m
Specifications:
1500C +/- 50C on max
Temperature maintained
temperature
Number of zones
Thickness
0.005-0.25mm
Width
130mm
Furnace length
850mm.
0.8-5.0mm
Width
80-250mm
Line speed
3-20 m/min
Coil tension
4000 kgs.
Welded strips are grinded in this machine to remove excess metal from the
butt weld and also it makes welded portion flat. After this strips can be used for cold
rolling in mills.
49
0.3-1.2mm
Width
30-250mm
Line speed
0.3 m/min
Number of rolls
17
30mm.
FLATNESS:
Coil set 10mm maximum over length of 1m by hanging sheet vertically.
CAMBER:
1.5mm over length of 1m providing starting material has edge wise
curvature 5mm.
SLITTING LINE:
It is used to slit the strip at specific width. There are slitting rolls are
arranged to this machine according to given width to cut the strip.
Accuracy of slitting
+/-0.125 on 4mm
+/-0.25 on 1mm
Cutter material
12mm Max
3mm Min
20x3mm Max
0.25mm
Rolling speed
15 m/min
50
PROCEDURAL
PROCESS:
STEPS
IN
THE INVESTMENT
CASTING
a. Filled wax
b. Unfilled wax
The filled wax are pure wax and are mixed with filler materials the
advantage of filler material is the wax cannot shrinkage. The unfilled wax is pure wax
but the wax is not mixed with filler material, gates are provided by this unfilled wax.
Small shallow vents cut in the pattern surface of the die provide adequate venting.
3. The wax patterns are produced by using wax injector machine.
A hydraulic wax injector machine of 12T capacity with a maximum
temperature of 2000 C is attained. The wax at a temperature of 66-700 C is injected in
to the die at a pressure of 10kg/cm2.
4. Wax pattern is removed from the mold and are inspected for dimensional
accuracy.
5. The wax patterns are assembled on a sprue.
6. Gates and spires are formed in the same manner as the wax pattern. Individual
wax pattern and gates thus produced may be welded together by assembling
on a sprue, to
a. Enable many small castings to be poured in one group for economy
51
15. After the solidification the castings are removed by breaking the mold.
16. The cast product is sand blasted to remove ceramic particles.
17. Castings are cut off and witness of the runners is ground off.
18. Heat treatment for castings is dined if required /sand blasted castings are
machine if required.
19. Final dimensional and visual inspection.
Testings are made for surface faults, gages are employed to check casting
dimensions, Radiography is done to determine internal soundness, to reveal cracks,
surface pits, surface porosity etc.
20. Material is dispatched.
Advantages:
1. Intricate shapes can be cast with excellent smoother surface and close
tolerance.
2. Irregular parts which cannot be machined or difficult to machine alloys may
be cast by investment casting process.
3. Section as thin as 0.75 mm may be cast.
Disadvantages:
1. This process is relatively slow.
2. Pattern is expendable; one wax pattern is required to make one investment
casting.
3. Production of wax pattern and then investment mold etc. make the process
relatively expensive as compared with other casting processes.
Applications:
1.
2.
3.
4.
53
POWDER METALLURGY
The art of producing metal powders and of utilizing metal powders for the
production of massive material and shaped objects is called powder metallurgy.
The metal powders used in Midhani are Mo powder of 99.9% purity,
tungsten and nickel Powder are imported. The tungsten products used in bulbs as
filaments and molybdenum wires, which are also used in bulbs but as supporting
elements for the filament. The main process consists of packing the required powder
in a required die and is compressed with a plunger on four sides of 600 tons hydraulic
press. The product obtained is very brittle so it is to be pre-sintered at 9500C for 1hr
then after sintering in H2 atmosphere, the bars obtained are of 48mm cross section,
then it is swaged to 18mm circular by passage through the die it is heated and graphite
coating is also given to the rod for easy passage through the die. The reduction of
diameter of wire is done in stage-by-stage operation until the required size is obtained.
2. Compacting press.
3. Pre-sintering furnace.
4. Sintering furnace.
5. Manual swaging.
6. Continuous swaging.
9. Wire Pickling.
SIEVING MACHINE:
The sieving machine is used for sieving the powders to in order to obtain
uniform and required size. The size of the powder required for compacting in
hydraulic press is below 200 meshes.
COMPACTING PRESS:
This machine is used to make compacts by applying pressure after the
sieving of the metal powders. The pressure applied for compaction is 600 tons. The
process consists of taking the powder in a required dies and leveled all over by
leveling scale. The die is placed below plunger and compressed for 45sec. various
size of compacts can be produced generally 500x48x48mm3 for molybdenum and
15x15x15mm3 for tungsten powder. The density that can be achieved by this
compacting is 50-60 %.
54
PRE-SINTERING FURNACE:
Heating element
Nichrome.
Temperature
10000C.
SINTERING FURNACE:
Heating element
Tungsten
Temperature
18000C
7. Keeping the outlet valve slightly open, pass H2 at 3.5-4m3/hrs and test for gas
leakage again.
8. After passing the furnace H2 gas for 6hrs @3.5-4m3/hrs leaping the outlet
valve slightly open, test the gas inside the furnace by collecting it in a small
tube and lighting. If there is no explosive sound, it indicates that there is no
more air left in the furnace and it is safe to switch on the furnace and light the
LPG pilot flame.
9. Pass H2 gas for 6hrs @ 3.5-4m3/hrs maintaining a positive pressure of H2
inside the furnace burn the H2 at the outlet.
10. Switch on the furnace and start heating.
11. Heat the furnace in the manual mode till 10000C is reached and then switch on
the auto mode till final temperature of 17900C is reached.
Heating schedule:
2000C
48hrs
4000C
24hrs
400-10000C
24hrs
1000-14000C
24hrs
14000C (maintain)
72hrs
12hrs
De-oxidation furnace:
In de-oxidation furnace the temperature that can be obtained is 18000C.
During sinter the size of compact is reduced. In this Mo compacts are generally
sintered.
Bell furnace:
In bell type of sintering furnace, tungsten compacts are sintered. The
maximum temperature that can be attained is 27000C. After arrangements of the
compacts, the furnace is closed by lowering the bell. All the atmospheric air that is in
the bell furnace is removed.
After creating vacuum H2 is sent at a rate of 6 cc
in to the furnace to maintain H2 atmosphere inside the furnace. In order to avoid the
oxidation of tungsten, after arrangement of the system, a current of 700 amp is
56
supplied. The temperature of sintering compacts is measured with the help of optical
pyrometer, which are arranged in the furnace. The minimum of 11000C and a
maximum of 42000C temperature can be measured by optical pyrometers.
MANUALSWAGING MACHINE:
Swaging is an operation which reduces the diameter and increases the
length of a given bar or rod without loss of the material by means of hammering.
The sintered compacts are heated in a furnace to acquire temperature
enabling the metal for hot working manual swaging. The swaging machine consists of
high-speed steel die in the center. There are two semis round dies combine to form a
single die. It is rotated at center by a motor. There are hammers around the die, which
moves die to and fro at its axis only. By this motion it gives stroke on the metal which
is helpful in reduction of size. It is done manually. Swaging of molybdenum is done at
hot condition only due its high strength and hardness. It reduces metal from 48 to 18
diameters.
Reheating furnace:
This furnace is for reheating the material after every swaging pass.
Heating element
Molybdenum
Temperature
16000C
57
Heating schedule:
2000C
24hrs
4003C
24hrs
400-10000C @ 50C/hr
1000-14000C@ 50C/hr
1400- 1430 in one hour.
Input diameter
Output diameter
Temperature
Tr-1200 M/c
6000C
Tr-300 M/c
0.3
6000C
Eight-Draft M/c
0.3
0.05
6000C
58
ANNEALING:
Annealing is done to remove internal stresses present in the wire. It is a
process of heating to elevated temperature, soaking at that temperature for some time
and cooling to room temperature.
59
POINTING MACHINE:
Before the drawing of the wire, one end of the wires is o be pointed in order
to go through the die easily for initiation. This pointing machine is used for pointing
the end of the wire.
Input Size
Output Size
In
In
1.
14mm
6mm
2.
9mm
3.5mm
3.
4mm
1.5mm
4.
2mm
1mm
60
A)
Machine
1.8max
B)
Machine
0.6max
C)
Machine
0.25max
0.15min
0.05min
0.02min
: AIS1310
: 0-20 m/min.
: 0.5 to 5mm
: 0.5 to 1mm
: 1045-11000C
After the drawing of the wires they may contain stressed and during drawing
the wire may become hard. In order to make it soft and to relive stresses heat
treatment is required.
SHAVING MACHINE:
Specifications:
Input size
9mm
Output size
4.5mm
Maximum Shaving :
0.125 mm/side.
0.125 mm/whole diameter
Lubricant used
Shaving machine consists of two dies, one die is like bull block machine die
in which some reduction takes place. The second die is a cone shaped die having a
sharp edge which shaves or peel the surface of the material, a slight change will occur
is dia of the wire after shaving .This is mainly used for managing steels and titanium
alloys.
355-405 mm
Speed
1900m/min.
Revolutions
1500 rpm.
In lathe machines we are fixing the bar in between the headstock and tail
stock toughing the center of the bar. But in this machine has no fixing at the center, so
62
Objectives:
UT detects cracks, seams pits, inclusions heat treatment variations, wall
thickness, coating thickness, coating thickness, electrical conductivity, magnetic
permeability and hardness.
Applications:
Tubing wires, ball bearings spot checks in all types of surface, metal
detection's metal sorting etc.
TUBE SHOP
MIDHANI has started producing seam welded titanium tubes and
supplies are being made for a variety of heat exchanger applications. The equipment
produce welded tubes of 0.5-2.5 mm in wall thickness, 12-40 mm in outer diameter
and in lengths up to a maximum of 18mm.
63
12-4 mm.
Wall thickness
0.5-2.5 mm.
1:10 to 1:60
Length
up to 18 mts.
Material
Titanium
torch. After the welding the tube passes through the cooling zone, which has
the gas and water. The gas used mainly to which is used to avoid oxidation.
The tube at the exit of the section has temperature 100c-200c depending
upon the wall thickness. The cooling water flow and the cool the production
room the room temperature.
6. In Seam Grinding Unit, the welded portion is given a fine finish.
7. In First Calibration Unit it has two vertical and two horizontal stands. In this
unit, the arc diameter is reduced is reduced to a certain limit so that the final
dimension is obtained in the second calibration stand.
8. The Tube Drawing Unit consists of 24 pairs of nylon blocks for holding and
drawing the tubes.
9. In Cleaning Unit the tube is once again cleaned in hot water at 70c.
10. A Hot Air Blower is used to blow over a filament where it gets heated up and
removes moisture
11. In Induction Annealing Unit, the annealing is done in a argon atmosphere to
relieve the internal stress which are produced during the drawing. For Ti, the
annealing is done at 600-650c and for steels it is done at 900-1000c.
12. In Cooling zone of cooling Unit, Ar atmosphere and water is used for cooling
as described earlier. The exit temperature of the tube is around 70c and is
further cooled by water to room temperature.
13. The Secondary Calibration Test consists of a horizontal and vertical stand
where the exact OD of the tube is obtained. The OD should be within the
tolerance limit.
14. In Straightening Unit, the tube is straightened and fed into the eddy current
unit.
65
15. The Eddy Current Unit is used to detect the defects in the tube. It has to be
first calibrated by using defect in the tube in the form notches. Then the values
obtained are compared with the standard defects. The number of defects are
counted and recorded.
16. In marking unit the tubes are numbered with respect to grade and dimension
are marked on the surface of the tube.
17. The spray unit works in the conjunction with the Eddy current unit. It sprays
black ink over the length of 100mm over the defected portion. These portions
are later cut.
18. In flying cut off unit, the tubes are cut to the required length the tube is taken
in and fixed by stopper. The trolley moves along with the movement of the
tube and cuts the tube to the required length without disturbing the process.
19. The roll out stands is used to hold the tubes after being cut into the required
lengths.
After the production of the tubes these tubes are tested in the immersion ultrasonic
testing.
elasticity and density of the material. With the frequency f of the sound wave this
results in the wavelength ,
=C/f
: wavelength (0101)
: frequency (MHz)
Technical implementation:
Electric pulses are generated by the transmitter of the instrument and fed to
the probe where they trigger ultrasonic pulses. At the same time the electron beam
starts with the initial pulse (IP) in the lower left hand corner of the CRT screen. Sound
waves thus reflected and received back by the probe generate the echoes (reflector
echo, back wall echo) displayed on the CRT screen. In this A-scan representation the
echo amplitude of a reflector is shown as a vertical trace and the time of flight or
distance as a horizontal trace. This allows a clear allocation of the sound path S to
each individual echo location of reflector, thickness measurement.
S = Ct/2
Where
S
In the pulse echo method the sound portion reflected back to the probe are
evaluated. The through-transmission method uses two probes, i.e., one transmitter
pulse another one is the receiver work piece+probe+7 transmitters+7 clocks+7
horizontal sweeps.
Ultrasonic pulses:
For this purpose a piezoelectric element (crystal, ceramic, and polymer) is
used. This transforms electrical energy into sound waves and vice versa. Due to
mechanical damping of transducer element this produce a damped oscillation-The
ultrasonic pulses and on receiving a wave signal, the electric RF pulse. The frequency
of pulse is determined by element thickness. Where-as the pulse length or frequency
of spectrum is determined by element damping.
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*100%
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: Bandwidth
fu
fl
fm
: Central frequency
Weak Damping:
Long pulse duration, with distinctive frequency and narrow spectrum (small
bandwidth)is especially suited for flaw elevation according to the DGS method.
Strong Damping:
Short pulse duration, wide spectrum (large bandwidth) high resolution, good
signal to noise ratio especially on coarse micro structure.
Probes:
A straight beam probe transmitted and received sound waves with one
element perpendicular to the surface of sheet metals, forging and casting.
The TR probe contains two elements. The transmitter and receiving function
are separated form on another electrically and acoustically-> 7 test on this work piece
and wall thickness measurements.
The angle-beam probe transmits and receives the sound waves at an angle to
the material surface weld testing, testing of sheets metals, tubes forging.
UTILITIES
Plant utilities include water, fuel, compressed air, steam and other gases like
oxygen and LPG.
WATER:
Water is the most important utility in any production unit. Water is required
for cooling the equipment, drinking, sanitation and other purposes. The average
requirement of MIDHANI is 5800 m3/day. This requirement is met through 450mm
diameter. The storage tank will have two components.
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RECIRCULATION OF WATER:
Since water is raise commodity now a days and also disposal of large
quantity of water is a problem, recirculation systems have been adopted in MIDHANI
which are more economical and practical, only make- up water is taken from the main
pipe line.
Two separate recirculation systems have been provided for water, one for
contaminated water during usage and other for clean water. The water contaminated
with scales and oils is then treated in a clarifier with chemical dosing and overflow
water is collected in hot well. The hot water is cooled in an induced draught cooling
tower. A similar re-circulating system without a clarifier will handle clean water.
Continuous supply of water is essential for furnaces. During power failure a
separate furnace cooling water main connected to an overhead tank. As soon as there
is a power failure, diesel generator is started manually. There is bound to be some
time gap before the generator is started, and during this time gap the furnaces are
supplied with cooling water from the emergency overhead tank through a pipe line
using a diesel engine. This engine operates one cold well sump pump and one hot well
sump pump. The cold well sump pump supplies cooling water to the furnace and hot
well sump pump, pumps back the water to the tank.
Fire hydrants are supplied water from drinking water line. Water
consumption for drinking and fire hydrants will be around 20m3/ Hr at an average. An
overhead tank of capacity 460m3 is always kept filled for fire hydrants.
STEAM:
Steam is another important plant utility. Steam is needed for heating
various chemicals, rinsing baths and for operating steam ejectors. Steam is used in
heat exchangers as a hot fluid. Steam is required in LPG system for evaporating LPG.
The maximum steam demand in MIDHANI is around 10 tons/Hr. Two boilers supply
the steam required for different purposes. The details of the boilers are given below.
Vaporize 4000
Type
Capacity
4000 kgs/Hr.
11 kg/cm2
Operating pressure
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11 kgs/cm2
Temperature
1870 C
Oxygen fraction
0.98
11 kgs/ cm2
Temperature
Efficiency
80% on coal
70% on oil
The material and construction of tubes are as per IS 226 and BS 3057/3
respectively.
COMPRESSED AIR:
Compressed air is required in a production unit to operate pneumatic valves
and cylinders, solenoid valves and other equipment operated on air.
The compressed air requirement in MIDHANI is met by three compressors
each having a capacity of 1800 m3/hr at a discharge pressure of
7 kg/cm2. The
compressors are reciprocating, water cooled, and two stage, double acting, electrically
driven type of compressors. The specifications of the compressors are as given below.
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Specifications:
Free air delivery
1800m3/hr
Working pressure
7 kg/cm2 at outlet
No: of cylinders
Four
Speed
975 rpm
Shaft HP
201 KW
Motor HP
165 KW
One oil bath type suction filter is fitted in each compressor in the suction
line. Three number of oil and dust separator are fitted and the separators are capable
of filtering the moisture up to 99.5% dry and dust particles up to 5 microns diameter.
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Mechanical Testing
Metallography
Non-Destructive testing
Stage Control Laboratory
Raw Materials Inspection Cell
Workshop.
MECHANICAL TESTING
Mechanical testing is done for obtaining some preliminary indications of the
suitability of a metal or alloy for a specific purpose. In mechanical testing, destructive
methods are given as follows:
1.
2.
3.
4.
5.
6.
7.
Tensile testing
Hardness testing
Impact testing
Fatigue testing
Creep testing
Bend test
Erichsen Cupping test
In mechanical testing the test sample are prepared according to the standards
specifications and are tested to cause destructions at the specimen. The product is
assumed to have some properties of the material from which the standard test piece
prepared. The destructive test cannot determine location and type of defect in a
material, but will show difference in the value of the property due to internal defects.
TENSILE TESTING:
In this testing tensile properties such as ultimate tensile strength, yield
strength, percentage elongation, percentage reduction in area are obtained from a
single test specimen.
To carry out this test there are universal testing machines supplied by M/s.
Instron Ltd., England. The capabilities of the machine are:
1. 500 KN- 50,000 Kg Dynamic/25,000 Static.
2. 100 KN- 10,000 Kg Static.
3. 250 KN- 25,000 Kg Static.
In these three machines, it is able to perform tension, compression, bend test
and fracture toughness. Both room temperature tension tests and high tension test are
done.
The specimens practically used to test are usually round, sheet and wire
samples depending upon the nature of the product being to be tested. It is performed
by subjecting the sample to a gradually tensile pull until it breaks.
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The centre is usually reduced in section to form gauge length before placing
the specimen in the machine, its diameter is measured with a micrometer. The small
pop marks are made at a distance apart corresponding to the gauge length in width
which the extension is to be measured.
After placing, the specimen is grips tightly the scale load in KN, cross head
to chard speed ratio is selected and then load is applied until fracture take place. The
load and elongation curve is drawn on the chart by the pen recorder.
HARDNESS TESTING:
Hardness is the resistance of a material to permanent deformation. For
metals, this property is a measure of their resistance to plastic deformation. The
equipment in hardness testing are:
1. Brinell Hardness Tester, from FIE, India.
2. Rockwell Hardness Tester, from FIE, India.
3. Vickers cum Brinell Hardness Tester, from Hectert, GDR.
4. Vickers Hardness Tester, from Matuzawa, Japan.
In the Brinell hardness tester, the penetrators to be used are a ball of either
2.5 or 10mm diameter. The load applied varies with the diameter of the penetrators
used. For Ferrous alloys, this formula is 30D2 where D is diameter of the penetrator.
After test has been done, it is necessary to measure the mean diameter of the
impression made on test specimen ball indentor. The measure of the diameter of the
impression is readily accomplished by the use of a graduate viewing at the top of the
machine. After attaining the diameter of impression, the BHN is obtained from the
standard charts, which have already calculated values of different impression by the
formula...
Kg/mm2
Where P is applied load in kg and D is diameter of indentor in mm and d is
the diameter of impression in mm.
The Brinell method is restricted to the material having a Brinell hardness
number as 350 maximum, above the penetrator may deform.
1. The load range is 250 kgs to 3000 kgs.
2. The maximum test height is 410mm.
3. Depth of the throat is 200mm.
The Rockwell Hardness testing machine is a direct reading testing machine,
means that the depth of impression measures directly the hard number after releasing
measures the load. In this loads are applied i.e. minor and major loads. For conducting
the test steel ball or brale indentor is used. In some times diamond indentor is also
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used. The hardness number from the dial indicator is taken in types of scales i.e. RC,
RB and RA. For different indentors different major loads are to be applied i.e. steel
ball 100 and brale 150 kgs.
The Vickers method applies especially to small, hard and thin specimens.
The penetrator to be used is a diamond on the form of a square based pyramid with an
included angle of 1360 between opposite faces. The impression formed in this test is
in of a square. The lengths of the two diagonals are estimated and the diagonal length
is compared with the standard Vickers hardness number chart, in with the values are
obtained by the given formula:
Kg/mm2
Where P= applied load in kgs, D= Diagonal length in mm.
Normally the Vickers cum Brinell tester is used and the HV values is given
to equalized HB values in another chart, where as so many cases are takes the HB
values only.
IMPACT TESTING:
In impact testing the resistance of a metal towards shock is measured by
means of pendulum type machine. There are three impact testing machines, from FIE,
India, conducting both Charpy and Izod impact test.
The pendulum impact testing machine consists of the frames of pendulum,
the frapping device, and the measuring equipment. The test specimens are prepared
according to the standard specification with either U or V notches.
In the Izod test, the notch on the specimen should face the pendulum striker.
In Charpy test the specimen rests freely on the supports, the specimen should be
placed in such a way that the notch is a parted to the direction of impact pendulum.
The test specimen is held in between the gripping heads. The pendulum is
raised to the top most position and held by a catch adjustment to give a constant
height of all tests. It is then released and allowed to fall and rupture the specimen
further, there is a dial attached concentrically with the pendulum shaft. The scale is
designed in such that the impact energy absorbed in breaking the specimen can be
read directly in joule.
The notch impact strength is evaluating the energy afforded on fracture of
the sample divided by the original cross-sectional area of the specimen at the notching
point.
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FATIGUE TESTING:
Fatigue is the term applied to desirable the failure of a metal or an alloy
under repeatedly applied stress which is usually less than that required to cause
fracture on a single application of load. Fatigue of metals is the property by which the
fail are relatively low value of the stress when the stress is repeated.
The axis of rotation is maintained for bending of metal material in normal
and high temperature.
Distance between fulcrum of load L cm (20)
Weight of poise (one side) W kgs
Diamond type diameter of test piece d cm
Average bending moment caused by the applied load in downward direction
from the two ends of the specimen with the help of load bearings is kg/cm.
LOADING:
For these entire tests a standard loading is taken considerably. The load is
represented and acted in Newtons only. By the beam mechanism the lead will act 10
times to that applied load the acting force is in Newtons, so that we have to be taken
that weights from kgs to Newtons.
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CREEP TEST:
The standard time given for creep testing of different grade specimens and
the time the maximum elongation is measured by the reading on the extensometer.
For each elongation is noted. The elongation must not be equalized to 0.2%, it must
be less than 0.2%.
The creep test measures the dimensional changes which occur from elevated
temperature exposure, while the stress rupture test measures the effect of temperature
on the long time load bearing characteristics.
In this laboratory round samples of 3 to 5mm diameter and sheets sample of
2mm thickness can be tested.
BEND TEST:
A test for ductility is applied by bending the material over a former known
radius through a specified angle. It is conducted for the purpose, of whether any
cracks to be developed while in the usage of different manner.
Sheet material specimen is held in between the round grips, bent first
through 900 to a side, then through 1800 from side to side until visible cracks are
produced. It is necessary the cracks must not be formed after complete 1800 angle
bends also.
METALLOGRAPHY:
The study of the internal structure of a metal or alloy in relation to its
physical and mechanical properties is called metallography. Metallography or
microscopy consists of microscope study of the structural characteristics of the metal
or an alloy. Metallography examination is usually carried out with the aid of reflection
light in order to investigate the nature such as grain size, shape and distribution of
various cracks and inclusions which have a great effect on mechanical properties of
the metal or an alloy. Lattice features such as grain boundaries slip bands; twin and
cracks are observed in metallography.
The lab consists of the equipment of preparing the sample suitable for the
microscopic study such as belt grinder, disc polishers, electric polisher or cloth and
various solutions for etching.
Microscope suitable for various purposes such as two numbers of classical
optical microscopes with maximum magnification of 1000x, two numbers of stereo
microscope with magnification one special type optical microscope (Axiomay) with
maximum magnification of 3200x.
There is auxiliary equipment for testing and taking photographs of the
structure and alloys of various materials.
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Micro hardness tester, having square based diamond pyramid indentor for
determining the hardness of any micro constituents present in the structure such as
Austenite, Martensite etc., in steels.
Properties of forge shop, HRM, CRM, PM shop and Titanium shop are tested
here.
HRM Products: Inclusions, grain size and micro structure to be examined in various
products.
Bar & Wire: Micro structure, grain size and depth of surface cracks to be examined
on the missile products.
PM Products: Grains count, porosity and grain size of sintered ingots, thorium
distribution in thoriated Tungsten.
Longitudinal sections taken parallel to the main axis of the material reveal in
general the following information:
1. Extent of deformation in the non-metallic inclusions.
2. Degree of plastic deformation as shown by grain distribution.
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