arci hyderabad facilities

7/31/2019 ARCI Hyderabad Facilities

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The Centre for Laser Processing of Materials (CLPM) works towards development and

promotion of application of laser-based solutions in the Indian industry through:

Application oriented R&D towards demonstrating feasibility of laser processingroute for specific industrial applications;

Research towards better scientific understanding of various processes; Job works of specialized nature; and Consultancy...

Research Areas

Laser Welding Laser Surface Treatment

o Laser hardeningo Laser cladding/alloying

Laser Drilling Laser Cutting

Facilities

6 kW Diode Laser 3.5 kW CO2 Slab laser 400 W Avg Pulsed Nd:YAG Laser 9 kW CO2 Transverse Flow Laser


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As far as the field of surface modification technologies are concerned, India has matured

significantly in recent years. The conspicuous upward trend in the adoption of surface

modification technologies by the Indian industry has also been catalysed by several initiatives

taken by the Government of Indias Department of Science & Technology (DST). ARCI

scientists have played a prominent role in piloting these initiatives and the organization has

consistently tried to identify coating technologies of national relevance and consciouslypursue those that are unavailable elsewhere in the country.

Over the years, ARCI has successfully projected itself as a leader in the field of surfacemodification. ARCI's Centre for Engineered Coatings has been engaged in developing a wide

spectrum of appropriate surfacing technologies to assist the Indian industry in meeting the

challenge of enhancing the durability and performance of components operating in adverse

environments. The efforts of the Centre for Engineered Coatings have focused on eventuallytransferring relevant technologies to private entrepreneurs in a cost-effective manner.

Several coating technologies are being simultaneously pursued by the Centre for Engineered

Coatings in an effort to offer a range of quality and cost to the potential user industries. Some

of these have matured and already successfully transferred to the industry while yet other

exciting technologies are presently on the anvil.

Major Coating Technologies Established at CEC

Detonation Spray Coating

Cold Spray Coating

Micro Arc Oxidation

Electro Spark Coating

Electron Beam Physical Vapour

Deposition


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Diamond Like Carbon Coating Solution Precursor Plasma Spray

Coatings

Pulsed Electro-Deposition coatings

Research Areas

Detonation Spray Coating Technology

D. Srinivasa Rao, G. Siva Kumar, D. Sen

DSC is a unique variant in the family of versatile thermal spraying which contributes

reputation among the exhaust surface modification technologies. The development of

Detonation spray coating technology at ARCI is aimed to transfer the total technology, along

with equipment and know-how of the coating process to the Indian entrepreneurs and also to

the other countries.

Process: A method of coating, where an explosive high temperature flux of gas mixtures is

used as a source for heating, accelerating and spraying the particles


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Salient Features

Excellent Adhesion Low Oxide Content

< 1% Porosity Good Tribological Properties

High Microhardness High Coating Thickness

Low Thermal Degradation Good Powder Efficiency

Advantages

Low Substrate Temperature Less Electrical Consumption

Low Cost of Operation Less Down Time

Less Gas Consumption Less Work Scrap

Less Water Consumption

Process Capabilities

Thickness Buildup: 5-25 m/shot Particle Velocity: 500 to 1000 m/s

Coating ThicknessParticle Temperature: up to

4000oC

Carbides/Cermets: 20-500 m Deposition Efficiency: 30 to 60%

Ceramics: 50-1,000 m Porosity: 0.1 to 1.0%


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Metals & Alloys: up to few mm Bond strength: >75 MPa

Coating Coverage: 0.5 to 1.0

m2/hr

Coating hardness: WC-Co-1,300

HvCr3 C2-NiCr-1,000 Hv

Type of Powders Sprayed

Metals, Oxides & Cermets, Carbides and Alloys

Substrate Materials

Metals, Alloys, Superalloys, Dielectric substrates, Plastics, Glass and

Ceramics (Any substrate having hardness < 65 HRC can be coated by DSC)

Examples of Powders Sprayed

Al2O3, Al2O3-TiO2, Cr3C2-NiCr, WC-Co, WC-Co-Cr, WC-17Co-8FEP, WC-10.5Co, WC-

10.5Ni, Ni-20Cr, CoCrAlY & NiCrAlY, SS316-Martensitic, Austenitic, Cr2O3, Aluminumbronze, NiCr-5Al, Stellite-6, Cr2O3-20 Al2O3, Ti(C,N)-38%(Ni, Co), Ti(C,N)- 38%(Ni, Co,

Mo), Fly ash, AlN (from SHS), Fe-Al (with Al2O3, Cr2O3), Cr3C2-NiCr- TiB2, Fe-SiC,

Al65Fe20Cu15, Fe, Ni, Cu and many pure metals.

DSC vs APS

Higher bond strength (> 10000

psi)

Controlled residual compressive

stress

Denser microstructure (< 1%

porosity)

Very thick coatings can be

produced without delamination

Reduced thermal degradationVery high melting point materials

like Zirconia can not be sprayed

Smoother as-coated surface finish (1-4m Ra)

DSC vs HVOF

Coating properties nearly similar HVOF has higher productivity

HVOF CANNOT SPRAY OXIDESDSC operating costs are much

lower

DSC fully indigenous spares/servicing issues much simpler

Latest News - Centre for Laser Processing of Materials

Optimization of laser welding process on Ti-6Al-4V sheets to obtain defect free joints withrequired mechanical strength


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Establishment of a new laser processing system based on a 6-kW Fiber-Coupled Diode Laserintegrated with a 6-axis robot and turn-tilt table

Laser hardening of crankshafts for reciprocating compressor Laser welding of tailor-welded blanks (TWB) in three steel combinations for formability

testing

Facilities

1) Coating techniques

Detonation Spray Coating Micro Arc Oxidation

Cold Spray Coating Diamond Like Carbon Coating

Electro Spark CoatingElectron Beam Physical Vapour

Deposition


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Solution Precursor Plasma Spray

CoatingPulsed Electrodeposition

2) Heat treatment

Thermal Cycling Furnace

3) Characterization Facilities


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PerthometerRotating Beam Fatigue Testing

Machine

Erosion Wear Tribometer Dry Sand Abrasion Wear Tribometer

Sliding Wear Tribometer

People

Name - D. Srinivasa Rao

Designation - Scientist-E & Team Leader


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Qualification - MS (Mechanical Engineering)

Areas of expertise - Surface Engineering, Industrial Applications of Coatings,

Implementation of coating technologies for production

eMail [email protected]

Name - N. Ravi

Designation - Scientist-D

Qualification - MTech (Industrial Metallurgy)

Areas of expertise - Diamond like Carbon Coatings and Material Characterization


Name - L. Rama Krishna

Designation - Scientist-D

Qualification - MTech (Materials &Metallurgical Engineering)

Areas of expertise - Micro Arc Oxidization Coatings and Tribological Performance

Evaluation


Name - G. Sivakumar
http://www.arci.res.in/query.aspx?employeeCode=69http://www.arci.res.in/query.aspx?employeeCode=69http://www.arci.res.in/query.aspx?employeeCode=69http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=69


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Designation - Technical Of cer-C

Qualification - Diploma in Mechanical Engineering

Areas of expertise - Detonation Spray Coating and Electron Beam Physical Vapour

Deposition


Advisors/Consultants

D Srinivasa Rao

Scientist-E & Team Leader

MS (Mechanical Engineering)

Areas of Expertise: Surface Engineering, Industrial

Applications of Coatings, Implementation of coating

technologies for production

eMail:[email protected]

N Ravi

Scientist-D

MTech (Industrial Metallurgy)

Areas of Expertise: Diamond like Carbon Coatings and

Material Characterization


L Rama Krishna

Scientist-D

MTech (material & Metallurgical Engineering)

Areas of Expertise: Micro Arc Oxidization Coatings and

Tribological Performance Evaluation

eMail:[email protected]@arci.res.in

G Sivakumar

Scientist-C

BTech (Mechanical Engineering)

Areas of Expertise: Detonation Spray and Solution Plasma

Spray Coatings


Dr R Kavitha

Scientist-C

PhD (Solution Precursor Coatings)

Areas of Expertise: Solution Precursor Based Coatings

http://www.arci.res.in/query.aspx?employeeCode=9http://www.arci.res.in/query.aspx?employeeCode=9http://www.arci.res.in/query.aspx?employeeCode=9mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.arci.res.in/query.aspx?employeeCode=9


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Nitin P Wasekar

Scientist-B

ME (Metallurgical Engineering)

Areas of Expertise: Pulsed Electrode Deposition and Micro Arc

Oxidization Coatings


P Sudharashan Phani

Scientist-B

BTech (Mechanical Engineering)

Areas of Expertise: Cold Spray Coatings and Modeling Studies


Naveen Manhar Chavan

Scientist-B

BTech (Metallurgy)

Areas of Expertise: Pulsed Electrodeposition

email:[email protected]

D Sen

Technical Officer-C

Diploma in Mechanical Engineering

Areas of Expertise: Detonation Spray Coating and Electron

Beam Physical Vapour Deposition


Solution precursor plasma sprayFrom Wikipedia, the free encyclopedia

Jump to:navigation,search

Solution Precursor Plasma Spray (SPPS) is athermal sprayprocess where a feedstock

solution is heated and then deposited onto a substrate. Basic properties of the process arefundamentally similar to other plasma spraying processes. However, instead of injecting a

powder into the plasma plume, a liquid precursor is used. The benefits of utilizing the SPPS

process include: the ability to create unique nanometer sized microstructures without the

injection feed problems normally associated with powder systems and flexible, rapid

exploration of novel precursor compositions.[1][2]

Contents

1 Background

2 The process 3 Thermal Barrier Coatings
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Backgroundhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Backgroundhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#The_processhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#The_processhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Thermal_Barrier_Coatingshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Thermal_Barrier_Coatingshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Thermal_Barrier_Coatingshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#The_processhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Backgroundhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headmailto:[email protected]:[email protected]:[email protected]:[email protected]


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Background

The use of a solution precursor was first reported as a coating technology by Karthikeyan, et

al.

[3][4][5]

In that work, Karthikeyan showed that the use of a solution precursor was in factfeasible, however, well adhered coatings could not be generated. Further work was reported

in 2001 which refined the process to producethermal barrier coatings,[6]

YAGfilms,[7]

and

silicon ceramic coatings.[8]

Since then, extensive research on the technology has been

explored in large part by theUniversity of ConnecticutandInframat Corporation.

The process

The precursor solution is formulated by dissolving salts (commonly zirconium and yttrium

when used to formulate thermal barrier coatings) in a solvent. Once dissolved, the solution is

then injected via a pressurized feed system. As with other thermal spray processes, feedstock

material is melted and then deposited onto a substrate. Typically, the SPPS process sees

material injected into aplasmaplume orHigh Velocity Oxygen Fuel(HVOF) combustion

flame. Once the solution is injected, the droplets go through several chemical and physical

changes[9]

and can arrive at the substrate in a several different states, from fully melted to

unpyrolized. The deposition state can be manipulated through spray parameters and can be

used to significantly control coating properties, such as density and strength.[2][10]

Thermal Barrier Coatings

Most current research on SPPS has examined is application to create thermal barrier coatings

(TBCs). These complexceramic/metallicmaterial systems are used to protect components inhot sections of gas turbine and diesel engines.

[11]The SPPS process lends itself particularly

well to the creation of these TBCs. Studies report the generation of coatings demonstrating

superior durability and mechanical properties.[12][13][14]

Superior durability is imparted by the

creation of controlled through thickness vertical cracks. These cracks only slightly increase

coating conductivity while allowing forstrainrelief ofstressgenerated by theCTEmismatch

between the coating and the substrate during cyclic heating. The generation of these through

thickness cracks was systematically explored and found to be caused by the depositing a

controlled portion of unpyrolized material in the coating.[15]

Superior mechanical properties

such as bond strength and in-plane toughness result from the nanometer sized microstructure

that are created by the SPPS process.

Other studies have shown that engineered coatings can reducethermal conductivityto some

of the lowest reported values for TBCs.[16][17]

These low thermal conductivities were achieved

through the generation of an alternating high-porosity, low-porosity microstructure or the

synthesis of a low conductivity precursor composition withrare earthdopants.

Research Areas

Back

LASER SURFACE HARDENING

4 Costs 5 References
http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-4http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-4http://en.wikipedia.org/wiki/Thermal_barrier_coatinghttp://en.wikipedia.org/wiki/Thermal_barrier_coatinghttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-5http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-5http://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://www.uconn.edu/http://www.uconn.edu/http://www.uconn.edu/http://en.wikipedia.org/wiki/Inframat_Corporationhttp://en.wikipedia.org/wiki/Inframat_Corporationhttp://en.wikipedia.org/wiki/Inframat_Corporationhttp://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-13http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-13http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Rare_earth_elementhttp://en.wikipedia.org/wiki/Rare_earth_elementhttp://en.wikipedia.org/wiki/Dopantshttp://en.wikipedia.org/wiki/Dopantshttp://en.wikipedia.org/wiki/Dopantshttp://www.arci.res.in/clp/research-areas.htmlhttp://www.arci.res.in/clp/research-areas.htmlhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Costshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Costshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Referenceshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Referenceshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Referenceshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Costshttp://www.arci.res.in/clp/research-areas.htmlhttp://en.wikipedia.org/wiki/Dopantshttp://en.wikipedia.org/wiki/Rare_earth_elementhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-13http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/Inframat_Corporationhttp://www.uconn.edu/http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-5http://en.wikipedia.org/wiki/Thermal_barrier_coatinghttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-4http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2


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Laser surface hardening is a selective surface hardening process wherein the desired

metallurgical and mechanical properties are achieved by a defocused laser beam irradiated

over the required area with average power density of 103

- 104

W/cm2

produced to desired

case depth. Hardening is effected by transformation, remelting or shock hardening.

Key Features & Advantages

Moderate to rapid cooling rates resulting in fine homogenous structures Selectively localized area processing Controlled case depth Minimal distortion Chemical cleanliness Minimal post treatment High process flexibility Excellent reproducibility Ease of processing with CNC programming Faster production rates No quenchant requirement

Typical Applications

Steam turbine blades Crank shafts Cam shafts Forming dies Cutting tool edges

Ongoing Application R & D Projects

Crankshaft for a reciprocating compressor Piston spacers & rings for IC engines Two-wheeler cam shafts Crossings for rail roads

LASER CLADDING/ALLOYING

Laser surface cladding is a process of deposition of cladding material (alloying species) over

a substrate to form a sound interfacial bond without diluting the clad with substrate. Laser

surface alloying is a process similar to surface melting except that another material (alloyingspecies) is injected into the melt pool. Typically an inexpensive base material is

alloyed/cladded with an expensive alloying material, resulting in desired improvements in

tribological properties of the alloyed region. Laser cladding has also progressed into direct

laser casting (Direct Metal Deposition) for low volume 3D components.


Moderate to rapid solidification rates resulting in fine homogenous structures Desired coating depth with dilution Minimal distortion with low HAZ Controlled thermal profiles and shape


15/18

Good surface finish Selective alloying/cladding Minimal wastage of costly alloying material Precise control of alloy geometry Extremely versatile Excellent metallurgical bonding Reduced porosity Excellent coating homogeneity High deposition efficiency Faster processing rates


Gas turbine blades Pump sleeves Engine valves Rotor shafts

Ground rolls Temper mills Automobile pitons Ball and gate valves Friction discs Crane shafts Brake drums Casting molds Excavator blades

Ongoing Application Development Projects

Valve seat cladding with stellite 6 Boiler burner tip baffle plates for erosion resistance Erosion resistant coating on turbine blades

LASER WELDING

Laser welding is a non-contact fusion welding process which involves melting and joining of

two similar or dissimilar materials by the application of heat generated by a fine focused spot

of laser beam.

Laser welding usually employs a power density of 105-107 W/cm2 and hence, categorized as

a power beam welding process. The welding can be done in conduction mode for thin

sections and keyhole mode for thick sections. Generally, the welds are made autogenously

but external addition of filler material to modify the microstructure is also feasible.

Key Features & Advantages of Laser Welding

High power densityo High depth of penetration (aspect ratios upto 20:1)o High welding speeds and low heat input

Can weld wide variety of materials with varying thickness


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Possibility to precisely focus the beam spot at desired locationo Appropriate heat balance can be obtained while welding dissimilar materials

or thicknesses

Pulsed mode operationo Low heat input precision welding

No vacuum requirement, unlike electron beam welding Can weld magnetic materials, unlike electron beam welding Non contact process and hence clean weld unlike Shielded Metal Arc Welding orTungsten Inert Gas welding Some laser wavelengths can be sent through optical fiber and to weld inaccessible

locations

Some Typical Applications

Tailor-Welded Blanks (TWB) for Automotive bodies Gear assemblies in automotive transmission Stringer welding to skin of fuselage

Sandwich panels for ship building Stainless steel equipment Hermetically sealed valves for solenoid applications

Ongoing R & D Projects

Tailor-weld blanks Welding of Ti-6Al-4V Thin section sensors to thick section structures made hardenable steels Dissimilar material joint Ti-SS Galvanised sheet steel Titanium parts for aerospace applications Micro welding of sensors to structures.

LASER DRILLING

Laser drilling involves material removal by vaporization and/or expulsion of molten material

due to irradiation of high laser intensities. There are two types of laser drilling processes:

percussion drilling (hole of diameter 1 mm).

Percussion drilling process involves a stationary beam and one or more pulses to penetrate

the thickness of material. Trepanning involves contour cutting of the hole by moving the

beam / workpiece to create the final dimensions of the hole.

Key Featyres & Advantages

Ability to produce small diameter holes with high aspect ratiosHoles can be drilledat shallow angles to the surface

Optical fiber delivery possible Ability to process a wide range of materials High production rates Drilling of micron level holes to rock drilling Non-contact drilling (no tool wear or breakage, no material distortion) Highly accurate and consistent results


17/18

Precise control of heat input Flexibility to address different applications (for prototypes and low-volume, small-lot

manufacturing)


Cooling holes in gas turbine blades Aerofoil Laminar Flow Fuel Injection Nozzles Fuel Filters Inkjet Printer Nozzles PCB Via Interconnects Catheters MEMS

Laser Cutting

Laser welding is a non-contact fusion welding process which involves melting and joining oftwo similar or dissimilar materials by the application of heat generated by a fine focused spot

of laser beam.

Laser welding usually employs a power density of 105-107 W/cm2 and hence, categorized as

a power beam welding process. The welding can be done in conduction mode for thin

sections and keyhole mode for thick sections. Generally, the welds are made autogenously

but external addition of filler material to modify the microstructure is also feasible.


High power densityo High depth of penetration (aspect ratios upto 20:1)o High welding speeds and low heat input

Can weld wide variety of materials with varying thickness Possibility to precisely focus the beam spot at desired location

o Appropriate heat balance can be obtained while welding dissimilar materialsor thicknesses

Pulsed mode operationo Low heat input precision welding

No vacuum requirement, unlike electron beam welding Can weld magnetic materials, unlike electron beam welding Non contact process and hence clean weld unlike Shielded Metal Arc Welding or

Tungsten Inert Gas welding

Some laser wavelengths can be sent through optical fiber and to weld inaccessiblelocations


18/18

Some typical Applications

Tailor-Welded Blanks (TWB) for Automotive bodies Gear assemblies in automotive transmission Stringer welding to skin of fuselage Sandwich panels for ship building Stainless steel equipment Hermetically sealed valves for solenoid applications

Ongoing R & D Projects

Tailor-weld blanks Welding of Ti-6Al-4V Thin section sensors to thick section structures made hardenable steels Dissimilar material joint Ti-SS Galvanised sheet steel Titanium parts for aerospace applications Micro welding of sensors to structures

arci hyderabad facilities

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