Indian Institute of Metals

Condensed Abstracts of the Technical Papersto be Presented at the

58th ANNUAL TECHNICAL MEETING OF

THE INDIAN INSTITUTE OF METALS

TrivandrumNovember 17-19, 2004

A2

Contents

Name of the Sessions / Topics Page

Iron Steel – I, II and III A3

Process Modelling & Automation A13

Secondary Processing (Ferrous) A16

Emerging Technologies A20

Non-ferrous Extraction A23

Non-ferrous Alloys A28

Secondary Processing (Non-ferrous) A34

Aerospace Materials A37

Microstructural Engineering - I and II A41

Mechanical Behaviour - I and II A47

Modelling & Simulation A54

Advanced Materials & Processes - I and II A57

Composites A65

Corrosion & Surface Engineering A68

Environment & Recycling A72

A3

IRON & STEEL MAKING

VISION 2020 OF INDIAN STEELINDUSTRY – POTENTIALS AND

STRATEGIES (Lead Lecture)S.K. Gupta

Jindal Vijayanagar Steel LimitedVidyanagar – 583275, KarnatakaEmail: [email protected]

Vision 2020 triggers the pursuit of India to become a developednation. At below 400 kg per capita steel consumption no countrygets an entry there. From a base of 32 kg, the mission seemsto be impossible. But many nations had consistently doubledtheir steel production and demand for decades. The paperattempts to provide a path breaking blue print.

AN OVERVIEW OF THE STAINLESSSTEEL INDUSTRY (INDIA/

INTERNATIONAL) AND ITS GROWTHTRENDS AND POTENTIAL

(Lead Lecture)Mrinmoy Roy

Executive DirectorSalem Steel Plant, Salem

The Twentieth century alloy - as it is popularly referred to,Stainless Steel made its entry into the world of alloys justunder a hundred years. The versatility of Stainless Steel lendsitself to a wide spectrum of uses ranging from kitchenware tocreative expressions in architecture- from injection needless tonuclear reactors.

DEVELOPMENT OF PROCESSTECHNOLOGY FOR PRODUCTION OF

ALLOYED PIG IRON IN BLASTFURNACE USING CHROMITE

OVERBURDENAshok Kumar, N.C. Mishra, K.L. Sarda,* L.K.

Singhal**, S.P. Mohanty, A.K. Padhy, S.K.Nanda and U.C. Behra#

*MECON Limited, Ranchi, **Director, Jindal StainlessLimited, Hisar, #IKIWL, Barbil, Orissa

Email: [email protected]

Industrial trial for production of Ni-Cr bearing pig iron wasconducted in blast furnace of IKIWL, Barbil using 25% to50% chromite overburden sinter in the burden. During threedays trial 250 tonnes of alloyed pig iron having Ni in therange of 0.39- 0.9% has been produced successfully first timein the country using the waste from chromite mines.

PACKED BED REDUCTION OF IRONORE-GRAPHITE COMPOSITE PELLETS

G.M. Chowdhury, G.G. Roy and S. K. RoyDepartment of Metallurgical and Materials Engineering,

Indian Institute of Technology, Kharagpur-721 302E-mail: [email protected]

To simulate the reduction of ore, coal composite pellets inactual shaft type furnace under reactive atmosphere, preliminaryexperiments were conducted in a tailor made thermo-gravimetricpacked bed reactor under inert argon atmosphere in thetemperature range 800oC to 1100oC. The lower activation energyestimated (30.3 kJ mol-1) for the reduction process suggeststhat the reduction in packed bed reactor may greatly beinfluenced by heat transfer.

DEVELOPMENT OF SELF-FLOWCASTABLE FOR SUSTAINING HIGHBLAST TEMPERATURES AT BLAST

FURNACEST.K. Pal*, J. Prasad*, R.K. Ahuja*, A.K.

Bhattacharya*, D.C. Choudhury**, S.B.R.Yadav** and A.K. Dasgupta**RDCIS, SAIL, Ranchi-834002

** Bokaro Steel Plant, SAIL,Bokaro-827001

E-mail: [email protected]

To improve performance and reduce refractory failures (redhot spots) of tuyere stocks, conventional castable has beenreplaced by self-flow low cement castables. The self flowcharacteristic ensures no voids and flaws during casting. It hashigh resistance to wear against passage of hot air. A high hotblast temperature of 10300C could be withstood with themodified tuyeres stock assembly.

IMPROVEMENT IN PERFORMANCE OFCOKE SCREEN AT COKE SORTING

PLANT OF RSPM. Kalet*, T.K. Das*, S. Tirkey*, M.L. Narula*,

Ram Avtar*, T.P. Acharyulu** and V. K.Mishra**

*RDCIS, SAIL, Ranchi-834002E-mail: [email protected]

**Rourkela Steel Plant, SAIL, Rourkela-769001

Size analysis of coke samples showed improvement in screeningof nut and breeze coke size fraction (-25 mm) in BF coke.With earlier screen the percentage of nut and breeze coke sizefractions in BF coke was 3.9-9.3%, where the same is foundto be 1.8-2.7% with the new screen material. Also the sizemeasurement of screen hole carried out after 3-4 months ofuse has indicated no increase in the size of hole. This is dueto the improved wear and corrosion resistant properties of thenew steel.

A4

CONTROLLING THERMAL REGIMEOF COKE OVENS – A NEW METHOD

Vikash Kumar*, U.K. Pathak**, U. Bhaskar*,S. Mazumdar*, P. Mazumdar** and M.S.

Sengupta**RDCIS, SAIL, Ranchi,

E-mail:[email protected]** Durgapur Steel Plant, SAIL, Durgapur-713203

In the carbonization process; demand-oriented heat flow is ofparamount importance to conserve energy, ensure coke quality,reduce pollution and increase service life of Coke Ovens.Conventional ways of heating control does not fulfil the aboverequirements. In view of this, supervisory control and dataacquisition system introduced in Coke Oven Battery # 1, DSP.The system has been successfully implemented and is in regularuse for controlling the heating regime.

PRODUCTION OF QUALITY BURNTDOLOMITE THROUGH ROTARY

KILNSGyanesh Jha, S. Roychowdhury, R.K.

Mukherjee and R.C. ShrivastavaSAIL, Bhilai Steel Plant

Bhilai – 490001

Burnt dolomite is used for fettling of Twin Hearth Furnaces(THF) of Steel Melting Shop –I of Bhilai Steel Plant. Thispaper deals with the production of burnt dolomite in RotaryKilns and steps taken to improve the quality of burnt dolomite,which has led to minimizing the procurement of Dead BurntMagnasite thereby improving the profitability of Bhilai SteelPlant. A saving of Rs. 7.34 Crores per annum by way ofreduction in procurement of costly Dead Burnt Magnasite andreduction in refractory consumption is anticipated. Also anincrease in production of burnt dolomite by 20% could beachieved.

PROCESS IMPROVEMENT MEASURESAT PELLET PLANT OF JINDAL

VIJAYANAGAR STEEL LIMITEDD.L. Saralaya, Suresh Kumar and M.Prabhu

Jindal Vijayanagar Steel Limited, Vidyanagar – 583275E-mail: [email protected]

Performance improvement measures in operation maintenanceand introduction of innovation like use of high ultra fine rawmaterial coupled with high aluminous characteristics, use oforganic binders and the hyper activation of bentonite to bringabout reduction in gangue content, Corex sludge addition ascarbon bearing material along with BOF sludge, etc, JVSL has

surpassed its rated capacity of 3 mtpa and has produced 3.25mt in 2003-04 with improved quality and reduced operationalcost. This plant has been upgraded to 4.2 mtpa in May 2004.

IMPROVEMENT IN IRON OREPELLETS QUALITY

D. Srinivas, T. Uma Devi, M. Prabhu andS.S. Gupta


With increasing level of alumina in iron ore fines feed forpelletisation process, critical properties like reductiondegradation index has been deteriorating. Pellet size wasoptimised and + 10 – 12 mm fraction was increased by controlof pelletising process and screening. Further, pilot scale studieswith different basicities of pellets have shown that increase ofbasicity to 1.2 from present level of 0.5 would significantlyimprove pellet quality.

OPTIMISATION OF COAL BLEND FORCOREX

P. Prachethan Kumar, T.K. Naha and S.S.Gupta


COREX process has been developed as an alternative to BlastFurnace and it uses non-coking coal unlike coke in blast furnaceas a fuel. Based on the use of several coals in COREX atJVSL, it was established that coals with superior Char Strengthafter Reaction and Char Reactivity Index resulted in improvedperformance of COREX. With this experience, the specificationsof coals for COREX have been revised, an optimum coal blendhas been developed which has helped JVSL to surpass ratedcapacity of COREX.

STRENGTHENING OF BLASTFURNACE REFRACTORY LINING

THROUGH TAR-PUMPINGG. Rajadhas, Kurre, S. Ahmed and S.K. Ghosh

Bhilai Steel Plant, BhilaiBhilai – 490001

In Blast Furnaces of Bhilai Steel Plant problem of intense gasburning around the tap hole area, increased heat loss from theupper-hearth bottom coolers and hearth coolers wereencountered. There was also sharp rise in body temperature ofone furnace around the bosh. To counter these problems asystem of Tar pumping into the refractory mass has beendeveloped and implemented successfully. This paper detailsthe scheme.

A5

EVALUATION OF ORGANIC BINDER INIRON ORE PELLETIZATIONS.S. Deginal*, K. Suresh Kumar**,

P.L.N. Reddy*and K.L. Bhat** Department of Metallurgical and MaterialsEngineering, National Institute of Technology

Karnataka, Surathkal.** Deputy General Manager, Pellet plant, JindalVijayanagar Steel Limited, Vidyanagar – 583275.


Iron ore pellets with organic binders were produced with thedosage of 150 g/ton and 190 g/ton by replacing bentonitecompletely in laboratory and partially in plant scale. Themetallurgical properties were assessed. Factors such as particlesize, moisture and mixing time have considerable influence onthe process and quality parameters.

MEASURES FOR MAINTAINING THEHEALTH OF THE BATTERY DURING

COAL CRISIS AT BHILAI STEEL PLANTB.C. Mandal , V. Singh, Y. Venkateswarlu, A.P.

Barnwal, S.K. Ghosh and S.K. Singhal,Bhilai Steel Plant, Bhilai– 490001


Oven pushing rate was reduced significantly to as low as 55ovens per day per Battery in BSP, due to severe coal crisis.This paper highlights the various measures adopted and thetechnological discipline adhered to which help to sustain thecrisis and maintain the health of battery and coke quality at afairly stable level.

AN EXPERIENCE IN ANCIENT IRONMAKING

P.K. Biswas and A.K. VaishNational Metallurgical Laboratory, Jamshedpur 831 007


Iron was being produced by smelting low grade ore in claymade furnaces using traditional charcoal as reductant beforeblast furnace era. The British failed to duplicate the process,which was rather an art than a science. The authors studied theiron making process in detail with respect to design and processparameters by the age old method at tribal site of Bishunpur,Gumla District and at NML to comprehend the process inmetallurgical parlance. Some developmental work was alsoattempted.

THE CONCEPT OF BASICITY IN GLASSMAKING AND PROCESS METALLURGY

Sumit Pal, Hem Shanker Ray and PranabChoudhury

CGCRI, Kolkata – 700 032E-mail: [email protected]

In this presentation the role of Optical Basicity (OB) is brieflyreviewed in the context of electrical, optical and thermodynamicproperties of glass systems. The concept of OB appears to beequally important in describing the behavior of both glassesand slags provided correct values of OB are taken.

ORE MICROSCOPY AND ITSRELEVANCE FOR SELECTION OF A

SUITABLE BENEFICIATION METHODFOR PROCESSING OF HIGH ALUMINA

IRON ORESVinod Kumar*, G.N. Jadhav** and N.K. Khosla#

*Department of Earth Sciences, IIT Bombay,Mumbai-400076.

E-mail: [email protected]*Department of Earth Sciences, IIT Bombay,

Mumbai-400076.#Department of Metallurgical Engineering, IIT Bombay,

Mumbai-400076.E-mail: [email protected]

This paper reviews the concentration operations currentlyemployed at Noamundi mines, Jharkhand, India and showshow ore microscopy may prove useful in understanding theefficacy of various concentration methods for beneficiation ofhigh alumina iron ores. Beneficiation studies involvingclassification (hydrocyclone), gravity separation (tabling andmulti gravity separator), wet high intensity magnetic separation(Jones type WHIMS and Eriez WHIMS) have been carried outand the mineral concentration results have been correlated tothe ore microscopy studies and detailed results are presentedin the paper.

DEPHOSPHORIZATION OFSTEELMAKING SLAG

P.N. Chaudhary, J. Pal, D.P. Singh, M. Singhand S. Ghosh

National Metallurgical Laboratory, Jamshedpur-831007E-mail: [email protected]

Amongst the different methods tried for phosphorus removal,chemical process has been considered most suitable because itutilizes the energy content of the slag. Initial tests have beenconducted using carbon as a reductant. The results have shown70-75% recovery of metallic values from slag whereasphosphorous removal varied in the range of 65-95%. In all thetests, P content of recovered metal is very high (1.5-2.5%)indicating that certain percentage of P comes to the metalphase.

A6

USE OF HOT METAL IN ELECTRICARC FURNACE FOR PRODUCTION IN

STEEL

M.S. Khan*, S.N. Sinha ** and M.D.Maheshwari*

*Tata steel Jamshedpur**Department of met Engg. & Material science


Electric Arc furnace has come up as a viable competitor toBOF in the production of tonnage steel for flat products forautomobile industries, through various developments intechnology, including use of virgin input materials like DRI,hot metal, pig iron and iron carbide. This paper reviews theuses of hot metal in various steel plants of the world, andpresents the results obtained at Usha Martin Industries Ltd.,Jamshedpur.

MANAGING COAL & COKE CRISISAND ENHNACHING BLAST FURNACE

PERFORMANCE IN BHILAI STEELPLANT

Kaushik Basu, Shankar Dutta, S.K. Ghosh andS. Ahamad

Bhilai Steel Plant, Bhilai– 490001E-mail: [email protected]

Bhilai Steel Plant encountered a severe shortfall in cokeproduction owing to coal crisis. Several innovative measureswere taken to reduce coke rate and maintain optimum level ofproduction under the prevailing circumstances. The paperhighlights these details.

ENHANCEMENT OF PERFORMANCEOF BF # 3 IN BHILAI STEEL PLANT

Shankar Dutta, Kaushik Basu, N.K. Das, G.K.Adil and Sulaiman Ahmad

Bhilai Steel Plant, BhilaiE-mail: [email protected]

Blast Furnaces of Bhilai Steel Plant are heading towards aproduction of 7.0 million tonne of hot metal by the year 2011-12 with all seven Blast furnaces in operation. It is very muchnecessary to go for up-gradation & modernizations of all theBlast Furnaces. This paper highlights on how the up-gradationand modernization in Blast Furnace # 3 helps to achieve aproductivity (w/v) level of 2.4 T/M3/THM.

AN EXPERIMENT WITH SPONGE IRONIN BLAST FURNACE

S.K. Ghosh , B.K. Prasad , Jagdish Singh ,S. Ahmed , S.B. Singh

Bhilai Steel Plant, Bhilai – 490001E-mail: [email protected]

Sponge Iron, though extensively used in Steel making can beused in Blast Furnaces as well. At Bhilai Steel Plant, a trialwas conducted with the usage of Sponge Iron in one of itssmall Blast Furnaces (1033 m3 useful volume). The ferrousburden constituted Iron Ore, Sinter and Sponge Iron. A cokesaving of 15 kg/thm was achieved with an equivalent productionrise of 52 t/day at a Sponge Iron consumption of 92 kg /thm.

STUDIES ON FLOTATION OF BHEL ATAND COAL FINES

Asha Immanuel RajuChemical Engineering Department

Andhra University,Visakhapatnam - 530 003

Email: [email protected],[email protected]

The present study deals with the development of a method forflotation of coal at Bhelatand washery. The optimum values ofvarious operating variable which greatly influence the flotationprocess on coal were determined. Flotation performance wasevaluated with respect to frother dosage, collector dosage,impeller speed on different feed size coal.

MANAGING BLAST FURNACEOPERATION DURING COKE CRISIS

PERIOD

P.K. Sinha, S.K. Dubey , S. Balaji and V.Dalmatov

Durgapur Steel Plant, Durgapur - 713203E-mail: [email protected]

Due to blanking of tuyeres all temperatures of the Bosh areastarted coming down to as low as 45- 500C from a level of150-2000C showing a considerable build up in Bosh. After onemonth the blank tuyeres in all the three furnaces are rotated tominimise the damage. Tuyeres are being opened in the furnacesas the Coal / Coke position has started improving. Productionlevel has started touching and crossing 6,000 tons markslowly.

A7

IT ENABLED QUALITY MANAGEMENTTHROUGH INTEGRATED

PRODUCTION PLANNING ANDCONTROL SYSTEM AT DURGAPUR

STEEL PLANTU.S. Gupta, K.K. Mohanty, A.K. Paul, D. Bose

and A. KananSinter Plant, Durgapur Steel Plant, SAIL,

Durgapur - 713203E-mail: [email protected]

Durgapur Steel Plant has developed an Integrated ComputerisedProduction, Planning and Control (PPC) System. The systemactivity starts with receipts of orders electronically from ourCentral Marketing Organisation (CMO) through the intra-network “SAILNET.” Once the order is received and accepted,the process of planning and scheduling starts and productiontakes place. Benefits of this system are discussed.

IMPROVEMENT IN PRODUCTIVITY OFSINTER PLANTS, DSP

A.K. Ray*, B. Choudhary*, A.C Nigam*,L. Mahato* and S.A. Balaji**

* Sinter Plant, Durgapur Steel Plant, SAIL,Durgapur - 713203

** RDCIS (Durgapur), Centre, SAIL,Durgapur - 713203


Durgapur Steel Plant has 3 sinter machines, SP#1 having 2machines of area 142.7 m2 each and suction of 300 – 350mmWC and SP#2 having modern machine of area 180 m2 andsuction of 1400 mmWC. This paper discusses the variousmeasures implemented in both SP#1 & SP#2 for improvingthe productivity of sinter machine.

GOOD BALLING – A PREREQUISITE INTHE ART OF QUALITY SINTER

PRODUCTIONMurlimohan, V.K.C. Shekar and S.K. Basar

Sintering Plant – 3, Sinter Bhawan.Bhilai Steel Plant, Bhilai - 490001.

E-mail: [email protected],[email protected]

In the latest Sinter Plant-3 of Bhilai Steel Plant, a unique trialwas conducted to find out the equations which can be helpfulfor finding the optimum speed of mixing cum noudilising drum(MND) at which best balling can be obtained. Based ongenerated data, a linear equation was derived by which speedof MND is continuously regulated for getting maximum balling.It helps in drastic reduction of permeability fluctuation resultinghigher productivity with in consistent quality.

ENHANCING THE PERFORMANCE OFTHE BELL FURNACES OF BSP –

A REVIEWR.R. Nagare

Blast Furnace, Bhilai Steel Plant, BhilaiE-mail: [email protected]

Bhilai has three smaller Blast Furnaces of 1033 cuM volumehaving conventional two bell system and with rotary chargingunit facility in BF # 3. Stock house conveyerisation and topequipments monitoring modified with PLC control system. Theproductivity was increased from 1.2 to 1.8 T/Cu.m/day tillyear 2000. Further improvement started after implementationof several ideas and innovations; Benchmarking performanceof BF#1 was achieved due to less downtime, use of BLT type,Charging pattern, mixing of non-coke material, better screeningof coke by frequency control. BF # 3 productivity and cokerate improved further due to tar Injection & Oxygen enrichmentfacility provided.

IMPLEMENATION OF ISO-9002QUALITY ASSURANCE SYSTEM IN

A SPONGE IRON PLANTSmitha Raithatha

Dept. of Metallurgical EngineeringGovt. Engineering College, Raipur


Sponge iron industries are fast becoming a key player in theIndian steel sector. However, there is not much awareness aboutquality or quality requirements in this industry at present. Thisindustry has to commit itself to quality and optimise itsoperations and practices, which can be done by subscribing toa Q.A.S as ISO-9002. In this paper an attempt has been madeto highlight the procedure for getting ISO-9002 certificationfor a sponge iron plant.

UTILISATION OF IRON ORE FINESGENERATED IN BHILAI

STEEL PLANTR.K. Agarwal and R Haldar

Bhilai Steel PlantE-mail: [email protected]

In Bhilai Steel plant, more than 8 million tones of non-usableiron ore fines have been dumped leading to large scaledegradation of agricultural land, deforestation, air and waterpollution. Present study suggests some innovative ways ofagglomeration and utilization of these wastes. These low-gradeiron ore agglomerates can be used directly in furnaces andConverters as coolant.

A8

DEVELOPMENT OF SPECIAL STEELROLLING IN BHILAI STEEL PLANT

N.K. Prasad and R HaldarBhilai Steel Plant, Bhilai


Bhilai Steel Plant has successfully developed and commerciallyadopted processes namely, Accelerated Cooling whicheliminates normalizing process, Temperature Control Rolling(TCR) and Normalizing Rolling (NR) impart uniquecombination of high strength toughness and weldability,Isothermal Treatment of Slabs improved the acceptance ofthicker plates on ultrasonic testing.

CONTRIBUTION OF BOKARO STEELPLANT IN THE DEVELOPMENT OF

HIGH STRENGTH MICRO ALLOYEDSTEELS FOR DEFENCE, STRUCTURAL

AND AUTOMOBILE INDUSTRY

M. Mandal, D. Chatterjee, M.M.S. Sodhi,R.S. Chowdhary and S. Ghosh*

R & C Laboratory, Bokaro Steel Plant, Bokaro SteelCity, Jharkhand-827011


With the introduction of state of the art Vertical Bending TypeConcast unit along with Secondary Refining facilities, BokaroSteel Plant took up regular production of micro alloyed steelin the E34, E38, BSK 46, SAILMA,IS 8500 Fe540B, API 5LX52/60/65, E-460/500/550, DMR249A,HSCR-26/35 grades.Clean steel produced through BOF- SRU-CC route havingbetter bend properties and a clean surface was accepted by thecustomer.

PRODUCTION OF CANNON TUBESTEEL THROUGH EAF – LF/VD – ESR

PROCESS

Ashutosh Kumar and R.N. JhaMetal and Steel Factory, Ishapore, 24 Parganas (N),

WB – 743144

Cannon tube steel is used for cannon tube manufacture fortank.. Previously the production of cannon tube steel was madeby using EAF steel making. There was huge rejection in thisroute and also shorter life of the product. EAF - LF/VD – ESRroute has been taken into practice to produce cannon tube steelwhere the rejection became extremely less & subsequentlyincreased life cycle.

IMPROVEMENT IN THEPERFORMANCE OF EDD QUALITYSTEEL AT BOKARO STEEL PLANT

WITH THE HELP OF MODIFIED STEELMAKING AND ROLLING PRACTICES

B. S. Minz, M. Mandal, M.M.S. Sodhi, S. Ghoshand P. N. Tripathy*

Bokaro Steel Plant, Jharkhand-827011E-mail: mandal_ [email protected]

In order to increase the market share of EDD steel (both HR& CR) for the automobile and cold reducer segment quality ofEDD steel (C=0.04%) has changed a lot and demand for highelongation along with high formability is required after coldrolling and annealing. Currently with the efficient practice ofcombined blowing technology (CBT) in SMS-2 along withsteel refining unit, slab casters, walking beam type slab reheatingfurnace, modernized finishing stand and run out table withlaminar jet cooling has made it possible for BSP to fulfil mostof the Indian demand of high formable extra deep drawingquality steel for automobile industry.

PHOSPHORUS IN IRON & STEELP. K. Tripathy, B. Bhattacharya and A. K. Das

Tata Steel, Jamshedpur –831001Email: [email protected]

This paper deals with measures of producing low phosphorussteel modification of slag chemistry and slag volume, use ofsix hole lance, bottom stirring during the blow, optimization ofslag chilling process near the blow end etc. The influence ofphosphorus on steel quality, the useful effects of phosphorusand its applications in some special grades of steel, e.g. highstrength steels for automobile industries is presented.

INFLUENCE OF BLOW PRACTICES ONEFFECTIVENESS OF SLAG SPLASHING

IN BOF VESSELS: A CASE STUDY OFVISAKHAPATNAM STEEL PLANT

K. Srinivas*, K. Anil Kumar*, G. Rajaraman**,Y. Lokeswara Rao**, S. Rajneesh# and B. Deo#

*Steel Melt shop, Visakhapatnam Steel Plant,Visakhapatnam-530031

**Quality assurance and Technology Development,Visakhapatnam steel plant

#Department of Materials and Metallurgical Engineering,IIT-Kanpur, Kanpur 208016

The retained slag after tapping is sprayed on to vessel liningby blowing nitrogen. slag samples, with and without reblow,have been analyzed by XRF and examined under SEM. Tuningof blow practices to end at good turn down chemistry of andfluidity of slag has improved slag splashing and thereby BOFvessel lining life.

A9

PRODUCTION OF BALL BEARINGSTEEL THROUGH EAF-CC ROUTE

M.M. Mahato*, A.K. Das.* and S.N.Sinha.*** Tayo Rolls Limited. Gamaria, Jamshedpur

** Dept. of Met. Engg. & Material Science, N.I.T.Jamshedpur

Sound quality Ball Bearing steel production can be achievedthrough E.A.F-C.C route economically and efficiently. It canproduce lesser amount of inclusions in steel. The morphologyof inclusion can be changed so that its removal becomes easyand convenient. Sulphur segregation in the billet is uniformlydistributed which reduces the number of rejection significantly.By this route it is possible to produce Ball bearing steel of anarrow range of sulphur and phosphorous upto the level of 0.010%.

SUCCESSFUL MAKING OF IS: 2879STEEL GRADE AT VSP

A.K. Rama Rao, G. Raghavendra Rao,G. Rajaraman and T. Goutham

Visakhapatnam Steel Plant, Visakhapatnam-530031E-mail: [email protected]

Generally the rimming steel having very low carbon contentcan’t be cast through continuous casting. The challenge is todevelop a suitable concast process to make IS: 2879 gradesteel. This involves modification of process for making EQgrade at VSP. This paper describes the journey towardssuccessful making of this grade with available resources to killthe steel with aluminium of <0.012% with alternate de-oxidizers.

PRODUCTION OF QUALITY STEELSUSING TUNDISH METALLURGY

TECHNIQUESSubhabrata Sen Gupta

M.N. Dastur & Company Pvt. Ltd, KolkataEmail: [email protected]

The modern tundish has become an efficient metallurgicalreactor, through improvements in flow modification devices,development of ceramic filters, inert gas stirring, use of syntheticslags etc. Major control functions possible in the tundish todayinclude control of fluid flow, oxidation prevention, improvementin cleanliness, inclusion morphology control, fine tuning ofcomposition and control of superheat. Such refinements andcontrols lead to better steel quality, increased yield of primematerial through lower rejections and grade diversionsimproving overall cost effectiveness. These techniques can alsobe employed for production of ultraclean and defect-freesteels.

PORE EVOLUTION DURINGSINTERING OF Fe-2Cu-0.9C ALLOYS

M. Das, A. K. Jain, A. Dutt, V.Tripathi, A.Upadhyaya

Department of Materials and Metallurgical Engineering,IIT-Kanpur, Kanpur -208016


To achieve high dimensional precision in P/M steels, typicallythe composition and sintering parameters are so adjusted so asto have very little dimensional change during sintering. Thispaper discusses the sintering behavior of Fe-2Cu-0.9C alloys.Fe-Cu system is transient liquid phase sintered when Cu contentis less than 9 mass %. Thus, ‘secondary’ pores are created. Tocontrol or compensate compact swelling, controlled additionof carbon is done which increases the strength of sintered Fe.Despite having the same porosity level, the nature of pores insintered condition is very different than those in the as-pressedsteels. This study examines the effect of sintering temperatureon the pore morphology and mechanical properties of sinteredFe-Cu-C steels.

WORKING EXPERIENCE OFDESULPHURISATION PRACTICE INBOKARO STEEL REFINING UNITS

A.K. Chakraborthy, S. Ghosh, K.K. Singh andK.L. Dewangan

BSP, SAIL, Bokaro-827001E-mail: [email protected]

In order to meet the desired properties of the end product andfor efficient calcium treatment for castability and inclusionshape modification, it is essential to bring down ‘Sulphur’ <0.010%. Understanding of the thermodynamics and kinetics ofthe slag metal interface at a basic and reducing atmosphereand the practice adopted at the ladle furnace has beencorroborated. Measures taken have helped the plant to achieveits objective of low sulphur steel production.

AUXILIARY FUEL INJECTION IN SAILBLAST FURNACES – PRESENT STATUS,

POTENTIAL AND FUTURE PLANS

B. Kedia, M.K. Lal, S. Chakrabarty and D.Mishra

Centre for Engineering & Technology, SAIL,Ranchi – 834 002

This paper deals with the present status, potential and futureplans for auxiliary fuel injection in SAIL Blast Furnaces. Thepaper also deals with plans during next 8 years for higheroxygen enrichment of blast, improvement in cooling systems,improvement in raw materials quality etc. to enhance BlastFurnace potential to accept higher auxiliary fuel injections.

A10

PROCESS DEVELOPMENT FORPRODUCTION OF LOW NITROGENSTEELS THROUGH ELECTRIC ARC

FURNACEB.V.R.Raja, N.Pal, A.S.Ray, P.L.Talwar and

N.P. JayaswalSAIL, Durgapur - 713208

With specifications calling for 60 ppm and below nitrogen insteel, studies were carried out for controlling nitrogen pick up.Accordingly, adoption of foamy slag practice, increasing DRIamount, no de-oxidation in EAF, lime stone cum slag mixtureusage during tapping followed by reduced treatment time andaluminium contents in LF/VAD units and applying argonshrouding during teeming resulted in achieving low nitrogencontents in steels produced through EAF.

STABILIZATION OF COAL DUSTINJECTION IN BF#6 AT BHILAI STEEL

PLANTR.N. Srivastava,* Ajay*, R.N. Singh*, Shanker

Dutta** and Sulaiman Ahmed***RDCIS, SAIL, Ranchi-834002

E-mail: [email protected]** Blast Furnace Department, Bhilai Steel Plant,

SAIL, Bhilai-490001

Through trials optimum coal injection rate was established.Keeping conducive blast parameters and slag chemistry, burdendistribution was adjusted to suppress peripheral flow andaccelerate central flow. To facilitate coal combustion and toarrest heat flux in bosh region, blow pipes with double lanceswere developed; sector charging of LD slag was introducedand bosh cooling was enhanced.

REDUCTION IN COKE RATE OF BLASTFURNACE NO.3, DSP THROUGH

ADOPTION OF LAYER CHARGINGS.K. Ojha*, P.K. Singh**, B.K. Das,

P.K. Sinha**, R.N. Singh* and V. Dalmatov***RDCIS, SAIL, Ranchi-834002

**Blast Furnace Department, Durgapur Steel Plant,SAIL,

Durgapur-713203, West BengalEmail: [email protected]

Charging of ferrous burden and coke in separate layers in blastfurnace results in improved gas utilisation, stable furnaceoperation and decreased coke rate. A two weeks trial of layercharging in blast furnace no.3 of DSP resulted in saving of3.7% in coke rate and improvement in productivity of 2.5% ascompared to mixed type of charging in base period.

USE OF UNDER BURDEN ANDVERTICAL PROBES IN BF# 5, BSL TO

IMPROVE GAS UTILISATIONTHROUGH BURDEN DISTRIBUTION

U.K. Banerjee*, S. Pal* and A.Mukhopadhayay**

*RDCIS, SAIL, Ranchi-834002**Bokaro Steel Plant, SAIL, Bokaro-827001


Based on the UBP and VP measurements, the burdendistribution has been carried out by adjusting the BLT matrixposition. The gas utilization efficiency, ETA CO [i.e. (%CO2/%CO2 + %CO)* 100] over the furnace height from the SL0position to almost the root of the cohesive zone has beendetermined. Formation of holding zones at ETA CO of 40/45% (Low temperature thermal Reserve Zone, LTRZ) and 30%(Thermal Reserve Zone TRZ) have been observed. Longerlength of the TRZ impairs gas movement through the centre ofthe furnace.

IMPROVEMENT IN SINTER QUALITYAND PRODUCTIVITY OF SINTERPLANT # 3, BHILAI STEEL PLANT

THROUGH AIR VOLUME CONTROLALONG THE SINTER MACHINEA. Mallick*, A.Das*, V.R.Deshmukh*,

A.G. Hazra*, D.K.S. Bhadoria*,D.P. Kushwaha**, Murli Mohan**,G.M.D. Murthy* and R.N. Singh*


** Sintering Plant # 3 Department, Bhilai Steel Plant,SAIL, Bhilai-490001

Plant scale trials were conducted to improve the yield of toplayer sinter by increasing heat holding time through throttlingof preferential wind boxes. Ignition temperature was optimisedand residence time of sinter mix was increased by controllingrotational speed of MND. These resulted in achieving 1.3t/m2/hr sinter productivity with consistent quality.

AUGMENTATION OF THE SYSTEMFOR LIME ADDITION TO IMPROVE

PERFORMANCE OF SP#2, DSPS.A. Balaji*, B.K. Das*, M.T. Raju*,

S.T. Selvan*, S. Kumar**, L. Mahato**,S. Jain** and S. Kundu**

*RDCIS SAIL, Ranchi-834002E-mail: [email protected]

**Durgapur Steel Plant, SAIL, Durgapur-713203

Lime has been recognized as one of strongest intensifier ofsintering process. Addition of lime fines improves the process

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granulation, improves the vertical sintering speed and resultsin overall increase in productivity. This paper describes thework done in augmenting the system for lime addition in SP#2,DSP utilizing the fines generated in New Lime CalcinationPlant. The industrial trial resulted in increase in SP#2productivity from 1.25 to 1.45 t/m2/hr.

USE OF DRI AS PARTIAL SUBSTITUTEOF SCRAP IN BOF AT ROURKELA

STEEL PLANT

R.K. Nath*, Y.P. Singh*, S. Ghosh*,S.N.S. Yadav*, P.C. Mahapatra*,

T.K. Pratihar*, S. Majumdar*, K.N. Jha*,P.C. Mohanty** and M.S. Barapanda**


** Steel Melt Shop-II, Rourkela Steel Plant, SAIL,Rourkela-769011

Rourkela Steel Plant is facing acute shortage of scrap bothw.r.t. quality and quantity. RSP and RDCIS jointly undertooka study to identify appropriate substitute to scrap and establishmethodology for its regular use in 150T BOF. Total 15 (Fifteen)trials were carried out with 100T DRI (Direct Reduced Iron)as partial replacement of scrap up to 35%. Technology for itsuse upto 45 kg/tcs of DRI has been established. The paperexplains in detail the methodology of usage, results achieved,problems likely to be encountered and measures to overcomethem for regular use of DRI in BOF.

EFFECTIVE USE OF RECYCLED LDSLAG IN BOF STEELMAKING

S.K. Sabyasachi*, A.K. Mukherjee,*P. Kumar**, S.S. Dutta*, P.C. Sahu** and

S. Mazumdar**RDCIS, SAIL, Ranchi-834002,E-mail: [email protected]

**Durgapur Steel Plant, SAIL, Durgapur-713203.

Use of recycled BOF slag at the start of blow helps in earlyslag formation and improves refining because of its prefusednature and free lime content. The paper describes the varioussteps taken on use of BOF slag in converter at DSP, Durgapur.Slag usage @ 10-15 kg/tcs resulted in saving of flux by6 - 7 kg /tcs.

DEVELOPMENT OF HOT PRESSEDMAGNESIA-CARBON ZONAL LININGIN 150T LF-CC LADLE TO INCREASELIFE TO 100 HEATS AT ROURKELA

STEEL PLANT

Swapan Kumar Garai*, Pulak Barua*,Nirmal Kanti Ghosh*, Purimetla Chintaiah*,

Manish Kujur*, Nayan Pal** andBijay Kumar Karan**

*RDCIS, SAIL, Ranchi-834002E-mail: [email protected] and [email protected]

**Rourkela Steel Plant, SAIL,Rourkela-769011

In Rourkela Steel Plant an average steel ladle lining life of 47heats was obtained in 2003-04. Wear profile of few campaignswere studied and based on wear profile a zonal lining designwas developed using three different quality hot pressed MgO-C bricks developed and manufactured in brick plant of RSPfor working lining of 150 T ladles. One set of developed zonallining installed in Ladle No. 1 in SMS-2 in January 2004.Theladle achieved a life of 106 heats with slag zone straight lifeof 57 heats which is highest among four integratedSAIL plants.

LIFE ENHANCEMENT AND COSTREDUCTION OF STEEL LADLES BY

IMPROVING MATERIAL AND DESIGNOF REFRACTORIES AT SMS-II, BSP

L. Tiwari*, R. K. Singh*, B. D. Chattaraj*,A. K. Bhattacharya**,

V. Kulkarni** and D. R. Dinda***RDCIS, SAIL, Ranchi-834002

E-mail: [email protected]**Bhilai Steel Plant, SAIL, Bhilai-490001

Ladle lining life at BSP was around 40 heats where18-20 heats were taken through VAD/ LF – RH route.Slag zones of these ladles were changed after 8-10 heats.Inhouse brick production with modifications ingranulometry, carbon content, introduction of plasticiser andchange in shape of bricks have improved the brick propertiesand enhanced the average lining life to 60 heats which includes25-28 secondary heats.

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IMPROVEMENT IN BOF LIFE BYDEVELOPMENT OF NEW LINING

DESIGN IN SMS-1, RSPP. Barua*, B. Kumar**, N.K. Ghosh*,B.K. Karn**, D.P. Chakraborti* and

L. Parthasarathy**R&D Centre for Iron & Steel, SAIL, Ranchi - 834002

E-mail: [email protected]**Rourkela Steel Plant, SAIL,

Rourkela - 769011

The average BOF lining life in SMS-1 was low due to adverseinput conditions, making of special grades of steel, less numberof blows etc. New lining design was developed based on studiesof wear patterns of past campaigns. A well directed action withrespect to slag passivation, modification and splashing/coatingwas undertaken. Zonal lining of barrel area with higher carboncontaining bricks improved the slag adherence. Themodification in lining practice, slag splashing/coating andchange in addition practices provided rewarding results withlife improved beyond 850 heats, which is a record for theshop.

UPGRADATION OF OPERATIONALEFFICIENCY FOR ENHANCED

PRODUCTIVITY AT STEEL MELTSHOP, ESSAR STEEL

D.Mojumdar*, G.D. Thaker*, Arun Kumar**,N.M. Jahagirdar*, A.Ghoshal**, KTR.Ramesh**

and Amritendu Roy**

*Steel Making Plant, Essar Steel Ltd, **Technology Cell, Essar Steel Ltd, Gujrat-394270


Steel makers throughout the world look for ways to lower theircost of operations in the face of stronger global competition.This paper discusses the journey of Steel Melt Shop, EssarSteel from a rated capacity of 1.6 to 2.4 MTPA and thereafter.It discusses the operating philosophy and the innovativeupgrades carried out in house at Essar Steel in line with thelatest advances of melt shop technology

QUALITY ORIENTED MAINTENANCEAPPROACH AT CONTINUOUS

CASTING PLANT, ESSAR STEELD. Mojumdar*, Mitesh Shah**, R. Sangwai**,P. Chaudhuri#, A.Ghoshal# and Anil Kumar#

*Steel Making Plant, Essar Steel Ltd, **ContinuousCasting Plant, Essar Steel Ltd,

#Technology Cell, Essar Steel Ltd, Gujrat-394270E-mail: [email protected]

The capability of a continuous casting plant with regard to theeconomical production of different grades as well as meeting

stringent quality requirements is largely determined by thecapability to integrate the manufacturing practices with efficientmaintenance practices. In its pursuit, Continuous Casting Plant,Essar Steel has adopted a consolidated “Quality OrientedMaintenance Approach”. This paper reviews the maintenancephilosophy adopted and implemented at the plant to achieve aworld-class quality.

CRANKSHAFT QUALITY STEELMAKING AT ALLOY STEELS PLANT,

DURGAPURS.K. Kar, S.K. Samanta and N. Pal

Research and control Laboratory, Alloy Steel Plant,Durgapur- 713208

Crank shaft quality application demands for a very clean steel.The paper in a nutshell demonstrates the requirements of CrankShaft Quality material, basic theory of production and capabilityof Alloy Steels Plant in exploiting and assimilating secondarymetallurgical technology in production of C.S.Q material.

PRODUCTIVITY ENHANCEMENT ATCONTINUOUS CASTER

Abhjit Sarkar, A.K. Tiwari, Ganapati Prasad,B. Reddi Prasad and I.A.K.Prakash

Jindal Vijayanagar Steel Limited, Toranagallu,Karnataka


Capacity of BOF shop at JVSL has been enhanced from 1.6mtpa to 2.5 mtpa without any major investment. Basic emphasiswas put to increase the productivity rate by increasing thethroughput from an average 2.4 tonnes/min to 2.8 tonnes/minby readjusting the machine K-factor and casting all slab widthsection at maximum speed. Reduction in machine turnaroundtime, increase in sequence length, abnormalities rate less than0.01 % and reduction in process losses has improved theproductivity rate with an average yield of 98.4 %. Further,additional facilities like Online Auto Mould width change andTube changer have been incorporated to increase the machineutilization.

PROBLEM OF SHRINKAGE AND COLDLAPS IN FOUNDRY

A.K. MisraVizag Steel Plant, Vizagapatanam - 530 032

A case study was undertaken at Foundry of Vizag Steel Plantwhere defects in casting such as slag holes, gas holes, blowholes, shrinkage and cold laps were found in some castings.By diagnosis of manufacturing process and observation it wasfound that by keeping pouring bush full during pouring havingproper bush size, a non-pressurized gating system, melt coldand pour hot and pouring temperature around 1390 oC we canreduce casting defects, mainly shrinkage and cold laps.

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OPERATING EXPERIENCE OFQUALITY STEEL MAKING IN TWIN

HEARTH FURNACESS.K. Roy and S.N. Singh

Bhilai Steel Plant, BhilaiE-mail: [email protected]

In the existing market, it is imperative to produce quality steelwith lower cost. Contrary to the existing trend of slag freetapping, in Twin Hearth Technology, tapping is done withconsiderable slag carry-over. By developing a typical syntheticslag from the waste of Lime Plant and adopting slag-aided de-oxidation practice, it has been possible to ensure consistentquality as well as cost effectiveness in the bulk steel producedfrom Twin-hearth furnaces.

ALKALI PROBLEMS IN BLASTFURNACES OF ROURKELA STEEL

PLANT

A.L. Kundu and H.S. PrakashRourkela Steel Plant, SAIL,

Rourkela-769 011

Alkali is considered to be a major concern for sustaining stableand smooth operation of a blast furnace. Alkali enters the blastfurnace through input materials e.g. coke, sinter, fluxes, ironand Mn ores and coming out through the slag, flue dust andsludge. But, there is always some alkali, accumulation insidethe furnace which is not desirable. An attempt has been madeto calculate the alkali balance and remedial measures havebeen suggested to reduce its input alkali and minimize theaccumulation inside the blast furnace.

COMMERCIAL PRODUCTIONOF LPG GRADE STEEL WITH

SUPERIOR QUALITYAND IMPROVEDYIELD AT ROURKELA

STEEL PLANT

Devasish Mishra* and U.C. Patra**R&C LAB, Rourkela Steel Plant, SAIL,

Rourkela-769 011

Rourkela steel plant in its quest for excellence and for achievingthe ever demanding LPG market has successfullycommercialized the production of deep drawing. This paperdescribes in detail about the technological modificationsthat were carried out for getting defects –free highquality deep drawing LPG coils along with close dimensionaltolerance.

EFFORTS FOR MAKING QUALITYSTEELS AT SMS-II OF ROURKELA

STEEL PLANT, ROURKELAS. Ghosh*, S. Chandrasekharan**, N.C. Jha**,M.K. Pradhan**, K.N. Jha*, B.B. Singh** and

M.S. Barpanda***RDCS, SAIL, Ranchi-834 002

E-mail: [email protected]** Rourkela Steel Plant, SAIL, Rourkela-769 011

The new steel melting shop of Rourkela Steel Plant is engagedin the production of flat products conforming to different sectorslike automobile, line pipe, electrical etc. Extensive processmodifications during ladle refining as well as casting havebeen carried out for the above grades of steels. Measuresdeveloped resulted in achieving carbon < 50 ppm.

A STUDY ON HOT METALTEMPERATURE DROP AT VARIOUSSTAGES AND MEASURES FOR ITS

IMPROVEMENT AT RSPA.L. Kundu, D. Chottopadhyay, M.K. Pradhan

and S.N. RoyRourkela Steel Plant, SAIL,

Rourkela-769 011

Significance of hot metal temperature is well known to ironand steel makers. All blast furnace operators desire to maximizehot metal and slag temperatures for smooth drainage and flowat a shortest time. Hot metal temperature drop from blast furnacecast house to steel melting shop no. II has been very high. Astudy was undertaken to find out the extent of drop in hotmetal temperature at various stages and necessary measureshave been taken for its improvement.

PROCESS MODELLING &AUTOMATION

AUTOMATION OF MOULD COOLINGSHOWER FOR CONSERVATION OFWATER AND INCREASING MOULD

LIFEShobh Nath Singh and Chaitanya Misra

SMS-1, BSP, Bhilai –490001Email: [email protected]

The automation of Mould Cooling Shower was designed toconserve water and increase mould life through controlledcooling. For providing effective mould coating (containingnatural graphite and water), the temperature of mould aftercooling in shower must be between 800 C to 1000 C. Thismodification has resulted in steep reduction in mouldconsumption and mould-stickers.

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STRATEGIES FOR DEVELOPMENT OFPROCESS CONTROL MODELS FORHOT METAL DESULFURIZATION:

CONVENTIONAL AND AI APPROACHESA. Dey*, R.K. Lingamaneni*, B. Deo* and

R. Boom**

* Department of Materials and MetallurgicalEngineering, IIT- Kanpur

E-mail: arghya@, [email protected]** CORUS, R&DT, Ijmuiden, Netherlands,


Control models are developed on the basis of plant data forhot metal desulphurization by using both conventional approachand also artificial intelligence approaches (AI) includingartificial neural nets genetic algorithm and fuzzy rule basedexperts system. A combination of conventional and AIapproaches provides a better model for process control on theshop floor.

EFFICACY OF ADVANCED VARIABLESELECTION AND REGRESSION

TECHNIQUES FOR ANALYSIS OF BOFDATA

Satish Kumar*, Mohd. Asif Khan**,Ajay Kumar Shukla*, K. Srinivas#, P.Nageshwar

Rao# and Brahma Deo*

*Department of Materials and MetallurgicalEngineering, IIT -Kanpur

**Department of Materials and MetallurgicalEngineering, IIT Madras

#Steelmaking Division, Visakhapatnam Steel Plant,Visakhapatnam-530031

Email: {satis@, akshuk@, bdeo@} iitk.ac.in

Operational data of BOF is analyzed by conventionalmultivariate analysis using eigen functions to plot Scree curve,the advanced Mahalanobis Taguchi System (MTS), and theapproach of heat and mass balance. Efficacy of differenttechniques is compared. The selected variables are then usedto develop artificial neural network (ANN) models forprediction of temperature of steel at tap.

PREDICTION OF YIELD STRENGTH OFHOT ROLLED MICROALLOYED

STEELS USING ARTIFICIAL NEURALNETWORK

Adity Ganguly, M.C. Sadhu and A. K. DasTata Steel, Jamshedpur –831001


Based on back-propagation Artificial Neural Network (ANN),a yield strength prediction model for micro alloyed grades

rolled at Hot Strip Mill of Tata Steel has been developed.Network architecture, such as number of hidden layers, learningrate etc. were decided using one-dimensional optimizationalgorithm. A data set of 1050 coils was used for training themodel. The final prediction root mean square error of the modelis 0.041 Avg. The model is being used for designing newchemistries and modifying chemistry or process parameters athot strip mill for micro alloyed grades.

HEAT TRANSFER ANALYSIS OF DRYSLAG FORMATION AND LANCE

SKULLING IN BOF VESSELSM. Malathi and B. Deo

Department of Materials and Metallurgical EngineeringIIT-Kanpur 208016


Heat transfer to lance inside the BOF takes place by conduction,convection and radiation inside the vessel and also by radiationfrom the hot spots formed in the jet impact zone. Heat transferanalysis is carried out to predict the dry slag formation periodwith the help of plant measurements on lance water temperatureduring different stages of blow.

MAPPING OF LADLE FURNACEPERFORMANCE AND ITS

COMPARATIVE EVALUATIONPradip K ThakurCET/SAIL Ranchi

The salient features of Ladle Furnace processing includes ladlerefractories stirring power, power input, Electrodes and powerconsumption, Carbon pick up, Gas content, Slagging and alloyaddition practice. The paper highlights the various measures tobe taken to evaluate LF performance and compare the samewith standard equipment for cost control and operationalimprovement.

DESIGN AND DEVELOPMENT OF ANIMPROVED EDGE CONTROL SYSTEMWITH RELIABLE HIGH FREQUENCY

POWER SOURCEB. Bhattacharya*, U.K. Chaudhary*, Prashant

Gupta**, K. Nafde*, S. Tripathy*,S.A. Hussain* and N.C. Pathak*

*Cold Rolling Mill, Bokaro Steel Plant SAIL, BokaroSteel City- 827011

* * RDCIS, SAIL, Ranchi-834002E-mail: [email protected]

Precise edge control is important to avoid side tracking andhaving better edge finishing during cold rolling and processingof a coil. Through in-house design and development of a noveland cost-effective improved edge control system with reliable

A15

high frequency power source using voltage regulator,transistorized oscillator and illumination system with bettercooling efficiency, it has been possible to reduce side trackingby 75% and electrical delays by 10% resulting in savings tothe tune of Rs. 54 lakh and solving the problem of non-availability of spares.

MODELING OF LIQUID FLOW IN THELOWER PART OF A BLAST FURNACE

V. Singh* and G.S. Gupta**

Department of Metallurgy, Indian Institute of Science,Bangalore-560012

**E-mail: [email protected]*E-mail: [email protected]

In the dropping zone of a blast furnace, gas flows counter-current as well as cross-current to the descending molten metaland slag. The low liquid flux rate is modeled using a forcebalance approach, because of its discrete nature. The gas flowhas been modeled using standard Navier-Stoke equations alongwith k-å model. Simulation results for the liquid distributionat the bottom of the bed are compared with published results.

COLD MODEL STUDY OF PRESSUREHYSTERESIS IN THE DROPPING ZONE

OF A BLAST FURNACES. Sarkar and G.S. Gupta*

Department of Metallurgy, Indian Institute of Science,Bangalore-560012

*E-mail: [email protected]

Raceway is an important zone in iron making blast furnace asit influences the aerodynamics of the furnace and smeltingprocess. The effect of raceway hysteresis on gas flow, using acold model, has been studied. Pressure hysteresis has beenobserved in some parts of the model. Experimental results arereported here and have been compared with theory. A goodagreement has been found between the two.

DEVELOPMENT OF FLOW MODIFIERSFOR HIGHER TUNDISH SEQUENCESN. Banerjee*, A. Bandopadhyay**, S. Das**,Madhusudan** S.K. Sahay* and D.S. Basu*


**Bhilai Steel Plant, SAIL, Bhilai – 490001

Improvement of tundish sequence length is desired by allsteelmakers. To achieve this goal, design of tundish turbulenceinhibition pad was carried out using physical modellingtechniques. The flow modifier was used at the 3-strand bloomtundish of Bhilai Steel Plant. It has shown advantages in terms

of high sequence size, lower tundish reoxidation and bettersteel properties. Regular use has resulted in improved plantperformance.

FLUID FLOW PATTERN IN COLDMODEL OF SLAB CASTER MOULD –

A PIV MEASUREMENTA. Paul, N. Pradhan, R. K. Singh and A.K. Ray

RDCIS, SAIL, Ranchi-834002Email: [email protected]

The fluid flow in a 0.4 scale water model of a slab castermould is investigated by Particle Image Velocimetery (PIV)system. The length of the set-up has been decided in such away that physical bottom of set-up does not affect the flowpattern in the mould. The experimental measurements showsin general double roll flow pattern in the mould. However,flow pattern is a strong function of flow rate and SENsubmergence depth. The meniscus oscillation increases withincrease in flow rate and decrease in SEN submergence depth.

OPTIMISATION OF HOT METALDESULPHURISATION REAGENT

CONSUMPTIOND.S. Vinoo, I.A.K. Prakash and S.S. Gupta


The performance analysis of desulphurisation hot metal withcalcium carbide based reagent shows that degree ofdesulphurisation and hot metal temperature had significantimpact on the consumption of reagent. Optimum consumptionof desulphurisation reagent is achieved by maintaining hotmetal temperature above 1360°C and degree of desulphurisationless than 80%. A computer based model has been developedto guide the operator to ensure optimum consumption ofdesulphurisation reagent

MODEL FOR PREDICTION OF STEELTEMPERATURE IN BOF-CCP PROCESS

D. Satish, I.A.K. Prakash and S.S. GuptaJindal Vjayanagar Steel Limited, Vidyanagar – 583275


In order to control superheat of steel being supplied tocontinuous casting machine a simplified real time model hasbeen developed to predict steel temperature at different locationsstarting from tapping from converter, Argon Rinsing Station,Ladle Heating Furnace and transportation of ladle from LHFto CCP. The model has been developed with minimum numberof inputs to ensure operator friendliness. The model predicationis within + 5°C for more than 90 % of the heats.

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MODELING OF TEMPERATUREPROFILE OF HOT CHARGED SLABS IN

HOT STRIP MILL RE-HEATINGFURNACE

S. Manjini and R.K. SharmaJindal Vijayanagar Steel Limited, Vidyanagar – 583275.


A mathematical model has been developed to obtain thetemperature profile of the slab at any instance in the re-heatingfurnace at Jindal Vijayanagar Steel Limited. The direct hotcharged slabs attained uniform re-heating temperature aheadof the soaking zone in the case of fixed re-heating time study.The re-heating time required to achieve the desired slab exittemperature for hot charged slabs were found to be less than2 hours 15minutes which increases the throughput of the re-heating furnace from the designed capacity of 250t/h to morethan 300t/h.

AN INSIGHT INTO ENERGY SAVINGMEASURES IN AN INTEGRATED

STEEL PLANTA.K. Vaish. S.D. Singh, R.K. Minz and

D. BandyopadhyayNational Metallurgical Laboratory -

Jamshedpur-831007E-mail: [email protected]

The manufacture of steel involves the huge amount of energyin an integrated steel plant. The cost and productivity of steelmaking process largely depends on the quality and consistencyof hot metal produced by the blast furnace and its subsequentrefining. The present communication deals with various energysaving measures during iron and steel making process in anintegrated steel plant.

USAGE OF PROCESS MODEL TOOPTIMIZE SINTER PLANT

OPERATIONDieter Bettinger, Bernhard Schürz, Klaus Stohl

and Sudip SenVOEST-ALPINE Industrieanlagenbau GmbH

P.O. Box 4, 4031 Linz, AustriaE-mail: [email protected]

In order to ensure smooth and cost effective sinter plantoperation VAI expanded and improved its proven, powerfulsinter plant automation package consisting of TechnologicalControl Systems (running on PLCs) and of online mathematicalprocess models (running on PCs). The Paper gives a goodoverview of the system functionality.

GRAPHICAL ANALYSIS OF BLASTFURNACE OPERATION

R.N. Ray, Anupam Baneerjee and S. Pramanik*Dept. of Metallurgical Engineering, NIT, Durgapur*Blast Furnace, Durgapur Steel plant, Durgapur -

713203E-mail: [email protected]

The understanding of blast furnace operation can be helpedgreatly by exploring relationship between (O/ Fe) and (O/C)(operating diagram). In constructing the operating diagram linewe have considered stoichiometry and enthalpy demand forknown inputs and outputs. The conclusions are drawn fromthe deviation of operating line from ideal one in regard to CO/CO2 ratio and coke rate.

SECONDARY PROCESSING

CHARACTERIZING HETEROGENEOUSDEFORMATION IN OPEN DIE

EXTRUSION OF AISI 1020 STEELSK. Srinivasan* and P. Venugopal**

* Dept. of Metallurgical and Materials Engg., N.I.T.K.,Surathkal

** Metal Forming Lab, I.I.T., Madras, ChennaiEmail: [email protected]

Metal forming processes involve heterogeneous deformationwherein shear strain rates are not zero. Open die extrusion isno exception. But it is found to be very less compared toconventional extrusion. This heterogeneity is characterised andstudied by simple hardness measurements in the deformationzone of the extrude. This hardness is related to strain andstress by constitutive equations which have been establishedby simple asymmetric compression test. Therefore any localvariations can be inferred. The tests were carried out at roomtemperature in a 100 ton Hydraulic Press at a strain rate of0.07s-1. The lubricant used was Molybdenum disulphide.

STABILITY OF STRIPS ON LONGRUNOUT TABLES: MODIFICATIONS AT

BOKARO HSMAlok Verma, N. K Gautam and A. S Mathur

Hot Strip Mill, Bokaro Steel Plant, SAILJharkhand-827011

Stability of strips on very long runout tables with down coilershas been a problem in hot strip mills which utilize the ROT forextensive air and water cooling. The problem was studied withvideo filming. Mechanical design of coiler strip switches waschanged and PLC software of guide operating scheme wasmodified to increase the stability of strip, leading to cobblefree operation and increase in productivity at Bokaro steelplant.

A17

IMPROVEMENT IN SHAPE OF COLDROLLED STEEL STRIPS WITH

STEPLESS CONTROL SYSTEM OFHYDRAULIC ACTUATORS

A.K Marik, P.C. Bhowmik*, Rakesh*,D. Sengupta and K. Nafde*RDCIS, SAIL, Ranchi-834002* Bokaro Steel Limited, SAILEmail: [email protected]

In order to meet the customer’s requirement and improvedcold rolled (CR) strip shape, the modified roll balancing systemwith stepless control has been designed and installed at laststand of TCM-I and SPM-I to correct the shape defect as faras possible manually, with the provision for varying of the rollseparating force from 0 to 100 bar by the operator. The modifiedwork roll bending system has resulted in improved strip flatnessby 20% and helped to correct the edge waviness and centrebuckles on the strip.

DEVELOPMENT ANDCOMMERCIALIZATION OF LOW

CARBON CORROSION RESISTANTTMT REBAR/WIRE ROD (Gr.Fe 415)

AND DRAWING QUALITY WIRE ROD(SWR 10/14) WITH 0.10% PHOSPHORUS

J. Singh*, D. B. Shrivastava*, S. N. Singh*,T. C. S. Prasad* and B. K. Panigrahi**

*Bhilai Steel Plant** RDCIS, SAIL, Ranchi-834002


A higher phosphorous (0.10% P) low carbon (0.10% C) hasbeen developed for high strength TMT rebar (Gr. Fe 415) anddrawing quality wire rod (SWR 10/14). The TMT rebar (dia.32 mm) is characterized by exceptionally good Charpy impacttoughness (160 Joule at RT, DBTT: -50° C) and weldability.The SWR wire rod (dia. 8/10 mm) could be drawn to 2.0 mmand 2.6 mm dia. Wire by batch and continuous processesrespectively and used as fence wire. Phosphorous additionimproved atmospheric corrosion resistance due to presence ofphosphorous in the exposed surface of wire.

IMPROVEMENT IN COLDHEADABILITY BY OPTIMIZING POST

ROLLING COOLING STRATEGYAtanu Banerjee, Arunangshu Halder, Sudipto

Sarkar, Indranil Chakraborty andM. D. Maheshwari *

Tata Steel, Jamshedpur –831001E-mail: [email protected]

Cold heading is the most critical operation in fastenermanufacturing. In cold forging, head of a bolt undergoes 80%

upsetting causing splitting from the base of surface defect.Sub-critical surface defect can become super critical if strengthof the material is high. The present paper discusses cause offailure during cold heading operation, effect of coolingparameters on laying head temperature and phasetransformation, change of water box cooling parameters andlaying head temperature to improve cold headability.

PRODUCTION OF WIDE PLATES INHIGH PURITY STAINLESS STEEL MDN

304L (REFINED)S.N. Jha

Mishra Dhatu Nigam Limited, HyderabadE-mail: [email protected]

MDN 304L (Refined) is high purity stainless steels whereelements like carbon, silicon, phosphorus and boron levelshave been controlled at very low levels. The steel ischaracterized by high degree of cleanliness, narrow band ofchemistry, high degree of structural integrity and predictableresponse to heat treatment. The manufacturing technology hasbeen established using commercial Electric Arc Melting,Vacuum Induction Refining and Electro slag Remelting. MDN304 is free from intergranual corrosion because of extremelylow levels of carbon, silicon, phosphorus, sulphur, and non-metallic inclusions.

IMPROVEMENTS AND INNOVATIONSIN ROLL TECHNOLOGY FOR

PREVENTION OF ROLL FAILURESUmesh Singhal

Tata Steel, Jamshedpur –831001

Roll failures can be avoided through proper design of thespecifications and physical dimensions, roll pass design,maintenance and usage. The Paper describes several suchpreventive measures against roll failures in the Flat and LongProduct Mills of Tata Steel which have contributed towardsreducing roll consumption over the years.

AN INVESTIGATION INTO THE WELDBREAKAGES IN COLD ROLLED

STRIPS AT HOT DIP GALVANISINGLINE OF BOKARO STEEL PLANT

M. Singh, S. Srikanth*, A.K. Mukherjee andK. Nafde

Bokaro Steel plant, Bokaro-827001Email: [email protected]

An assessment of the welding machine for reconditioning andupgradation indicated that the changeover from ignitroncontactors to solid state thyristors for phase shift current control,the adoption of microprocessor-controlled selection andimplementation of pre-programmed weld schedules for differentgauges and the retrofitting of a knurl dressing system are most

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advantageous and imperative for achieving a sound, improvedand consistent weld quality in HDGL.

QUALITY IMPROVEMENTS OFFORGED CRM WORK – ROLLS

A.K. VermaForged Roll Division, Gontermann-Peipers (India) Ltd.,

Kolkata (W.B.)Email: [email protected]

The increasing requirement for critical surface finish and textureof flat rolled product, mill productivity and roll shop efficiencydemands the manufacture of quality CRM work rolls of highwear resistance in modern cold rolling mills. The paperdescribes the advancements made in the steel melting, forging,heat treatments and quality control measures taken for thequality improvements of the forged work rolls which are basedon experience with rolls manufacturing since last 3 decades.

COMPARATIVE EVALUATION OFTHERMO-MECHANICALLY TREATED

MICRO-ALLOYED STEELSCONTAINING NIOBIUM AND OR

VANADIUMS.K. Sen*, V. Kumar*, S.K. Dhua*, M.S. Prasad*,Kundan Prakash*, C.B.Sharma,* P.K. Dutta**,C.D. Singh*, A. Ray*, S. Bhattacharyya** and

G.M.D. Murty**RDCIS, SAIL, Ranchi-834002

E-mail: [email protected]**Bhilai Steel Plant, Bhilai-490001

Theoretically calculated Tnr, r3 and Bs temperatures help toexplain the microstructure, and mechanical properties of thesteels. 0.04% Nb steel and 0.04 % Nb 0.035% V steel havegood tensile and impact properties. These two steels havetheoretical Tnr and r3 temperature as 966.76, 1007.660C and740.30C, 744.40C respectively. Present results show thatoptimum Al, minimum banded structure, fine ferrite grain size(8-9.5 micron) and rolling below Tnr will lead to betterproperties in Nb, V microalloyed steels.

IMPROVEMENT IN PRODUCTIVITYAND SURFACE QUALITY OF

CONTINUOUSLY ANNEALED COILSP.P. Sengupta*, P. Kumar*, S. Rath*,

G.K. Sinha*, A.K. Marik*, D. Sengupta*,M. Roy** and M. Singh**

*RDCIS, SAIL, Ranchi-834002E-Mail: [email protected]

**Rourkela Steel Plant, Rourkela-769 011, Orissa

Increase of line speed resulted in improved productivity ofcontinuously annealed coils at CRM, RSP by 27%. Increased

heat input to furnace and modifications of annealing cycle hadresulted in increased line speed. The Surface Reflectance ofannealed coils was increased from 75 to 90% by introductionof high pressure rinsing system and use of a superior cleaningagent.

STUDY ON CAUSES AND PREVENTIONOF HOT STRIP MILL BACKUP ROLL

SPALLINGK.K. Singh, C. Mandal, R.S. Verma, P.C. Das

and S. ChakrabortyRDCIS, SAIL, Ranchi – 834002


The reasons of frequent incidence of spalling of backup rollsof Hot Strip Mill of Bokaro Steel Plant have been analysed.The remedial measures evolved include shortening of campaignlength and maintaining an optimum dressing amount. The useof superior rolls material has been suggested for prolongedcampaign length and reduced roll consumption.

MILL STATUS MONITORING ANDCONTROL SYSTEM FOR RAIL AND

STRUCTURAL MILLDeepak Kumar*, Anup Prasad*, N.

Harikumar**, S.K. Sablok*, Ranjana Muley**,S.K. Roy*, S.S. Verma** and N. Neogi*

*RDCIS, SAIL, Ranchi-834002E-Mail: [email protected]

** Rail & Structural Mill, Bhilai Steel Plant, SAIL,Bhilai-490001

E-Mail: [email protected]

A mill status monitoring system has been designed, developedand commissioned at Rail & Structural Mill of Bhilai SteelPlant using industry standard communication network andPLCs. This system is capable of checking pre-rolling millreadiness, online monitoring of operation mechanisms andcontrolling through forbiddance in case of abnormality to helpin reduction of cobbles.

BASE CAPACITY ENHANCEMENT OFHOOD ANNEALING FURNACES AT

CRM, RSPA.K.P. Singh, S.K. Ghosh, S. Parida, S.T. Selvan

and Y. SinghRDCIS, SAIL, Ranchi – 834002


The base capacity of hood annealing line was increased from30T to 42 Tons through various design modifications. Earlierthe individual bases were used to process only two coils perbatch, which can now process three coils. The incorporateddesign modification has been able to increase the batch charge

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weight for hood annealing from 28 Tons (approx.) to 42 Tons(approx.), resulting in increase in productivity of base from1.36 t/hr to 1.66 t/hr.

DEVELOPMENT OF LOW CARBONSTEEL HOT ROLLED STEEL FOR

DIRECT FORMING APPLICATIONSU.B. Jagdale, S.K. Tiwary, Deepak Gupta and

A.M. KulkarniEssar Steel Ltd. Hazira, Surat, Gujrat-394270


The mechanical properties achieved in the thickness range of2.9 to 4 mm were in the range of YS –20- 22 Kg/mm2, UTS33-35 Kg/mm2 and % El – 45% Minimum along with YS/UTSratio of 0.6–0.70. Trials were taken at different customers formaking lower and upper half compressor shell of refrigeratoras well as air conditioner and material has been formedsuccessfully without any difficulties. Now we are supplyingthe material in bulk for various customers.

TRACKING AND ELIMINATION OFROLLED IN SCALE DURING HOT

ROLLING OF STEELK.S. Choudhary, S. Chattopadhyay, Babu

Venkatesh and Vichore MukulEssar Steel Ltd., Hazira, Surat,

Gujrat-394270E-mail: [email protected]

The main focus of the study was on the elimination of randomscale (RS) occurrence in the extremely surface critical gradeslike Interstitial Free steels (IF), extra low carbon steels (EDD)and steels designed for greater than 90% reduction during coldrolling. The incremental actions were taken embracing newconcepts to reduce the problem. With the help of above initiativeit was possible to reduce the RIS problem thereby decreasingthe quality rejection at Mill as well as at Customer’s end.

CONTROL OF EDGE DEFECTS INCOLD ROLLING GRADES DUE TO

ALUMINUM MARKING ON SLABS ATESSAR STEEL LTD.

Deepak Gupta and A. M. KulkarniEssar Steel Ltd., Hazira, Surat,

Gujrat-394270E-mail: [email protected]

A large number of coils were observed at the service centreand a very strong locational co-relation emerged as these defectswere observed to occur in coils at a location which correspondsto the aluminium marking on the slabs. Close examinationrevealed that burrs were formed at the edges and some of theseburrs were rolled on the surface of the coil. These rolled- in-

burrs get chipped off and leave edge cuts on the surface of thecoils. Trials were conducted with the above parameters andthis resulted in elimination of the edge defects in cold rollinggrades.

ROLL FAILURES IN HOT STRIP MILLS– AN ASSESSMENT

Tanmay Bhattacharyya, Sudipto Sarkar, SBhaskar, J C Pandey and M D Maheshwari

Tata Steel, Jamshedpur – 831007E-mail: [email protected]

Recently number of roll failures ascended in the roughing milland the first two stands of the finishing mills of hot strip millof the authors’ works. For roughing mill the rolls failedpredominantly due to overload. For finishing mills, failureswere caused by thermal shock, left over small cracks etc.However, some roll manufacturing abnormalities (e.g. bondabnormality, improper nodularization of core) were significantlyidentified. This paper details the indepth study carried out tounderstand the reasons for failure.

REDUCING SCALE-LOSS DURING HOTROLLINGS.P. Shenoy

Steel Plant Specialities, 211, Raikar Chambers,Govandi East, Mumbai- 400 088


Hot rolling involves controlled plastic deformation of heatedmetals and alloys into desired long or flat products. Mechanismof scaling and decarburisation and the attendant harmful effectsare explained. A unique ESPON coating process, developed byan Indian firm, is found to be a economical method to minimizethese problems.

HOT SLAB CHARGING IN HOT STRIPMILL - AN EFFECTIVE TOOL FOR

PRODUCTIVITY AND ENERGYOPTIMIZATION

Suneel P Raichur, R.K. Sharma, D.K. Tripathiand S.P. Srivastava


JVSL has successfully introduced hot charging of slabs fromcontinuous casting machine to reheating furnace of HSM. Thepercentage of hot charging has increased form 36 to 75% duringthe 27 months of its operation with the daily charging reachinga level of 95%. This practice has resulted in an increase in thefurnace productivity (27 to 60%) and consequent decrease infuel and power to the extent of 9.5%. This in turn has madeit possible for the mill to produce more from one furnace atlower power and fuel rate.

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STANDARDISATION OF ROLLINGPROCESS FOR FLAT PRODUCTS

Sandeep Hegde* and R.K. Yadava***Jindal Vijayanagar Steel Ltd., Vidyanagar – 583275

**MNIT, JaipurE-mail: [email protected]

The main goal of the rolling process is to determine theoptimum means of producing the best quality rolled productsat optimum cost. The optimization criteria of rolling operationmay vary depending on product requirement. Based on studiesof the rolling operation of Bokaro Steel plant, Bokaro andJindal Vijaynagar Steel Ltd., Bellary (Karnataka), an attempthas been made for the development of an off-line rolling processto predict the capability for flat products of different grades ofsteel.

STUDY OF BAKE HARDENABILITY OFEXTRA DEEP DRAWING AND

INTERSTITIAL FREE STEEL SHEETSSUITABLE FOR AUTO BODY

APPLICATIONA.K. Vaish, M.M. Humane, A.V. Nachankar*,

P.K. De, D.V. Moghe* and S.U. Pathak*National Metallurgical Laboratory -

Jamshedpur-831007*Visvesvaraya National Institute of Technology, Nagpur


Bake hardenable steel sheets are preferred for auto body panelsdue to their high forming rates. They exhibit capacity forsignificant increase in strength through work hardening duringpart forming and strain aging during paint baking. The bakehardenability of EDD and IF steel sheets have been studiedwith regard to varying time and temperature conditions duringannealing.

VAI STECKLE MILL TECHNOLOGYECONOMIC AND FLEXIBLE

SOLUTIONS FOR HOT-STRIP ANDPLATE PRODUCTION

G. Thaller, G. Djumlija and W. Gruber – VAI/Austria

N. Champion and A. Marples – VAI-UK/U.K.E-mail: [email protected]

VAI has been involved in nearly all major Steckel mill projectsin recent years, for new installations and revamps. This paperprovides various Steckel Mill and Plate-Steckel Mill solutionsoffering a highly attractive process route for steel producers ateconomic investment for production of carbon, stainless andspecial steel grades.

A COMPARATIVE STUDY OFMICROSTRUCTURE AND TEXTUREFORMATION IN A (Ti+Nb)- IF STEEL

AFTER ULTRA HIGH LEVELS OFCOLD ROLLING AND ANNEALING

Rajib Saha and R.K.RayDepartment of Materials and Metallurgical Engineering

IIT- Kanpur, Kanpur-208016E-mail: [email protected]

The present investigation deals with texture development afterultra high levels of cold rolling upto 98% followed by annealingin a (Ti+Nb)- IF steel. The results have indicated that increasingthe amount of cold reduction from 90 to 98 percent makes thekinetics of recrystallization sluggish. The textures andmicrostructures of the steel samples correlate well with coldreduction levels

OPTIMIZATION OF HEAT TREATMENTOF WHEELS FOR IMPROVED

MECHANICAL PROPERTIES ANDPRODUCTIVITY

U.S. Biswas, A. Kannan, B. Roy, R.S. Tewari,A. Bhatacharyya and A.K. Mukherjee

Durgapur Steel Plant, Durgapur-713203E-mail: [email protected]

Heat treatment of wheels plays a vital role in achieving thedesired mechanical properties within the stipulated chemicalcomposition. This required a re-look the entire heat treatmentcycle of wheels for improving their mechanical propertiesincluding Y.S. to T.S. and fracture toughness on a consistentbasis. This paper deals with various studies conducted in thisconnection and results thereof for BG Coaching wheels.

EMERGING TECHNOLOGIES

EFFECTIVE BORON IN STEEL -SIGNIFICANCE AND ONLINE

DETERMINATIONAtanu Banerjee, K.N. Udpa, Sudipto Sarkar,

Indranil Chakraborty and M. D. Maheshwari *Tata Steel, Jamshedpur –831001


Small amount of boron remarkably improves hardenability ofsteel. Soluble part of the total boron in steel effectively increasesthe hardenability. Balance of the amount form precipitates anddoes not contribute to the hardenability of the steel. Existingmethods to determine soluble boron content in steel are tedious.The paper describes the trial with optical emission spectroscopy,which determines soluble boron content in steel within thestipulated time of steel making. The results obtained on certifiedmaterials using the technique are also presented in the paper.

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THEORETICAL AND PRACTICALASPECTS OF MgO-C REFRACTORY

WEAR IN BOF VESSELS ANDTRANSFER LADLES

Pramod Kumar Gupta*, Arghya Dey*, Brahma

Deo*, K. Srinivas**, P. Nageshwar Rao**,S. Ghosh#

*Department of Materials and MetallurgicalEngineering, IIT-Kanpur, Kanpur-208016E-mail: [email protected], [email protected]

**Steelmaking Division, Visakhapatnam Steel Plant,Visakhapatnam-530031.

#Bokaro Steel plant, Bokaro-827001

MgO-C brick samples from 145-ton BOF and 300 ton ladleshave been investigated using SEM and EPMA to understandthe wear mechanism. A kinetic model is developed to describethe wear rate. Modifications in operating strategy increasedthe refractory from 900 heats to greater than 2200 in the caseof BOF.

SYNTHESIS ANDCHARACTERIZATION OF GRAPHITE

IN CAST IRONSK.K. Singh

Department of Foundry Technology, National Instituteof Foundry and Forge Technology, Hatia,

Ranchi – 834 003E-mail: [email protected]

In this study, the nodularity, nodule size and distribution werecontrolled by proper control of charge materials, nodularizingand inoculation treatments. The grid count method and Areamethods were used for measurement of nodule count, size andsize distribution of nodules. The estimated nodularity valueincreased from heat No.I (Gray Iron) to IV (S.G. Iron). Thenodule size decreased from heat No.II to IV. The frequenciesof fine nodules increased with increase in Heat Nos. It hasshown decreased strength and improved ductility with increasein heat no. from II to IV.

DEVELOPMENT OF TITANIUM – HIGHSTRENGTH STEEL CLADDED

COMPONENTS BY EXPLOSIONCLADDING ROUTE

M .Chatterjee# and B. Hanumanth Rao*#Mishra Dhatu Nigam Limited Hyderabad.

*Explofab Metals Ltd. Hyderabad.E-mail: [email protected]

In the present work, a technology for cladding of Grade 2Titanium (Yield strength 350 MPa) on high strength steelforgings having yield strength of 700–850 MPa have beensuccessfully developed. Best properties are obtained under

conditions where intermetallic formation is minimum and whenthey are formed in small isolated pockets surrounded by ductilematrix. The present paper discusses the cladding methodologyas well as the microstructure and properties obtained underdifferent processing conditions.

THE CASTRIP® PROCESS – AN UPDATEON RECENT EXPERIENCES AT NUCOR

CRAWFORDSVILLEPeter Campbell, Richard Wechsler, Rama

Mahapatra and Wal Blejde Castrip LLC, 2100 Rexford Rd., Suite 420, Charlotte,

NC, 28226, U.S.AEmail: [email protected]

Nucor Steel is currently operating world’s first commercialstrip casting facility for production of thin plain-carbon steelsheet employing the CASTRIP® twin-roll casting process. Todate, the plant has produced in excess of 100,000 tons. Thispaper will report on the progress at the plant plus next stepsin the commercialisation of this breakthrough technology.

LABORATORY STUDIES ON THEWEAR BEHAVIOUR OF STEPPED

AUSTEMPERED DUCTILE IRON BALLSIN GRINDING IRON ORE

B. S. Jayaraj, K.R. Udupa and K.L. BhatDept. of Metallurgical and Materials Engg. NITK,

Surathkal -575 025

In the present study, an attempt has been made to evaluate thesuitability of austempered ductile iron as grinding mediamaterial for grinding the iron ore in a ball mill. The wear rateof ADI was compared with En-31 forged steel balls. The wearbehaviour of ADI in grinding iron ore is not only dependenton the hardness but also on the microstructure, phaseconstituents of the ADI material. The wear resistance and theenergy consumed by ADI ball were found to be better.

A NOVEL TECHNIQUE FOR FLUORIDEREMOVAL IN THE PICKLING LINE

EFFLUENT FOR STAINLESS STEELSS. Ramachandran and R. Baskar

Dept. of Chemical EngineeringLecturer Kongu Engineering College, Erode, TN 638 052


The rejected mixed acid and wash water from stainless steelpickling lines result in a Fluoride load in the effluent. TheFluoride content of (around 8 ppm) due to the solubility ofCaF2 is much higher than the allowable 2 ppm. To mitigate theabove problem a novel technique of sludge recycle was tried.The paper discusses the details of this trial.

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MIS BEHAVIOUR OF BORON STEELSC.V. Ramesh Kumar, Mahesh Kulkarni,A.S. Phaneendra* and T.J. Saravanan

Dept. of Qlty Engg., EM Division, BEML, K.G.F.* Dept. Of Qlty Engg., HP Division, BEMLl, K.G.


This case study throws light on behaviour of cost effectiveBoron Steel during carburising, where-in the effect of boronon hardenability is unpredictable. This has necessitated inconducting a series of experiments to obtain similar consistentresults, which would have been obtained in conventionalcarburising steels like SAE8620H.

DEVELOPMENT OF FINEPARTICULATE MONITORING SYSTEM

FOR LD AND MIXED GAS LINES ATRSP

G.D. Maheshwari*, N. Dash**, P. Banerjee*, S.Prakash*, S.M. Mazumder* and

S.Bhattacharya**RDCIS, SAIL, Ranchi – 834002

E-mail: [email protected]**Energy Mgt. Dept. Rourkela Steel Plant, SAIL,

Rourkela-769011

To monitor the concentration of dust present in the gas lines,a monitoring probe has been designed and installed by RDCISin LD and mixed gas lines near to the gas mixer tank. Theprobe system has special safety features like compressed airejector, purging facility for probe and discharge of sample gasafter dilution to prevent any hazard. The system is being usedby Rourkela Steel Plant for monitoring quality of gas. Thefeed back of the system can help in improvement in performanceof gas cleaning equipment in respective shops.

HIGH VELOCITY BURNER FORLADLE HEATING

D. Zamindar¬, M. Sen¬, M.Choubey¬, P.Karmakar¬¬ and S. Sen¬

¬RDCIS, SAIL, Ranchi-834002E-mail: [email protected],

[email protected]¬¬ IISCO, SAIL, Burnpur- 713325

Ladle heating system of SMS, IISCO is inefficient, mainly dueto tube in tube type burner with a very short and lezzy flame.In this work a high velocity burner designed tailor made forIISCO ladles and tested at site. Excellent result achieved withhigh thrust & long flame touching ladle bottom and heatinguniformly.

CHARACTERIZATION OFGALVANIZED SHEETS FROM VARIOUS

SOURCES/MANUFACTURERSMandipkaur Pabla, Ajay Patel, Bobby Pujara

and T.V.N. MurtyEssar steel Ltd., Hazira, Gujrat-394270


The coating of steel or iron with zinc using various processesis called ‘galvanizing’. Total 13 corrugated sheets were receivedand complete characterization was carried out to understandthe characteristics of the zinc coating. The coating thickness(m) was found to vary from 10 to 20m for different suppliers.The characterization of the different layers of zinc coatingshows presence of different layers viz. Eta, Zeta, Delta andGamma.

ANNEALING BEHAVIOUR OF COPPERBEARING IF STEELS

R.K. Rana, S.B. Singh and O.N. MohantyDepartment of Metallurgical and Materials Engineering

IIT-Kharagpur, Kharagpur -721302E-mail: [email protected]

The annealing behaviour of Cu-containing IF steel (IF-Cu) hasbeen studied using Thermo Electric Power (TEP), electricalresistivity, hardness measurements and optical metallography.The TEP value of the cold worked material increased uponannealing due to annihilation of dislocations. TEP, resistivityand hardness values of IF steels showed sharp change duringthe first few minutes of annealing. This leads to the conclusionthat most of the hardness drop of cold worked IF steels duringannealing is due to recovery only and not due torecrystallisation.

STUDIES ON LASER ASSISTEDFABRICATION OF AISI 316L STAINLESS

STEELJ. Dutta Majumdar*, S. M. Ganeshan*,

I. Manna* and Lin Li+

*Department of Metallurgical and MaterialsEngineering, IIT-Kharagpur, Kharagpur, - 721302

+Department of Mechanical, Aerospace andManufacturing Engineering, LPRC, UMIST, P. O. BOX

88, Manchester M60 1QD, UKE-mail: [email protected]

The present study concerns laser assisted fabrication of 316Lstainless steel by melting the feedstock powder using a Laser-line diode laser (maximum power of 1.5 kW) and layer bylayer deposition of the melt on a substrate. The physical andmicrostructural characteristics of the fabricated component werestudied. Significant improvements in mechanical andelectrochemical properties were achieved as compared to theconventionally available one.

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MECHATRONIC SYSTEMS FORQUALITY OPTIMISATION IN STEEL

PRODUCTION AND RESEARCHMichael Traugott,

Vatron - voestalpine mechatronics GmbHVoestalpine str. 3, A-4031 Linz / AustriaE-mail: [email protected]

Combining expertises in the fields of mechanics, electrotechnics,sensorics, computer science, instrumentation and testingtechnology, this presentation will focus on customizedmeasuring and control-systems along the complete productionrange of steelmaking and processing industries. The vatronteam has developed about 60 different mechatronic systemsthat have proven their industrial durability in more than 150worldwide references. The presentation will cover theexperiences collected at Voestalpine Stahl production sites.Some of these most production critical and advanced systemswill be described, their advantages pinpointed and applicationsdiscussed.

DEVELOPMENT OF SEMI PROCESSEDELECTRICAL STEEL AT M/S UTTAM

GALVA STEEL LIMITEDAnuj Miglani*, S.G. Tudekar*,

R.N. Mukherjee*, Munshi Prasad*,A. Saxena**, B.K. Jha** and S.K. Chaudhuri**

* M/s Uttam Galva Steels Limited, Donvat** RDCIS, SAIL, Ranchi


The present paper discusses the development of Semi ProcessedElectrical Steel with low silicon (0.25% and 0.60%) and lowercore-loss (<6 W/kg and <4.5 W/kg respectively) for Fractionaland low horsepower motors. At UGSL attempts were made toachieve the lower core loss value through selection of Chemicalcomposition range, hot rolling and cold rolling parameters.Control was exercised during Bell Annealing and Skin pass.

DEVELOPMENT OF SUPER EDD AND IFSTEEL WITH HIGH AVERAGE PLASTIC

ANISOTROPY AT M/S UTTAM GALVAAnuj Miglani*, S.G. Tudekar*, R.N.

Mukherjee*, Munshi Prasad*, B. Sarkar**,B.K. Jha**, and S.K. Chaudhuri**

* M/s Uttam Galva Steels Limited, Donvat** RDCIS, SAIL, Ranchi


The present paper discusses the role of hot band microstructureand subsequent processing parameters on the final r-value ofthe cold-rolled EDD/IF steel for undergoing Criticaldeformation. The typical final anisotropy value achieved in theIF grade is 2.1 and EDD grade was between 1.7–1.9. Withsuch excellent combination of properties, several critical

components were formed for automotive and GeneralEngineering application.

IMPROVEMENT IN VAR-HEAT-SHIELD-LIFE THROUGH INNOVATIVE MONO-LITHIC ZONAL REFRACTORY LINING

R.B. Gupta, D. Upadhyay and S.K. VadherRourkela Steel Plant, SAIL, Rourkela-769 011

After adopting continuous casting route of steel production,the treatment time and holding time of ladle increased manyfold at VAR Secondary station. This has resulted in poor lifeof VAR-Refractory heat shield. To overcome this, many liningpatterns with different kind of refractory materials were usedand VAR heat shield life could be increased many fold. Thispaper depicts all such developments.

NON-FERROUS EXTRACTION

BULK SULPHIDE PRECIPITATIONFROM SEA NODULE LEACH LIQUOR

AND DISSOLUTION IN CHLORIDEMEDIA

K.K. Sahu and R.K. JanaMetal Extraction and Forming Division

National Metallurgical Laboratory, Jamshedpur – 831 007Email: [email protected]

In order to reduce the volume of leach liquor, size ofequipments, cost of capital and energy, it was proposed toadopt bulk sulphide precipitation of the valuable metals fromthe dilute leach liquor followed by redissolution in chloridemedia and SX-EW operation. Bulk sulphide was precipitatedfrom manganese nodule leach solution containing 800 ppmCu, 970 ppm Ni, 67 ppm Co and 150 ppm Zn. Completeprecipitation of all metal sulphide was achieved with 5% excesssodium sulphide concentration to the stoichiometricrequirement. Various leaching parameters such as acid, sodiumchloride, ferric chloride concentrations, temperature etc. havebeen studied to optimize the leaching conditions forredissolution of bulk sulphide precipitate.

IMPROVEMENT OF COBALTEXTRACTION IN REDUCTION-ROAST

AMMONIA LEACHING OF SEANODULES

T.C. Alex, T.B.Singh and R. K. JanaMetal Extraction and Forming Division


Realizing the importance of polymetallic sea nodules as futureresource of copper, nickel and cobalt, National Metallurgical

A24

Laboratory, Jamshedpur has developed a process followingreduction roast and ammonia leaching route for their extraction.Though copper and nickel extractions from roasted sea nodulesin ammonical leaching were well above 90%, the cobaltrecovery was only in the range of 50 –60%. Studies using puremetal powders have shown that co-precipitation of cobalt withiron and manganese was the main reason for the low cobaltrecovery. Attempts have been made to minimise thecoprecipitation of cobalt using some additives during leaching.Preliminary results of leaching experiments with differentadditives showed that some of the additives could control thecobalt coprecipitation very effectively.

ION EXCHANGE PROCESS FORGALLIUM RECOVERY

M.Ramasami, P.Selvi, M.H.P.Samuel,P.Adaikkalam and G.N.Srinivasan

Central Electrochemical Research Institute,Karaikudi-630 006


An environment friendly separation technique for the recoveryof gallium from Bayer Liquors using chelating ion exchangeresins is presented. The synthesis of the resin, its adsorptionand elution characteristics and the designing of a pilot plant torecover gallium on a 100g/day scale is described.

THE ANODIC DISSOLUTION OFTUNGSTEN

S.Hairunisha, M.H.P.Samuel, J.PrabakarRethinaraj, P.Adaikkalam, S.Kulandaisami and

G.N.SrinivasanCentral ElectroChemical Research Institute,

Karaikudi 630006Email: [email protected]

The recovery of tungsten from tungsten alloy swarf throughthe anodic dissolution of the scrap in sodium hydroxide solutionwas investigated. The optimum concentration of the electrolyteand the anode potential for the dissolution of tungsten at 100%efficiency was determined. The effect of rotation on thedissolution of tungsten was also studied.

SOLVENT EXTRACTION OF COPPERFROM AMMONIACAL SOLUTIONS

P.Adaikkalam and G.N. Srinivasan,Central Electrochemical Research Institute, Karaikudi-

630 006Email: [email protected]

Solvent extraction has an edge over the conventional chemicalmethods like precipitation for recovery of copper. In this paper,the use of DEHPA (Di ethyl Hexyl Phosphoric Acid) for itsrecovery from ammoniacal cupric chloride solution is described.The factors affecting the recovery such as pH, extractant

concentration, copper concentration, A/O ratio etc. have beenstudied on laboratory scale and reported.

SOLVENT EXTRACTION OF GALLIUMFROM CHLORIDE SOLUTION USING

D2EHPAM.S. Vinodhkumar P. Adaikkalam and

G.N.Srinivasan.Central Electrochemical Research Institute,

Karaikudi-630 006Email: [email protected]

Gallium is an important material in the semiconductor industry.Electrolysis is one of the methods to recover gallium fromBayer’s liquor using mercury cathode. Solvent extraction isanother alternative technique for the extraction of gallium.Thefactors affecting the recovery such as pH, extractantconcentration, aqueous to organic ratio, gallium concentrationand impurities effect have been studied on laboratory scaleand reported.

RECOVERY OF HIGH PURE LEADFROM SCRAP LEAD ACID BATTERIES

BY ELECTRO REFINININGP. Ramachandran and V. Nandakumar,

Central Electrochemical Research Institute,Karaikudi-630 006


Electro refining of lead was investigated for producing highpure lead from the scrap lead-acid batteries. The batteryscrap was smelted directly in an electric furnace to lead metal,which was subsequently electrorefined in a fluoborate medium. The purity level of electrorefined lead was greater than 99.99. Recovery of antimony, energy consumption, monitoring ofelectrolyte additives and cell voltage rise are discussed.

RECOVERY OF COPPER AS SALT BYCRYSTALLISATION FROM COPPER

SPENT SOLUTION OF A COPPER UNIT.A Agrawal, S Kumari, D Bagchi, V. Kumar and

B D PandeyMetal Extraction and Forming Division NationalMetallurgical Laboratory, Jamshedpur – 831 007


From the point of view of metal recovery and reuse fromcopper spent electrolyte containing 40-50 g/L Cu, 10-20 g/LNi, 170-200 g/L H2SO4 of a copper plant, a bench scale studyon the preparation of metal sulphate from a spent coppersolution with/ without following a partial decopperisation stepprior to crystallization was done. Copper sulphate crystal witha little nickel contamination (0.7-2.27%) obtained withoutdecopperisation can be recycled back to electro-refinery plantto make up the copper level in electrolyte/ can be used as

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chemical. The mixed sulphate crystal obtained afterdecopperisation could be processed to separate the valuablemetals such as Cu and Ni by solvent extraction using reagentssuch as LIX 84/Cyanex 272, which lead to the development ofa process flow sheet, for preparing value added products suchas high pure metal salts/metal powders.

GAS-PHASE SULPHATION OF NICKELSPENT CATALYST FOR RECOVERY OF

NICKELB.B.Kar

Regional Research laboratory, Bhubaneswar.Email: [email protected]

The sulphur trioxide roasting of nickel spent catalyst wasinvestigated at temperatures from 5000C to 7500C. The kineticsof the sulphation appeared to be a transport controlled process.A two-step sulphation process was investigated that takesadvantage of the rate characteristics. The selectivity is achievedat 7000C with 94% of the nickel recovery

UPGRADATION OF INDIAN ILMENITES— PROSPECTS AND PITFALLS

CVGK Murty, S.Asokan, Amit Chatterjee andB.Muthuraman

Tata Steel, Titania Business Unit, ChennaiEmail: [email protected]

While direct consumption share of ilmenite in TiO2 pigment isdeclining, consumption of upgraded ilmenite (Synthetic Rutileor TiO2 slag) has been increasing strongly, world over. Indianilmenites with 50-53% TiO2, can be used for production ofTiO2 pigment through chloride route, only after upgradation.However, upgradation of ilmenite has its own prospects andpitfalls. Apart from technical issues, factors like high powertariff, inadequate infrastructure facilities, complex and expensivelogistics, disposal of process wastes, requirement of suitablesolid reductants, market preferences, etc., make ilmeniteupgradation formidable. In this context, the upgradation ofIndian ilmenites are discussed in this paper.

SOLVENT EXTRACTION SEPARATIONAND RECOVERY OF Cd(II), Ni(II) AND

Co(II) FROM CHLORIDE LEACHLIQUORS OF SPENT BATTERIES WITH

COMMERCIAL EXTRACTANTS(CYANEX 923 AND CYANEX 272)

B. Ramachandra Reddy, D. Neela Priya andP. Radhika

Indian Institute of Chemical Technology (CSIR),Hyderabad – 500 007


This paper reports the development of environmental friendlyhydrometallurgical flowsheet for the separation and recovery

of Cd, Ni and Co from chloride leach liquors of spent Ni – Cdbatteries by solvent extraction technique using commercialextractants, Cyanex 923 and Cyanex 272. Leach liquor (LL)contains Cd - 6.272, Ni – 21.56, Co – 0.14 (g/l) with pH 1.Cd separation was carried out by contacting the LL with 0.6M Cyanex 923 in two stages at A:O ratio of unity. A three-stage stripping of Cd from L.O (6.267 g/l Cd) at A:O phaseratio of 1.75 yielded > 99.9% Cd efficiency. Ni and Co co-extraction was nil.

ELECTROCHEMICAL REDUCTION OFTiO2 TO PRODUCE TITANIUM SPONGE

Ch.R.V.S. Nagesh, C.S. Ramachandran andV.V. Bhanuprasad

DMRL, Kanchanbagh, Hyderabad-500 058

In the present work electrochemical reduction of TiO2 granitesat a temperature of 950oC in molten calcium chloride bathunder argon atmosphere carried out in the new experimentalset up which has been very encouraging and sponge grainswith complete metallization could be prepared for the firsttime by this novel route. Characterization of sponge samplesby SEM and EDAX confirmed titanium metal with less than5000 ppm oxygen.

FFC CAMBRIDGE PROCESS: A NOVELMOLTEN SALT

ELECTROMETALLURGICAL PROCESSFOR REDUCTION OF METAL OXIDES

K.S. Mohandas and D.J. FrayUniversity of Cambridge, Cambridge CB2 3QZ,

United Kingdom.Email: [email protected]

The FFC (Fray-Farthing-Chen) Cambridge process is a newprocess for production of metals and alloys from their solidoxides directly by molten salt electrolysis. The process isespecially suitable for reduction of oxides of the transitionmetals and actinides. Presently the process is being studied, inpilot plant scale, for the production of titanium metal and Ti-based alloys. The paper gives an overview of the process andits present status with respect to titanium production.Preliminary experimental results on the electroreduction ofzirconia and silica are presented.

PERFORMANCE ENHANCEMENT OFANODE BAKING FURNACES AT

HINDALCO’S ALUMINIUM SMELTERS.C. Tandon, Arun Kumar and R.N. Prasad

Hindalco Industries Ltd., Renukoot – 231 217,Sonbhadra, U.P.


In view of increased primary aluminum smelting capacity atHINDALCO, enhancement of anode baking became necessary.

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A performance enhancement programme for Bake Furnaceswas undertaken to increase productivity, optimise fuel oilconsumption and improve anode quality & refractory life. Astrategic plan for regulating heat distribution in Bake Furnaceswas worked out by introducing micro-processor based fuelfiring and draft control system. There is substantial gain inanode baking capacity and quality of carbon anodes besidesreduction in fuel oil consumption. Heat Regulation System sodeveloped is a low cost retrofit solution for performanceenhancement of anode Bake Furnaces.

INVESTIGATIONS IN THE SCALEUPSTUDIES FOR HIGH PURITY

ALUMINIUMT. Selvin Devasahayam, V. Samson Packiaraj

Raphael, A.Visuvasam,C.K. Murugesan, S. Angappan, L.John

Berchmans, S. Srikantan, V. Ananth andC.O.Augustin

Central Electrochemical Research Institute,Karaikudi 630 006

E Mail: [email protected]

Commercial aluminium has a purity of 99.5-99.7%. Theimportant impurities in the primary aluminium are Fe and Siwith traces of alkali and alkaline earth metals. The presentinvestigation deals with a two-layer electro-refining process,in which, commercial molten aluminium acts as the anode andhigh pure molten aluminium acts as the cathode. Both theelectrodes are separated by a thin refractory partition andallowed to float over a molten electrolyte. Electro-refining cellsof different capacities upto 1000A are operated and studieshave been carried out. The refined metal has a purity of morethan 99.9% with traces of impurities like Fe and Si. Furtherinvestigations are under progress for improving the quality ofthe refined metal and the refining process in an economicalmanner.

COMMERCIALISATION OF TITANIUMSPONGE PRODUCTION IN INDIA

C.S. Ramachandran and Ch. R.V.S NageshDefence Metallurgical Research Laboratory,

Kanchanbagh PO, Hyderabad-500 058

This paper brings out the results of the technologydemonstration and quality data of the Titanium spongeproduction in India. A road map has been evolved for earlycommercialization of the technology developed at DMRL forthe country’s self reliance with respect to this strategicmetal.

ELECTRO-WINNING OF COBALTFROM PURIFIED LEACH LIQUORS OF

SECONDARY SOURCESPamela Alex, A.C. Bidaye, I.G.Sharma and

A.K.SuriMaterial Processing Division, Bhabha Atomic Research

Centre,Mumbai—400085


In the electro-winning campaign of cobalt, the optimumparameters such as a temperature of 600 C, a CCD of 400 A/M2 and a minimum pH of 3, established using syntheticsolutions were test examined on leach liquors generated duringprocessing of secondary resources of cobalt. The findings werecomparable and reproducible except, a decrease in currentefficiency from 95% to 80%.

EXTRACTION OF URANIUM USINGION IMPRINTING TECHNOLOGY

J. Mary Gladis, P. Metilda and T. Prasada RaoRegional Research Laboratory(CSIR), Trivandrum.


Ion imprinting technique creates plastic receptors that crabspecific ions. Ion imprinted polymer (IIP) particles wereprepared for the extraction of uranium by forming polymerizablecomplex of uranium and allowed to copolymerize styrene anddivinyl benzene in the presence of porogen. The studies on thesynthesis of uranyl IIP materials using binary / ternarycomplexes and different porogens were carried out to getefficient IIP for the extraction of uranium. Hence, ion imprintingtechnique renders a unique method for the extraction from seawater and lean ores and minerals and recovery from nuclearspent fuels.

4-ACYLBIS(1-PHENYL-3-METHYL-5-PYRAZOLONES) AS EXTRACTANTS

FOR LANTHANOIDSRani Pavithran and M. L. P. Reddy

Regional Research Laboratory, Thiruvananthapuram-695 019.


4-Acylbispyrazolones with varying polymethylene chain length(n = 4, 6, 8 and 10) have been synthesized and examined theirsolvent extraction behavior towards trivalent lanthanoids (Nd3+,Eu3+ and Tm3+). The extraction of Ln3+ ions increasesmonotonically with increasing atomic number of these metalions. These reagents showed an initial increase in the extractionefficiency of Ln3+ ion with increasing polymethylene chainlength, -(CH2)n-, from n = 4 to n = 8 and thereafter a decreasingtrend, for n = 10. The equilibrium constants of the extractedcomplexes, deduced by nonlinear regression analysis, werecorrelated with the polymethylene chain length.

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ALUMINIUM ELECTROLYSIS – THEPAST AND FUTURE

M.K.B. NairSmelter Plant, National Aluminium Co. Ltd.,


Aluminium remained elusive till the end of 19th century, thoughit occupied 8 % of the earths crust. The youngest amongstnon-ferrous metals, it has surpassed all others in productionand myriad applications. This review highlights the short history,long and pain taking experience of Scientists and Technologists,successes and failures, and development of modern aluminiumtechnology, with special reference to Indian aluminium industry.

BIOLEACHING OF INDIAN OCEANNODULES WITH REFERENCE TO

EXTRACTION OF VALUABLE METALSBY ASPERGILLUS NIGER

K. D. Mehta, Chitrangada Das,N. K. Singh and B. D. Pandey

MEF Division, NML, Jamshedpur – 831007Email: [email protected]

The biorecovery of the metals from the ores/ concentrates/wastes is an alternate ecofriendly process to conventional pyro/hydro-metallurgical processes. The advantageous use of themicrobial phenomenon was explored in the present investigationfor the bioleaching of valuable metals from the ferromanganeseocean nodules. Aspergillus niger procured from a culture bankwas used to leach copper, nickel, cobalt, manganese and iron.

SELECTIVE REDUCTION OFPOLYMETALLIC SEA NODULES

Sanjay PrasadNational Metallurgical Laboratory,

Jamshedpur - 831 007Email: [email protected]

Polymetallic sea nodules of Indian Ocean has been studied theeffect of different reductants on reducibility of metals. Tworeductants namely saw dust and fuel oil were choosen for thepresent investigation. It was found that near 700oC both are

equally good reductants. Their reduction experiments werecarried out in a tubular furnace.After the reduction the calcinewas tested for their metallic content. Based on the resultsobtained it was found that 10% fuel oil reduces well all themetals. The reduction of 95%,80%and 53% copper, nickel andcobalt respectively was found at 750oC in 90 minutes, whereasreduction with 20% saw dust was 95%,93.5% and 68% copper,nickel and cobalt respectively at 700oC in 60 minutes.

A COMPARATIVE STUDY ON THEESTIMATION OF TITANIUM IN

COLUMBIUM ALLOY USINGSPECTROPHOTOMETRY, XRF AND

ICP-AES TECHNIQUESR. Rajeev, Salu Jacob, Annamma Abraham,

T.S. Ramasubramanian and K.G.KannanVikram Sarabhai Space Centre, Trivandrum


Columbium alloy, C 103, containing hafnium and titanium asthe major alloying elements, is a high temperature resistantalloy which is used for various aerospace applications. Theprecise and accurate determination of titanium in the alloy willbe essential for the development and qualification of thematerial. Quantitative estimation of titanium in columbium alloywas carried out using Spectrophotometry, XRF and ICP-AES.Microwave digestion of the sample was carried out for rapidand effective dissolution. The matrix effect and spectralinterference on the analytical lines of titanium in each techniqueare discussed. The analysis results were compared and verifiedby using standard addition method and by synthetic standards.The advantages and disadvantages of all the three techniquesare highlighted.

DEVELOPMENT OF CU-CO-FE PRE-ALLOYED POWDERS BY

HYDROMETALLURGICAL PROCESSR.R. Thorat, P.K. Brahmankar and

T.R. Rama Mohan*,Dr. Babasaheb Ambedkar Technological University,

Lonere, Raigad-402 103* Indian Institute of Technology, Powai,

Mumbai-400 076Email: [email protected]

The paper presents the synthesis of Cu-Co-Fe pre-alloyedpowder by hydrometallurgical process for the consolidation ofrock cutting diamond tools. Premixed salts of copper, cobalt,and iron were reduced in hydrogen atmosphere to develop thepowder. The final microstructure of the powder was of twophase material (Copper and a-iron).

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NON FERROUS ALLOYS

INFLUENCE OF HEAT TREATMENTPARAMETERS ON ABRASIVE WEAR

BEHAVIOUR OF TWO CAST Al-SiALLOYS

B. Shah Kinjal, Sandeep Kumar andD. K. Dwivedi*

National Institute of Technology, Hamirpur: 177005 (HP)*Indian Institute of Technology, Roorkee: 247 667 (UP)


In the present paper, influence of heat treatment parameters(aging time & temperature) on abrasive wear behavior of twocast Al-12%Si-0.6Mg-3%Cu and Al-18%Si-0.6Mg-3%Cu hasbeen reported. The wear resistance initially increases withincrease in ageing time and subsequently decreases. Similarlythe wear resistance increases with increase in ageing temperaturefrom 150 to 1900C and thereafter decreases. SEM and opticalmicrostructural studies were also carried out to establish therelation between microstructure and mechanism of wear.

CHALLANGES IN DEVELOPMENT OFDISPERSION STRENGTHENED

Cu-8Cr-4Nb ALLOY Kedar Bhide and N.B.Dhokey

Govt. College of Engineering, Pune –411005Email: [email protected]

Copper alloys with high strength and high thermal conductivitycontaining fine, dispersed particles have received a lot ofattention. In the present work liquid metallurgy route wasattempted. Initial part of the research was focused onunderstanding thermodynamic aspects such as solubility,stability of the Cr2Nb phase, selection of crucible. Trials wereperformed in vacuum induction furnace. After conducting thematerial characterization, conclusions were drawn to highlightproblems faced in the development of this alloy.

ROLE OF ELECTROPLATEDINTERLAYERS IN CONTINUOUS

DRIVE FRICTION WELDING OF AA6061 TO AISI 304 DISSIMILAR METALS

G.Madhusudhan Reddy T.Mohandas,K. Mandar Govind Rao* and A. Sambasiva Rao

Defence Metallurgical Research Laboratory,Hyderabad - 50058

*National Institute of Technology, Warangal- 506004Email: [email protected]

Metallurgical problems are inherent in the joining of aluminiumalloy to stainless steel by conventional fusion welding processes.

With this in mind the effect of Cu, Ni and Ag in the form ofelectroplating as interlayer materials has been investigated.EPMA of welds without interlayer revealed that the interfacemicrostructure consists of Fe2Al5 with some FeAl3, which arehighly brittle. Welds with copper and nickel as interlayersexhibited the presence of CuAl2 and Ni3Al intermetallicsrespectively which are less brittle compared to Fe2Al5 and FeAl3.On the other hand welds with silver interlayer exhibited goodquality due to the formation of soft Ag2Al at the interface ofthe joint.

DEVELOPMENT OF DOUBLE-WALLCO-AXIAL FIN TUBE AS CLAD FOR

RESEARCH REACTOR FUEL PINRakesh Kumar, Arbind Kumar, Gargi

Chaudhari and R P SinghBhabha Atomic Research Centre, Trombay,

Mumbai – 400 085Email: [email protected]

Double-wall co-axial aluminum clad tube has been developedto increase the residence time of fuel in the research reactor.25 double-wall co-axial fin tubes of dimensions 13.00 mm ID,1.40 mm wall thickness (total) and 3500 mm long have beenmanufactured using the available facilities and raw material.The paper discusses in detail about the, process flow-sheet,quality evaluation techniques used and their results.

MICROSTRUCTURE ANDMECHANICAL BEHAVIOUR OFMULTIPHASE Mo-Si-B ALLOYS

A. K. Srivastava, *S. Raje, **Sweety Kumari,**N. Eswara Prasad and R. Mitra

Department of Metallurgical and Materials EngineeringIndian Institute of Technology, Kharagpur – 721 302,

West Bengal*Department of Metallurgical Engineering

VNIT, Nagpur**Defence Metallurgical Research Laboratory

P.O. Kanchanbagh,Hyderabad – 500 058 (A.P.)


The mechanical behaviour of Mo-Si-B or Mo-Si-B-Al alloysshowing different volume fractions of -Mo, Mo3Si, Mo5SiB2as well as fine particles of SiO2 or Al2O3 in the microstructurehas been studied. Considerable improvement in the roomtemperature fracture toughness and flexural strength is achieved,because of crack bridging and constrained plastic deformationin ductile -Mo phase. Compressive yield strengths and workhardening behavior of the Mo-Si-B alloys in the temperaturerange of 1100-1350oC, show impressive strength retention dueto the presence of Mo3Si and Mo5SiB2 phases.

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EFFECT OF Mo ONMICROSTRUCTURE AND

MECHANICAL PROPERTIES OFNb-Si-Mo ALLOYS

K. Chattopadhyay, *G. Balachandran, R. Mitraand K. K. Ray

Department of Metallurgical and Materials EngineeringIndian Institute of Technology, Kharagpur – 721302,

West Bengal*Defence Metallurgical Research Laboratory,

Hyderabad – 500 058Email: [email protected]

The effect of molybdenum on microstructure modulation andmechanical properties of three Niobium-Silicon-Molybdenumalloys have been investigated. The influence of Mo on volumefraction, size and morphology of the phases, lattice parameterof NbSS particles, and on hardness and indentation fracturetoughness of these refractory metal-intermetallic compositeshas been reported.

INTERMEDIATE TEMPERATUREOXIDATION BEHAVIOUR OF MO-Si-B

AND Mo-Si-B-Al ALLOYSSharma Paswan, *V. V. Rama Rao, R. Mitra and

S. K. RoyDepartment of Metallurgical and Materials Engineering

Indian Institute of Technology, Kharagpur – 721302*Defence Metallurgical Research Laboratory,

Hyderabad – 500 058Email: [email protected]

The isothermal oxidation behaviour of selected Mo-Si-B ternaryand Mo-Si-B-Al quarternary alloys in the temperature range400-700oC and at 1150oC for periods between 20 h and 300 hin dry air was investigated. The effects of alloy composition,temperature and time of exposure on the oxidation kineticsand mechanisms were studied, with emphasis on themorphology and constituents of oxide scales. Prior shortexposure of the alloys at high temperature, significantlyimproved their lower temperature oxidation resistance.

EFFECT OF COPPER ADDITIONS ANDCOLD WORKING ON AGENING

RESPONSE OF Al-0.5 Si-0.5 Mg - 1.0 NiALLOY

A.K. Bhargava, Y.V.S.S. Prasad andMayur Marwal

Malaviya National Institute of Technology, JaipurEmail: [email protected]

In the present work, effect of coper additions and cold workingon ageing response of Al - 0.5 Si - 0.5Mg - 1.0Ni alloy havebeen studied and the results are compared with aluminum alloys

6061 and 4032. The present alloys Al-0.5Si-0.5Mg-1.0Ni-(0.95–1.42) Cu exhibt a peak hardness of 101 BHN in T6condition as against 73 BHN exhibited by 6061 alloy in thesame condition. The present alloys in the T8 condition (coldworked and artificially aged) shows the hardness 121 BHNwhich is comparable to 4032 alloy in T6 condition.

OXIDE-SCALE AND -CASINGCHARACTERISATION IN Ti6Al-4V

ALLOY OXIDISED IN OXYGEN GAS

M.N. Mungole, M. Surendar andS. Bhargava

Dept. Met Engg., IIT, Kanpur.

In the present work oxidation study of Ti – 6Al – 4V alloy hasbeen carried out in dynamic oxygen gas and the results relatedto characterization of oxide scale and - casing in detail forthe alloy oxidised at 1050, 1150, 1250, 1340 K for 2, 4, 8 and12 hrs are presented. The oxide scale and - casingmorphology, their constituents, microhardness, thickness etcwere determined through visual and microscopic observation,X-ray diffraction and microhardness measurement.

STUDIES OF PERMANENT MOULDCASTING AND RAPIDLY SOLIDIFIED

Zn-27 Al ALLOYY.V.S.S. Prasad, A.K. Bhargava, S.K. Jain and

Ramesh ChandMalaviya National Institute of Technology, Jaipur


In the present work Al-27 wt% Zn alloy produced by permanentmould casting and the same alloy is rapidly solidified (by meltspinning). The microstructure of permanent mould cast alloyconsists of dendrites and eutectic mixture. Dendritic structureis absent in rapidly solidified (RS) alloy. The hardness of RSribbons is more than the permanent mould cast alloy. On ageingmelt spun alloy ribbons show an increase of hardness. XRD ofmelt spun product shows peaks from single phase as comparedto two phases in permanent mould cast alloy.

HYDROGEN-INDUCED DELAYEDFAILURE OF AA 7020 ALLOY

Santosh Kumar, T. Jagdish Babu andT. K.G. Namboodhiri

Department of Metallurgical EngineeringBanaras Hindu University,

Varanasi-221005Email: [email protected]

AA 7020, an Al-Zn-Mg alloy, is widely used in aerospaceapplications. Weldments in this alloy were observed to crackupon storage. This study was conducted to determine whether

A30

the cracking could be due to hydrogen embrittlement. Thealloy, in T6, duplex aged and welded conditions, was found tobe susceptible to hydrogen induced delayed failure. Air-quenching makes the alloy least susceptible to hydrogen.Susceptibility increases with water quenching or welding. Theobserved results are explained on the basis of the microstructureof the alloy.

METASTABLE PHASES IN Al-FeALLOYS: A STUDY BY MA AND RSP

S. S. Nayak, D. H. Kim *, S.K. Pabi andB. S. Murty **

Department of Metallurgical and Materials Engineering,Indian Institute of Technology, Kharagpur 721 302,

India* Center for Noncrystalline Materials, Department ofMetallurgical Engineering, Yonsei University, Seoul

120-749, South Korea** Department of Metallurgical and Materials

Engineering, Indian Institute of Technology, Madras,Chennai 600 036, India


In present work, formation of metastable phases like micro/nano quasicrystals (RSP) and intermetallics like Al5Fe2, Al13Fe4and Al3Fe (with increasing thermodynamic stability) have beenreported in Al-Fe alloys of nominal composition Al100-xFex, (x= 2.5, 5, 10, 15 and 20). Highest hardness value of 12GPa wasobserved in the nanocomposites.

EFFECT OF Cu POWDER TYPE ANDSINTERING TEMPERATURE ON

MICROWAVE SINTERING OF Cu-10SnALLOYS

Uddanti Ravikiran and Anish UpadhyayaDepartment of Materials & Metallurgical Engineering

Indian Institute of Technology,Kanpur-208016


The present work examines the effect of electrolytic, atomizedand prealloyed bronze powder on the microwave sintering ofCu-10Sn alloys. The bronze alloys were sintered in transientliquid phase and supersolidus conditions at 700 and 840°C,respectively. The bronze compacts are sintered using microwaveheating in 70% less time. Compared to conventional sintering,the microwave sintered bronze results in significantenhancement of mechanical properties. The difference in themechanical properties has been correlated to the varyingresponse of bronze powders to the sintering temperature andheating mode.

EFFECT OF PROCESSINGPARAMETERS ON SPRAY FORMING OF

AZ31 Mg -ALLOYR. C. Anandani, Ajay Dhar, Rajiv Chopra,Rajiv Sikand, A.K. Gupta, Sachin Gupta*,Niraj Nayan*, Govind*, I. RajaRao*, K.

Suseelan Nair*and M.C. Mittal*Metals & Alloys Group

National Physical Laboratory,New Delhi-12 .

*Materials & Metallurgy GroupVikram Sarabhai Space Centre, Trivandrum-22


Mg-alloy AZ31 was spray formed with varied processparameters to get the dense deposit. Grain size of the order of40-50 mm were found in the deposit and did not changesignificantly from bottom to top. Minor density change wasnoticed in the deposit with higher density at the top. Highersuperheat resulted in finer grain size due to increasedatomization efficiency but it enhanced the oxidation of droplets.

CHEMICAL CHARECTERISATION OFMAGNETOCALORIC Gd-Si-Ge ALLOY

Shanker, B.Shravan kumar and V.Lalithakumari

Analytical Chemistry Group, D.M.R.L,Hyderabad-500058


The paper deals with chemical charecterisation of RE basedmagnetic Gd-Si-Ge alloys. Methods are developed and samplesare analysed for Gd at 75-80% using complexometry andOptical Emission Spectrometry (OES), Si at 15-25% bygravimetry Ge at 15-30% and impurity elements of Cu, Fe andAl at ppm levels by Atomic Absorption Spectrometry (AAS).Results are validated by using synthetic standards.

INFLUENCE OF MICROSTRUCTUREAND TRACE RESIDUAL ELEMENTS ON

THE CREEP PROPERTIES OF IMI834H. Mishra, P. Ghosal, T.K. Nandy and

P.K.SagarDefence Metallurgical Research Laboratory,

Kanchanbagh, Hyderabad-58.Email: [email protected]

The creep performance of near alpha Ti-alloys such as Ti-6242and IMI 834 is significantly influenced by the microstructureand the presence of fast diffusing residual elements like Fe,Ni. In the present study, creep properties of three IMI834melts, obtained from various sources containing different levels

A31

of Fe and Ni, have been evaluated. Based on the results, themechanism for high temperature deformation has been proposedand the influence of Fe and Ni has been discussed in relationto the proposed mechanism and the information available inliterature.

CONVERGENT NOZZLE IN SPRAYATOMIZATION AND DEPOSITION OF

7075 ALUMINIUM ALLOYM. Jeyakumar, G. S. Gupta and Subodh Kumar

Indian Institute of Science, Bangalore 560 012, IndiaEmail: [email protected]

7075 aluminum alloy is atomized and deposited on the substrateusing two types of convergent nozzles, one is a convergentnozzle and another one is a convergent nozzle with 2 mmparallel portion. The variation of gas and melt flow rates andthe properties of deposit such as yield, porosity andmicrostructure, are investigated.

INFLUENCE OF AGING CYCLES ONMECHANICAL PROPERTIES AND

CORROSION RESISTANCE OF AFNOR7020 ALUMINIUM ALLOY FORGINGS.

Basavaraj, Dr. B.K. Muralidhara* and V.Diwakara Rao**

G.B. Pant Polytechnic, Okhla, New Delhi.*U.V.C.E., Bangalore University, Bangalore.

**Managing Director, Vishnu Forge Ltd., BangaloreEmail: [email protected]

Studies indicate that artificially aged AFNOR 7020 aluminumalloy exhibit superior mechanical properties. Artificial ageingtreatment given twice appears to be more effective. However,corrosion resistance of artificially aged AFNOR 7020 aluminiumalloy was found to be lower than that off naturally aged alloy.

MICROSTRUCTURE AND CYCLICOXIDATION BEHAVIOUR OF Pt-

ALUMINIDE COATING ON Ti-BASEALLOY IMI-834

D.K. DasDefence Metallurgical Research Laboratory,

Kanchanbagh, Hyderabad 500058.Email: [email protected], [email protected]

Near-á Ti-alloy such as IMI-834 and IMI-829 have poor hightemperature oxidation resistance which severely restricts theiruse in gas turbine applications. Several protective coatings onthe above alloys have been applied to improve their oxidationproperties. In the present study, Pt-aluminide coating has beenapplied on IMI 834 alloy to enhance its oxidation performance.The microstructural features of this coating its oxidationperformance at 650 and 750°C have also been studied.

STUDIES ON FRICTION WELDING OFALUMINUM-COPPER (AA2014) ALLOY

TO ALUMINUM-MAGNESIUM –SILICON ALLOY (AA6061)

M. Ashfaq, H. Khalid Rafi and K. Prasad RaoIndian Institute of Technology, Madras


Three important parameters Friction force, Forge force andBurn-off are varied during Friction welding of AA6061 toAA2014. Very fine recrystallized grain structure could be seenin the interface region. Hardness and tensile test results wouldbe correlated with the findings from the microscopic images ofthe grain structure.

DEVELOPMENT OF LOCOMOTIVEPISTON FORGINGS USING Al-Si ALLOYA.Venkata Ramana*, R.S.Tripathy, R.R.Bhat,

G. Madhusudan and Jagannath Nayak*Foundry & Forge Division, Hindustan Aeronautics

Limited, Bangalore – 560 017* Department of Metallurgical & Materials Engineering,

NIT Karnataka, SurathkalEmail: [email protected]

A locomotive piston forging generally undergoes closed-dieforgings with feedstock of extruded Al-Si billets. The presentwork aims at use of indigenously produced direct chill (D.C.)cast billets followed by forging in hydraulic press. Tensileproperties, hardness and microstructure of piston forgings madefrom of D.C. cast billet, 3-stages and 5-stages ‘C’ process arecompared to piston forgings made from extruded billet. It isobserved that 5-stages ‘C’ process billet gave superiormechanical properties when compared to billets with no C-process and with 3 stages C-process. Moreover, the pistonforgings produced through direct forging of extruded billetsshowed comparable mechanical properties. Microstructuralfeatures revealed a fine distribution of Si particles with a grainsize in the range of ASTM no. 8-8.5.

STUDY ON EFFECT OF SOLUTIONIZ-ING/AGEING TEMPERATURE AND TIMEON GRAIN SIZE OF SU718 RINGSVaisakhi S Nandi, R. R. Bhat, D. Roy and D. Dutta

Foundry & Forge Division, Hindustan AeronauticsLimited, Bangalore


Rings made of Superalloy (SU) 718 are being widely used inKaveri engine of Light Combat Aircraft (LCA) because ofhigh strength upto 700oC with good corrosion resistance andexcellent weldability. In the production of some of the largersize rings, rolling and heat treatment operations resulted invery coarse grains (ASTM grain size no. 1-2) with isolatedfine grains.

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EFFECT OF SECTION THICKNESS ANDMODIFICATION MELT TREATMENT

ON THERMAL ANALYSISPARAMETERS OF A357 ALLOYSathyapal Hegde, Girish Kumar and

K. Narayan PrabhuNational Institute of Technology Karnataka, Surathkal

P.O. Srinivasnagar 575 025, Karnataka State, IndiaEmail: [email protected]

Thermal analysis is an effective NDT tool to assess the degreeof modification. The thermal analysis parameters are known tovary significantly with casting conditions. The effect of melttreatment and casting section thickness on the thermal analysisparameters of Al-Si-Mg foundry alloy during solidification inmetallic moulds was investigated.

HEAT TRANSFER ANDSOLIDIFICATION BEHAVIOUR OF

MODIFIED A357 ALLOYGirish Kumar, Sathyapal Hegde and K.

Narayan PrabhuNational Institute of Technology Karnataka, Surathkal

P.O. Srinivasnagar 575 025, Karnataka State, IndiaEmail: [email protected]

The solidification behaviour of modified A357 alloy wasinvestigated. The results revealed that the heat of solidificationand casting/mould interfacial heat flux transients were affectedsignificantly by modification melt treatment. A eutectic growthmodel was used to predict growth velocities and grain sizes.High growth velocities yielded fully modified structures.

INFLUENCE OF PROCESS PARA-METERS FOR THE PREPARATION OF Al-Ti AND Al-B MASTER ALLOYS FOR THEGRAIN REFINEMENT OF Al-7Si ALLOY

S. A. Kori, V. Auradi and M. Chakrabortya

Basaveshwar Engineering College, Bagalkot – 587 102,Karnataka

aIndian Institute of technology, Kharagpur-721302.Email: [email protected]

In the present study various binary Al-Ti and Al-B masteralloys prepared by salt route under different processingconditions were assessed for their grain refining efficiency onAl-7Si alloy. Results suggest that a reaction temperature of8000C and a minimum reaction time of 60 min. were essentialin order to achieve the completion of the reaction in Al-Ti andAl-B master alloys. Further, results of macroscopy and DASanalysis reveal that Al-7Si alloy shows better grain refiningresponse to Al-3B and Al-3Ti master alloys prepared at 8000C60min. when compared to the master alloys prepared underdifferent reaction temperature and time.

EFFECT OF PHOSPHOROUS ADDITIONON DRY SLIDING WEAR BEHAVOUROF HYPEREUTECTIC Al-Si ALLOYSS.A. Kori, T.M. Chandrashekharaiah, B.M.

Angadi and V. AuradiBasaveshwar Engineering College, Bagalkot – 587 102,

KarnatakaEmail: [email protected]

In the present study, the effect of phosphorus addition on drysliding wear behaviour of hypereutectic Al-Si alloys (Al-13,14, 15, 17 and 20%Si) has been investigated using Pin-On-Disc wear testing machine. Various parameters such ascomposition of the alloy, normal pressures, sliding distances,and sliding speeds were studied. Wear test specimens werecharacterized by optical microscope and image analyzer. Theresults suggest that wear resistance decreases with increasingsilicon content and increases with the addition of 0.02%P tothe melt when compared to the as cast hypereutectic alloys.

DEVELOPMENT OF HIGH STRENGTHALUMINUM ALLOYS FOR ELEVATED

TEMPERATURE APPLICATIONS BYMECHANICAL ALLOYING

M. Sudhakara Rao, T. Raghu and G.G. Saha,Defence Metallurgical Research Laboratory,

Kanchanbagh, Hyderabad -500 058.Email: [email protected]

A study has been taken up to synthesize two alloys systems:Al – Ti and Al – Ni – Zr by mechanical alloying. Milling ofelemental powders has been carried out in a high energy ballmill for different milling conditions. As milled powders havebeen characterised for their size, microstructure and hardness.The progress of milling at different extents of milling timeperiods was followed by X – Ray diffraction of the powders.Lattice parameters and crystalline sizes of the alloys wereevaluated from the X- ray data. Analysis has been carried outto understand the non – equilibrium solid solubility changes inthe system.

CONTRIBUTIONS OF KERALAARTISANS TO THE METALLURGICAL

HERITAGE OF INDIAS.G.K. Pillai, R.M. Pillai and A.D. DamodaranRegional Research Laboratory, Thiruvananthapuram-

695 019Email: [email protected]

‘Aranmula Kannadi’ (Aranmula Metal Mirror) and ‘KadavaloorOttukinnam’ (Kadavaloor Eating Bowl) are the two remarkablecontributions of unlettered Kerala artisans to the metallurgicalheritage of India and Kerala in particular. These two processeshad been evolved only from intuition and experience withoutany access to currently available knowledge or tools. This paper

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highlights the processes involved in making the ‘AranmulaKannadi’ and ‘Kadavaloor Ottukinnam’ and the metallurgicalscience behind these two processes.

MICROSTRUCTURALCHARACTERIZATION OF CALCIUM

ADDED Al-7Si-0.3Mg-XFe ALLOYS.S.Sreeja Kumari, R.M.Pillai, S.G.K.Pillai,

P.Prabhakar Rao and B.C.PaiRegional Research Laboratory (CSIR),

Thiruvanathapuram – 695 019.Email: [email protected]

The microstructural characteristics of calcium added Al-7Si-0.3Mg-XFe (X= 0.2 and 0.8%) alloy have been investigatedusing, optical metallography, image analysis SEM/EDS andthermal analysis. It has been found that Ca addition modifiesthe eutectic Si structure and refines the size of platelike Fe-intermetallic phases. The mechanism for these microstructuralchanges has been discussed.

EFFECT OF SQUEEZE PRESSURE ONTHE MICROSTRUCTURE AND

MECHANICAL PROPERTIES OF 2124-AlALLOY

K.Sukumaran, K.K.Ravikumar, S.G.K.Pillai,M.Ravi, V.John, R.M.Pillai and B.C.Pai

Regional Research Laboratory,Thiruvananthapuram-695 019

Squeeze casting is an alternative, well developed, cost effectivemetal shaping method adopted by many industries especiallyin the automobile sector for the manufacture of a host ofcomponents. In the present investigation, 2124-Al alloy wassubjected to squeeze casting. The effect of squeeze pressurewas correlated with the microstructural parameters such asDAS, features of porosity and other micro constituents andmechanical properties. The results indicate a considerablereduction of defects level with the increase of squeeze pressureof the order of 100MPa.

QUALITY THIN WALL MAGNESIUMALLOY CASTINGS THROUGH LOW

PRESSURE CASTING PROCESSA. Srinivasan, T. Soman, K.K. Ravikumar, V.

John, U.T.S. Pillai and B.C. PaiRegional Research Laboratory, Trivandurm


Producing defect free quality magnesium alloy casting for hightemperature application is a challenging task. The present work

aims to produce AZ91 magnesium alloy castings by LPCprocess using an indigenously designed and developed LPCmachine. The microstructure and mechanical propertiesevaluated are compared with those of the gravity castings.Improved mechanical properties both room and hightemperature are noticed with LP cast AZ91 alloy.

BLISTER FREE HEAT TREATABLEALUMINUM ALLOY CASTINGS BYSEMISOLID METAL PROCESSING

B.R.K. Rao, V.M. Nimbalkar, A. Gaurav Rao,V.P. Balaji, Daya Lama, V.P. Deshmukh and

A.K. Shah,Naval Materials Research Laboratory,

Ambernath – 421506, Thane.

Present work describes processing stages involved during Semi– solid processing (SSM) of Aluminium alloy LM25 feed stockraw materials and some of the trails initiated to demonstratethe SSM technology capability for producing both thin andthick wall castings with varied flow lengths. Surface blisteringafter heat treatment could be controlled by optimizingthixocasting filling profiles using the real time controlled diecasting machine. The test components produced indicated goodresponse during T6 heat treatment and achieved strength levelgreater than 300 MPa having better ductility in comparison toconventionally cast components.

MICROSTRUCTURE EVOLUTION INISOTHERMALLY HELD SEMI-SOLID

Al-7Si-0.3Mg ALLOYShankargoud Nyamannavar*, M.Ravi and K.

Narayan Prabhu*Regional Research Laboratory, Trivandrum – 695 019

*National Institute of Technology Karnataka,Suratkal-575 025


In semi-solid metal (SSM) processing, to obtain sphericalparticles, the solid dendrites are broken up using mechanical,electromagnetic forces or by isothermally holding. Afterisothermal holding and cooling at higher rates, instabilities areformed on the primary á particles. The tolerable Fe contentand the interaction of Sr modifier with Fe in the isothermallyheld 356 alloy has been studied (at 590oC, holding for 8000sec.) at various cooling rates (0.1 to 100 K/sec.) in terms ofthe instabilities, primary á particle size, entrapped liquid andthe eutectic Si size and shape. Thermal analysis and quantitativemicrostructure analysis was used to correlate the evolvedmicrostructural features.

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STRUCTURE - PROPERTYCORRELATION STUDIES ON

STRONTIUM MODIFIED Al-7Si-0.3 MgALLOY

K. Pratheesh*, M. Ravi,M.C. Shaji and V. John

*Vidhya College of Engineering, Trichur, KeralaRegional Research Laboratory, Trivandrum-695 019


The morphology of eutectic Si in the slow cooled as castmicrostructure of Al-7Si-0.3Mg (356) alloy is acicular, flakeor plate shaped. Addition of modifiers such as Sr or Na changesacicular Si to lamellar or fibrous shape which leads to improvedmechanical properties. The fading characteristics of the alloymelts subjected to modification using 0.02, 0.04, 0.06 and0.08% Sr were assessed at different holding times of 10, 20,30, 45, 60 and 90 minutes. The results indicate that when 0.02% Sr is used, fading starts at about 20 minutes itself. When0.08 % Sr is used, modified structure is observed even after 90minutes of holding, but this results in an overmodifiedmicrostructure. The mechanical properties correlate reasonablywell with the observed microstructures particularly thequantitative Si particle parameters measured by image analysis.

STUDIES ON AA 6061 ALUMINUMALLOY WELDS

N.Ramanaiah and K.Prasad RaoDepartment of Metallurgical and Materials Engineering,

IIT MadrasEmail: [email protected]

AA 6000 series alloys, like other age hardenable alloys, sufferfrom solidification cracking and loss of strength in the fusionzone and softening in heat-affected zone. In order to avoid hotcracking in fusion zone, fillers with non-heat treatablecompositions, such as AA 4043 and AA 5356 are used. As aresult, fusion zone strength values will be very poor comparedto that of base metal. Therefore the strength of the fusion zoneneeds to be increased, so that the cost and weight savingswould be significant. Further, these welds also suffer fromsignificant HAZ softening. This paper presents results ofattempts to improve both fusion zone and HAZ propertiesmainly by using water-cooled copper back up plates duringwelding.

MICROPOROSITY FORMATION INNORMALLY CAST AND SEMI-SOLID

Al-7Si-0.3Mg ALLOY

M.Ravi, Roschen Sasikumar andKalyanaraman*

Regional Research Laboratory, Trivandrum – 695 019*National Institute of Technology Karnataka,

Suratkal-575 025Email: [email protected]

In castings, porosity is detrimental to the mechanical properties,pressure tightness and corrosion resistance etc.. Feedingdifficulties were believed to be the reason for the formation ofmicroporosity. However, calculations show that homogeneousas well as heterogeneous nucleation of pores in the liquid isvery difficult. Based on the observations of bubble growth insuccinonitrile-argon alloy by in-situ method a hypothesis isproposed here that the pre-existing bubbles are the source forporosity in the casting. This hypothesis was tested and verifiedby comparing porosity in samples of Al-7Si-0.3Mg alloysolidified under the same conditions with and without pre-existing bubbles in the normally cast as well as semi-solidalloy.

SECONDARY PROCESING

HOT WORKABILITY OF Ti-5.5Al-1FeAND Ti-6Al-4V: A COMPARISON

V.V.Balasubrahmanyam, T.Seshacharyulu* andY.V.R.K.Prasad**

Andhra University, Visakhapatnam 530003*Air Force Research Laboratory, Wright-Patterson AFB,

OH 45433, USA**Indian Institute of Science, Bangalore 560012

The hot workability of Ti-5.5Al-1Fe and Ti-6Al-4V is comparedwith the help of processing maps developed over widetemperature and strain rate ranges. At slow strain rates, boththe alloys exhibit superplasticity in the + phase field anddynamic recrystallization in the â phase field, which are idealfor hot working these alloys. Regimes of damage mechanismsmanifested as adiabatic shear bands in the + range andunstable flow in the b range occur at high strain rates andthese deformation conditions should be avoided for obtainingcontrolled microstructures.

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EQUAL CHANNEL ANGULARPRESSING OF COMMERCIALLY PURE

ALUMINIUMR P Sugvaneswar, T Thirumalai,

J Krishnamoorthi, B Ravisankar andP C Angelo

PSG College of Technology, Coimbatore - 641 004Email: [email protected]

Equal Channel Angular Pressing (ECAP) is a method in whichthe grain size is refined to sub micro and nano meter levelwithout any change in the dimension. The grain refinement inECAP is achieved by forcing the sample through a speciallydesigned die, which assists in deformation of material in itsshearing plane. In the present work, the effect of strain byECAP on commercial purity aluminum has been studied. TheECAP die has been designed and fabricated with the shearingplane angle 120o. Metallographic studies on Aluminum samplesconfirm appreciable grain refinement. The hardness is alsoincreased significantly.

HOT WORKING CHARACTERISTICSOF IMI 834 ALLOY FOR COMPRESSOR

ROTOR BLADE APPLICATIONSR.Srinivasan, R.Mathivanan, M.S.Velpari and

R.KrishnamoorthyHindustan Aeronautics Limited, Bangalore-560 017


The near alpha titanium alloy IMI 834 material was subjectedto different types of hot working operations to realize thin aerofoiled section precision blade forgings. Samples from variousstages and different temperatures of forgings were analyzedfor all properties after heat treatment and parameters optimizedto achieve desired results.

EVALUATION OF EQUAL CHANNELANGULAR EXTRUSION AS AN

INTERMEDIATE PROCESSING STEPPRIOR TO COLD EXTRUSION IN A6XXX SERIES ALUMINIUM ALLOY

D. Nagarajan, Uday Chakkingal andP.Venugopal,

Materials Forming Laboratory, Indian Institute ofTechnology Madras.


Equal Channel Angular Extrusion (ECAE) is a severe plasticdeformation process for obtaining ultrafine-grainedmicrostructures. In this study effect of subsequent processingof ECA extruded Aluminium alloy specimen by conventionalcold extrusion has been investigated. Mechanical testing and

microscopy were carried out to evaluate the benefits of ECAextrusion as a prior deformation step.

DEVELOPMENT OFMICROSTRUCTURES AND

MECHANICAL PROPERTIES INCOMMERCIAL PURITY COPPER

AFTER A COMBINATION OF EQUALCHANNEL ANGULAR EXTRUSION AND

COLD ROLLINGA. Krishnaiah, Uday Chakkingal and

P. VenugopalMaterials Forming Laboratory, Indian Institute of

Technology Madras.Email: [email protected]

Equal channel angular extrusion (ECAE) as an intermediateprocess, was used to deform samples of pure copper using120o die. ECAEed copper samples were rolled to ~50%reduction to study the microstructural and mechanicalproperties. The effect of ECAE as an intermediate processingstep prior to rolling has been evaluated.

HOT EXTRUSION OF TITANIUM ANDTITANIUM ALLOYS

S.K. Jha, Kumar Vaibhaw, P.K. Krishanan andN. Saibaba

Extrusion and Piercing Plant, Nuclear Fuel Complex,Hyderabad.


This paper describes the different extrusion parameters used toextrude titanium and its alloys. This paper also elaborates thedeformation mechanism operative during hot working ofTitanium and its alloys. Large quantity of these alloys hasbeen processed and meeting stringent quality requirement.

EXTRUSION OF URANIUM AND ITSHEAT TREATMENT

M.M. Hussain, A.K. Singh, S.P. Singh andR.P. Singh

Bhabha Atomic Research Centre,Trombay, Mumbai-400 085


The purpose of this paper is to highlight the optimization ofimportant parameters for uranium extrusion and its heattreatment for fabrication of fuel rods for nuclear researchreactors so as to achieve satisfactory fuel performance underreactor conditions. The paper also emphasizes the importanceof die designs for uranium rod extrusion.

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IMPORTANCE OF RAW MATERIALSCHARACTERIZATION ON THE

QUALITY OF ALUMINUM ALLOYFORGINGS

G. Ravi Krishna, R.R. Bhat, D. Dutta,S.Kulkarni and R.Srinivasan

Foundry & Forge Division, Hindustan AeronauticsLimited, Bangalore – 560 017Email: [email protected]

The characterization of raw material bar stock used for differentmetal working processes is an essential step in achieving goodquality final products. In the present study, two cases ofaluminum alloy forgings, where use of raw material withimproper metallurgical characteristics had resulted in defectsin the final forging, are discussed. In the first case, AA 7075ring forging exhibited linear defects at its centre section duringultrasonic examination. The segregation of brittle, coarseintermetallic phases at the centre section of the raw materialbar stock forging was identified as the cause for the observeddefects in the final forging. In the second case, AA 2014 ringforging exhibited linear defects throughout its cross-section atvarious locations of the ring. Detailed investigation revealedthat the raw material used for the forging process had significantamount of porosity and this porosity appeared to have survivedduring the subsequent hot deformation and had appeared as alinear indication during ultrasonic testing of the ringforging.

GRAIN REFINEMENT OF Cu-Zn-AlSMAS BY EQUAL CHANNEL ANGULAR

PRESSINGR. Manna, Basava Kumar Mudda, N.K.

Mukhopadhyay and G.V.S. SastryCentre of Advanced Study, Institute of Technology,

Banaras Hindu UniversityVaranasi – 221005

Emails: [email protected],[email protected]

Shape memory alloys(SMA) are those special class of alloysundergoing martensitic transformation which memorise orrestore upon heating to a characteristic temperature their originalshape, after deformation in martensitic state. Cu-Zn-Al SMAsare excellent with respect to their ductility and grain boundaryfracture. However coarse grained structure in these alloys resultin poor mechanical performance. The present work is aimed atrefining the microstructure of Cu-Zn-Al SMAs by using EqualChannel Angular Pressing (ECAP) technique. The degree ofmicrostructural refinement achieved and the transformationproducts will be analysed and discussed.

DELVELOPMENT OF HOTDEFORMATION TEXTURE ANDMICROTEXTURE ON THE HOT

ROLLED Zr-1NB AND Zr-2.5Nb ALLOYSC. Vanitha, M. Kiran Kumar, I. Samajdar,

G.K. Dey*and D. Srivastava*,Dept. Of Met. Engg. and Mater. Sci., IIT Bombay,

Powai, Mumbai – 400076*Mater. Sci. Division, BARC, Trombay,

Mumbai – 400085Email: [email protected]

The nuclear components made up of zirconium alloys undergodimensional changes during service are strongly affected bythe neutron fluence and irradiation temperature. Thesedimensional changes are dependant on the crystallographicorientations. The present study brings out the results andanalysis of warm/hot deformation texture and microtexturedevelopments on Zr-2.5 and Zr-1Nb. It was found that Zr-1Nbmaterial showed considerable change in the texture whereasZr-2.5Nb material showed only a slight modification in texture.

DYNAMIC RECRYSTALLISATION ANDFLOW INSTABILITIES IN HOT

DEFORMED Mg-3Al-1Zn ALLOYLalu.G.Robin, K.Raghukandan, U.T.S.Pillai*

and B.C.Pai*

Annamalai University, Annamalainagar - 608 002.* Regional Research Laboratory, Thiruvananthapuram -

695015Email: [email protected]

Processing maps were generated for Mg-3Al-1Zn (AZ31) alloythrough which the hot deformation characteristics of the alloywere investigated. The domain of dynamic recrystallization(DRX) of this alloy was identified and the optimum conditionfor the hot working of the alloy was evolved. Hot extrusionwas also conducted to validate the findings based on theprocessing maps.

EFFECT OF HEIGHT / DIAMETERRATIO ON THE HIGH TEMPERATURE

DEFORMATION BEHAVIOUR OFTITANIUM ALLOY IMI 834

I.Balasundar, M Sudhakara Rao, T.Raghu andG.G.Saha

Defence Metallurgical Research Laboratory, Hyderabad– 500 058


The deformation behavior of a material depends on itschemistry, initial microstructure, processing history, applied

A37

temperature, strain rate, specimen geometry, applied state-of-stress (SoS) and SoS existing in the deformation zone. In thispaper the effect of specimen geometry (height / diameter ratio– 1.0, 1.5, 2.0) on the high temperature deformation behaviorof a titanium alloy (IMI 834) has been studied and reported.Finite element analysis was also carried out with varyingspecimen geometry in order to ascertain the reasons for thevariation in deformation behavior under identical processingconditions.

EFFECT OF INGOT PROCESSING ONTHE MICROSTRUCTURE AND THE

MECHANICAL PROPERTIES OF THEZr-2.5WT%Nb TUBES FOR

PRESSURISED HEAVY WATERNUCLEAR REACTORS

T Sanyal and K KapoorNuclear Fuel Complex, Hyderabad, India 500 062


In case of Zr-2.5 wt% Nb material for PHWR, the processingof melted and cast ingot to final tubes can be divided into twostages. In the first stage these ingots are processed to hollowbillets though a series of thermo mechanical treatments. In thesecond stage these billets are hot extruded to hollow tubeblanks, which are cold pilgered or cold drawn to tubes. In thecurrent study, three processing methods were considered.Samples were collected at different stages for analysis like,optical microscopy, x-ray diffraction and transmission electronmicroscopy (TEM). Tensile properties were evaluated withsamples taken from the axial direction of the tubes at the finalstage. For analysis of fracture surface and chemical analysison the fracture surface, SEM with EDS was used.

AEROSPACE MATERIALS

A NEW GENERATION MATERIAL FORAEROSPACE APPLICATIONS

Pravin Dharammali and Sanjay SawantGovt. College of Engineering Pune- 411005,Email: [email protected]

Al – Li alloy have been developed primarily to reduce theweight of Aircraft & Aerospace structures. Powder MetallurgicalTechnique is more effective in achieving greater compositionalflexibility with regards to alloy design strategies. Vacuumcasting is generally preferred for high purity Al casting.Recovery of Al-Li alloy has been investigated using techniqueslike ICP & weight analysis method. X-ray diffraction show thephases like T1 (Al2CuLi), T2 (Al6CuLi3), q (CuAl2) & d’ (Al3Li)which contribute to strengthening are precipitated after aging.Explosion potential of melt with water, with salt bath, Hydrogencontamination problem, toxicity of Li fumes formed duringmelting were the drawbacks during casting of Al-Li alloys.

Ni-Ti SHAPE MEMORY ALLOYS FORAEROSPACE APPLICATIONS

Niraj Nayan, Govind, Sachin Gupta and K.Suseelan Nair

Vikram Sarabhai Space Centre, ISRO, Trivandrum –695022.


Shape memory alloys exhibit pseudoelastic as well aspseudoplastic behavior depending upon the temperature. Duringthese transformations, it can accommodate strain upto 8% orexert stress upto 750 MPa by twinning and detwinningprocesses. Thus, it provides tremendous opportunities to designactuators/sensors for many SMART systems. This paper focuseson the usage of NiTinol SMAs in space industry.

PROCESS REQUIREMENT ANDPAYLOAD DEVELOPMENT FOR Mg

EXPERIMENT ON GROWTH OFQUASICRYSTALS IN SPACE

N.K. Ramakrishna Naidu, Y.C. Ranaware, S.C.Sharma, K. Suseelan Nair and M.C. Mittal

Vikram Sarabhai Space Centre, Trivandrum – 695022Email: [email protected]

ISRO is poised to conduct its first mg experiment on thesynthesis of Ga-Mg-Zn based quasicrystals aboard a recoverablespace capsule (SRE Mission). The payload for this experimentconsists of an Isothermal Heating Furnace (IHF), which hasbeen designed and developed to withstand the harshenvironment it will experience during ascent, orbital and reentryphases of the Mission. This paper brings out salient details ofthe process requirements for the experiment and highlights thedevelopment work carried out to design and realize the mgpayload.

PROCESS PARAMETERS ANDPROPERTY DEVELOPMENT IN C-

FOAMS FOR SPACE APPLICATIONSN.K. Ramakrishna Naidu, S.C. Sharma,

K. Suseelan Nair and M.C. MittalVikram Sarabhai Space Centre, Trivandrum-695 022


Reticulated vitreous carbon (RVC) foams are a new class ofopen cell, low-density materials that have attractive mechanicaland thermal properties. This paper mainly highlights theexperimental approach formulated to develop C-foam and theprocess details adopted to tailor its properties. The establishedprocess technique is based on impregnation of sacrificialsubstrate by a carbon-rich resin. The resin-enriched substrateis then subjected to progressive stages of pyrolysis,carbonization and graphitization under controlled conditionsof temperature, heating and cooling rates and environment.

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CHARACTERISATION OF CASTCOLUMNAR GRAINED TURBINE

AIRFOIL COMPONENTS FOR THEKAVERI ENGINE.

D. Chatterjee, N. Hazari and N. DasDefence Metallurgical Research Laboratory,

Hyderabad-500058Email: [email protected]

Ni-base super alloy have been the only class of materials usedfor the airfoil components in the turbine. Stringent evaluationprocedures have been adopted to characterize the cast columnargrained airfoil components of nickel base super alloyCM247LC. This paper presents the evaluation procedures andresults obtained by characterisation of castings with respect tothe alloy chemistry, microstructure of the cast component,mechanical properties, various Physical and solidificationdefects through stringent non destructive tests.

METALLURGICAL ANALYSIS ONCRACKED Ti-6Al-4V LINER OF GAS

STORAGE BOTTLE USED IN LIQUIDPROPULSION SYSTEM OF SATELLITE

LAUNCH VEHICLEAbhay K. Jha,V.Diwakar, K.Sreekumar And

M.C.MittalMaterials and Metallurgy Group, Vikram Sarabhai

Space Centre,Indian Space Research Organisation(ISRO),

Trivandrum 695 022Email: [email protected]

A gaseous helium storing gas bottle with Ti-6Al-4V liner,fabricated by electron beam welding of two forged andmachined hemispheres (designated as male and female domes)and wound with Kevlar fibre around it, failed prematurelyduring the auto frettage cycle of pressure testing. The failurewas identified to be due to the differences and non-uniformityin the microstructures of the domes.

METALLURGICAL ANALYSIS OF THEFAILURE OF LIQUID OXYGEN (LOX)TANK DURING POST – PROPELLENT

EXPULSION TRIAL (PET)Abhay K. Jha,V.Diwakar, K.Sreekumar and

M.C.MittalMaterials and Metallurgy Group,

Vikram Sarabhai Space Centre, Indian Space ResearchOrganisation(ISRO), Trivandrum 695 022


Metallurgical analysis of a catastrophically failed Liquid oxygenCryo-engine tank made of AA 2219 during the PET along thetop ring / dome weld fusion line revealed formation of intenseshear bands under adiabatic condition in the areas adjacent tothe primary failure. This microstructure resulted instantaneouslyduring a high strain rate event by the combined effects of thehighly localized shear deformation and the high temperaturerise that occurred within the shear bands.

METALLURGICAL ANALYSIS OF THEFAILED ISOGRID PROPELLENT

STORAGE TANKAbhay K. Jha. P. Ramesh Narayanan,

V.Diwakar, K.Sreekumar and M.C.MittalMaterials and Metallurgy Group, Vikram Sarabhai

Space Centre,Indian Space Research Organisation (ISRO),

Trivandrum 695 022Email: [email protected]

A cryo engine liquid Oxygen tank, made of AA2219, withisogrid configuration and welded with imported Recess conesub-assembly failed prematurely during proof pressure testing.A microstructural traverse revealed that the recess cone ringcontained clusters of non uniformly distributed particles,persisting from the melting stage of the material. Cracks,originating at the weld repair zones propagated fast during thepressure testing along the favorably oriented grain boundariesthickened by liquation phenomenon.

CHARACTERIZATION OFINDIGENOUSLY DEVELOPEDAERONAUTICAL GRADE 7010

ALUMINIUM ALLOY EXTRUSIONSFOR CORROSION PROPERTIES

M.K Sridhar, B.K Murulidhara * and P.Raghothama Rao **

*Aeronautical Development Agency, Banaglore**University Viswesvarya College of Engg., Bangalore


High strength Al-Mg-Zn alloy 7010 has been developedindigenously for aeronautical applications. This alloy hasexcellent Stress Corrosion Cracking (SCC) and exfoliationresistance compared to the earlier 7075 alloy. The over-aged,T73651 temper has been developed for this purpose. SCC andexfoliation resistance have been verified by testing as per ASTMG47 and ASTM G34 respectively. Indigenously developed 7010alloy has been certified by airworthiness agencies foraeronautical use.

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DEVELOPMENT OF AA7449 ALLOYFORGING FOR AERO APPLICATIONS

R.Mathivanan, Debashis Roy, Karthikeyan,R.Krishnamoorthy and R.R.Bhat

Foundry & Forge Division, Hindustan AeronauticsLimited, Bangalore – 560 017Email: [email protected]

The continued efforts to reduce weight and thereby cost inaeronautical industries led to the development of several neweraluminium alloys. One such alloy–AA 7449 has a tensilestrength as high as 580 MPa with 8% elongation. The alloy isthought of as a likely material to replace 7075 and 7150 alloysin aeronautical applications. Literature available on forgeabilityand heat treatment aspects of AA7449 is scanty. In view ofthis, an attempt was made to study the forgeability and heattreatment response of this alloy for aeronautical applications.

FRICTION STIR WELDING OFAA2219 Al ALLOY

S. Biju, R.K. Gupta, K. Chenniappan, B.RGhosh and P. P. Sinha

Vikram Sarabhai space Centre, Trivandrum-22Email: [email protected]

Aluminium alloy AA2219 is reported to have dramatically lowyield strength in the fusion welded weldments. Friction stirwelding (FSW) is a newly developed solid state weldingprocess, which was tried on AA2219 Al. alloy to eliminate allthe deleterious metallurgical factors otherwise present in allthe fusion welding processes. In this paper, first cut observationswith respect to a limited number of tool configurations used inthe initial experiments are presented. It has been found that theweld strength is a function of tool configuration, appliedpressure, tool rotation (rpm), and travel speed.

PROCESSING OF ADVANCEDMATERIALS FOR AEROSPACE

APPLICATIONS THROUGH VACUUMHOT PRESSING

A.K. Shukla, R. Suresh Kumar, M.G. Samuel,S. Babu, Gopinath Pai and M.C. Mittal

Materials and Metallurgy Group, Vikram SarabhaiSpace Center, ISRO

Thiruvananthapuram 695022Email: [email protected]

New developments in aerospace technologies call for processingof advanced materials like intermetallics, ceramics and ceramic-matrix composites that have to perform under extremeenvironments. Vacuum Hot Pressing is one of the preferredmethods for high temperature processing under controlledenvironment. The present paper discusses some of ourexperiences in the processing of silicon carbide based advancedceramics. The role and effect of different sintering additiveswas studied using different material characterization techniques.The effect of processing parameters like pressure, temperatureand time on the densification behavior of these materials isalso presented.

MAIN GEAR BOX HOUSING CASTINGFOR A HELICOPTER AND ITS

EVALUATION FOR AIRWORTHINESSCERTIFICATION

Kishora Shetty, *R. Raghavendra Bhat,P. Raghothama Rao and D. Pradeesh Kumar

Regional Centre for Military Airworthiness (Foundry &Forge), Vimanapura P.O, Bangalore – 560 017.

*Hindustan Aeronautics Limited, Foundry & ForgeDivision, Vimanapura P.O, Bangalore – 560 017.


The Main Gear Box (MGB) housing casting of the AdvancedLight Helicopter (ALH) is a complicated, large sized sandcasting made of magnesium alloy. The castings wereindigenously produced and evaluated for Airworthinesscertification. During major overhaul of helicopters at scheduledinspection of 250 flying hours, cracks were noticed on thelongitudinal booster cut-out area of swash plate attachmentregion, at the vertical rib connected to the MGB wall andattached body. Three failed indigenous MGB housings weresubjected to detailed failure analysis. This paper deals with themetallurgical failure investigation, modifications incorporatedto casting after failure investigation and evaluation of the castingfor airworthiness certification.

ULTRA HIGH STRENGTH Al ALLOYEXTRUSIONS BY I/M ROUTE

C. Mondal, A.K. Mukhopadhyay, T. Raghu,V.K. Varma, K.S. Prasad, N.R.Rao and

V.K.W.R. KulkarniDefence Metallurgical Research Laboratory, Hyderabad


The present work reports the results on 7055 Al alloy extrusionsdemonstrating that optimization of alloy composition,homogenization schedule, extrusion processing variables andpost-solutionizing aging heat treatments leads to the attainmentof significantly high tensile yield strength of 725 MPa. Suchtensile properties (as shown in the following table) are mostreproducible.

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COMPARISON OF CONVENTIONALAND NON-CONVENTIONAL METHOD

OF ANODIZING FOR AEROSPACEMATERIAL

I. B. Dave*, S. C. Khurana and K. B. PaiMetallurgical Engg., Deptt.,

M.S. University of Baroda, Baroda.S&. S.S. Ghandhy College of Engg. & Tech. Surat


Little information is available about the nature & quality offilm formed on Al-Li alloys during anodizing. In this paper, anattempt has been made to evaluate and study the quality ofpassive anodized oxide film. Studies have been carried out onthe oxide film developed on Al-Cu (2014) and Al-Cu-Li (1441,8090) alloys before and after anodizing using Potentio-dynamicand Electrochemical Impedance (EIS) techniques in variousconcentrations of NaCl viz.( 0.5%, 2%, 3.5%) solutions. Theresults obtained were systematically evaluated and discussed

GAMMA TITANIUM ALUMINIDESTHROUGH REACTION SYNTHESIS

FOR SPACE APPLICATIONS

Bhanu Pant, Vijaya Agarwala*, R.C. Agarwala*

and P.P. SinhaVikram Sarabhai Space Center, Trivandrum 695 022*Indian Institute of Technology, Roorkee 247 667.


This paper covers the work carried out in the area of gammatitanium aluminides development for prospective spaceapplications. In this work, reaction synthesis process is usedfor producing these high performance materials for hightemperature space applications (upto about 1273K). This workhas resulted in near full density gamma titanium aluminides,which has been characterized by density measurement, XRD,OM, TEM and mechanical property evaluation (at ambientand elevated temperatures). In the present paper, details ofexperiments carried out for reaction synthesis of thesealuminides are presented and the results are discussed in detail.

TITANIUM ALLOYS, ALUMINIDES ANDBIMETALS FOR SPACE APPLICATIONS

FROM 20K TO 1273KBhanu Pant, S. K. Singh, and M. C. Mittal

Vikram Sarabhai Space Centre, Trivandrum - 695 022Email: [email protected]

This paper deals with research and development activitiesrelated to different titanium alloys, bimetallic components andgamma titanium aluminides for various space applications.Processing technology for titanium alloy Ti-6Al-4V has beendeveloped and components are fully qualified for various spaceapplications while, development of Ti-5Al-2.5Sn-ELI alloycomponent is in advanced stages. Newer developments in theareas of beta titanium alloys (high strength applications) andtitanium aluminides (high temperature applications) are in thenascent stage. Bimetallic components are needed for facilitatingjoining of two dissimilar parts. Details of the research anddevelopment efforts in all the three types of titanium alloys (á,â and á+â types), bimetallic component development (on Al2219 alloy-SS321 steel system) and gamma-type titaniumaluminides have been presented in this paper.

CHARACTERIZATION OF AGEINGBEHAVIOUR IN 18 wt% NICKEL

MARAGING STEEL USINGULTRASONIC PARAMETRES

K.V. Rajkumar, Anish Kumar, T. Jayakumar,Baldev Raj and K.K.Ray*

Indira Gandhi Centre for Atomic Research, Kalpakkam– 603 102

*Indian Institute of Technology, Kharagpur - 721 032

In the present work characterization of ageing behavior in 18Wt Pct Nickel maraging steel have been studied with the useof ultrasonic parameters. Results revealed that hardness andultrasonic parameter (longitudinal wave velocity) exhibited asimilar behaviour with aging time. The influence of intermetallicphases such as Ni3Ti and Fe2Mo and the reversion of martensiteto austenite formed by thermal ageing treatments on theultrasonic parameters have been evaluated.

SHAPE MEMORY ALLOYS AND THEIRAPPLICATIONS IN A FIGHTER

AIRCRAFT

B. AshokADA, Bangalore


Shape memory alloys are unique from other materials as undercertain circumstances they can remember and revert back totheir original shape. This paper recounts the experiences indevising unique method in assembling these ferrule rings inthe pipe assemblies and training the manpower in the assemblytechniques. Compared to conventional shrink fit or swagedjoints, the joints made of shape memory alloys are a “truejoint”, reliable and unlike other joints offers constant clampingstress over the entire aircraft service.

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MICROSTRUCTURALENGINEERING

STUDY ON THE ENHANCEDFRACTURE TOUGHNESS OBSERVED

IN ALUMINA-13 WT % TITANIA ASPLASMA SPRAYED COATINGS

R.Venkataraman, R.Krishnamurthy1, D.K.Das2

and B.Venkataraman2

National Metallurgical Lab, Jamshedpur, 1 IndianInstitute of Technology

Madras, Chennai,2 Defence Metallurgical Lab, Kanchanbagh, Hyderabad.


A systematic investigation on the fracture toughnessmeasurements of plasma sprayed alumina-13 wt% titaniacoatings by microindentation technique was carried out. Theenhancement in the adhesive strength of the as plasma sprayedcoatings was observed when tested with a newer technique ofadhesive/cohesive strength measurement developed exclusivelyfor thinner coatings of thickness less than 380 ms. The testingmethod apparently conform the modified version of the ASTMD-3359-B crosshatch testing methodology.

MICROSTRUCTURALCHARACTERIZATION OF PSEUDO-

BINARY Gd5Si4 -– Gd5Ge4 ALLOYSM. Manivel Raja, R. Balamuralikrishnan, R.

Gopalan, V. Lalitha Kumari and V.Chandrasekharan

Defence Metallurgical Research Laboratory,Hyderabad – 500 058.

The pseudo-binary Gd5Si4 -– Gd5Ge4 alloys are potentialcandidates for magnetic refrigeration applications, as they showgiant magneto-caloric effect (MCE) near room temperature dueto the magneto-structural transition. The results of structuraland magnetic studies on arc-melted Gd5(SixGe1-x)4, with x =0.375, 0.425 and 0.5 alloys were reported in this paper.

EFFECT OF PRE-STRAINING ON LOWCYCLE FATIGUE BEHAVIOUR OF

NEAR TITANIUM ALLOY IMI834 ATROOM TEMPERATURE

K.V. Sai Srinadh and Vakil SinghBanaras Hindu University, Varanasi-221005

E-mail: [email protected] ; [email protected]

Effect of 15% pre straining by cold rolling, on low CycleFatigue (LCF) behavior of the near-a titanium alloy IMI 834,markedly increases fatigue life at low strain amplitudes, reduces

fatigue life at high strain amplitudes and is attributed toexhaustion of ductility of the material.

STRUCTURE PROPERTY CO-RELATIONS IN A CONTROLLED

TRANSFORMATION SEMI AUSTENITICSTAINLESS STEEL

S. Narahari Prasad and Pallab SarkarMishra Dhatu Nigam Ltd, Hyderabad.

In this paper, an attempt has been made at MIDHANI to relatethe properties of MDN-60 with the composition by means ofan empirical relation. This paper also describes the effect ofeach element on its structure and properties.

EFFECT OF DELTA FERRITE ONPROPERTIES OF A PRECIPITATION

HARDENABLE MARTENSITICSTAINLESS STEEL

S. Narahari Prasad and U.V.Gururaja MishraDhatu Nigam Ltd. Hyderabad-500 058.

This paper describes the effect of delta ferrite andhomogenization treatment and properties of a precipitationhardenable martensitic stainless steel MDN-59.

EFFECT OF MICROSTRUCTURE ONTHE UNLUBRICATED WEAR

BEHAVIOR OF A ZINC-ALUMINIUMALLOY

Pritha ChoudhuryIndian Institute of Technology, Kanpur – 208016


This paper investigates the effect of the addition of commercialmaster alloys Al-5Ti-1B and Al-5Sr to the melt with respect tothe microstructures and unlubricated wear properties of a zinc-aluminium alloy. Addition of the master alloys modifies themicrostructure, improves the bulk hardness and the wearresistance of the zinc-aluminium alloy.

METALLOGRAPHIC CHARACTERIZA-TION OF ACTIVE METAL BRAZED

CERAMIC-METAL JOINTS P.Prakash, T.Mohandas and P. Dharma Raju1

Defence Metallurgical Research Laboratory,Hyderabad-500 058,

1National Institute of Technology, Warangal-500 004.

In this work, SiC & Al203 Ceramic is joined to itself and toother structural materials such as AISI 304 SS, Inconel 718etc, through Active Metal Brazing route. Detailed

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microstructural analysis of these joints was carried out usingOptical, SEM, EPMA and XRD, to understand the chemistryof these interfaces, which influences the performance of thesejoints.

CHARACTERISATION OF HIGH-ENERGY MILLED HEAVY ALLOY

SYSTEMS

P. Ghosal, A.K. Singh and T. P. BagchiDefence Metallurgical Research Laboratory,

Kanchanbagh (PO) Hyderabad - 500 058.

Elemental mix, swarfs and filed chips of heavy alloy weresubjected to high-energy milling and stress-relieving annealing.XRD and TEM showed reduced stress level after annealingsans grain growth. Lattice parameter of tungsten decreased,lattice parameters of nickel-base matrix increased due to solidsolution effect. Possible size reduction mechanism discussed.

MICROSTRUCTURALINVESTIGATIONS ON GIANT

MAGNETOSTRICTIVE Tb-Dy-FeSYSTEM

Mithun Palit, S. Pandian,R. Balamuralikrishnan, A.K. Singh and

V. ChandrasekaranDefence Metallurgical Research Laboratory,

Hyderabad – 500 058.

In this present study alloy of (Tb0.27Dy0.73)Fe1.95 was cast in rodform and studied for the microstructural features in as-castcondition, followed by a post - heat treatment (1123 K)condition. The texture development was studied by zoning theas-cast rod. Details of these studies are presented in this paper.

GRAIN BOUNDARY EFFECTS ONSPINODAL DECOMPOSITION

H. Ramanarayan and T.A. AbinandananIndian Institute of Science, Bangalore 560 012


The results on the effect of a grain boundary on spinodaldecomposition, studied using a phase field model of apolycrystalline alloy are presented. In particular, the study isfocussed on the role of an enhanced diffusivity at the grain

boundary that leads to an interesting new phenomenon:discontinuous spinodal decomposition.

ELASTIC STRESS EFFECTS ONGROWTH AND MORPHOLOGICAL

EVOLUTIONM.P. Gururajan and T.A. Abinandanan

Indian Institute of Science, Bangalore-560 012.E-mail: [email protected]

In this presentation, we describe a diffuse interface formulationfor studying elastic stress effects on growth and morphologicalevolution in an elastically inhomogeneous system and a fewpreliminary results in a model binary alloy system.

A COMPARATIVE STUDY OFRECRYSTALLIZATION BEHAVIOUR OF

TWO PACKAGING ALLOYS BYDIFFERENTIAL SCANNING

CALORIMETRY (DSC)Rajat K. Roy, Sujoy Kar1, Karabi Das,

Siddhartha DasIndian Institute of Technology, Kharagpur-721302, India,

1 The Ohio State University, OH-43210, USAE-mail: [email protected]

Recrystallization behaviour of two packaging alloys AA1235and AA8011 was studied by differential scanning calorimetry(DSC), electrical resistivity, hardness measurement and electronmicroscopy. The alloy AA1235 shows high activation energyfor precipitation but low activation energy for recrystallizationthan the other alloy. For AA8011 alloy higher amount of Feparticles inhibits the start of recrystallization.

MICROSTRUCTURAL EVALUATION OFThO2-3.75%UO2 PELLETS PREPARED

BY CAP PROCESST.R.G. Kutty, P.S. Somayajulu, P. Sengupta,

K. Bhanumoorthy, Jose P. Panakkal,S. Majumdar and H.S. Kamath

Bhabha Atomic Research Centre, Mumbai-400 085.E-mail: [email protected]

ThO2-3.75%UO2 fuel is prepared at AFFF, Tarapur by arelatively new process called Coated Agglomerate Pelletization(CAP) technique which is based on minimizing the number ofprocess steps required for shielded operation. This paper dealswith microstructural studies on the above pellet using opticalmicroscopy, scanning electron microscopy (SEM) and electronprobe microanalysis (EPMA).

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CBED-HOLZ: A TEM-BASEDTECHNIQUE FOR ACCURATE

LATTICE PARAMETERMEASUREMENT

R. Balamuralikrishnan, D.V. Sridhara Rao andK. Muraleedharan

Defence Metallurgical Research Laboratory,Kanchanbagh PO, Hyderabad


The transmission electron microscopy based convergent beamelectron diffraction - higher order Laue zone (CBED-HOLZ)lines technique is the only technique wherein accurate latticeparameter (to fourth decimal in nm) information can be obtainedwith very high spatial resolution. The CBED-HOLZ technique,and its application to nickel-base superalloys and semiconductorheterostructures, will be presented.

PHASE STABILITY ANDMICROSTRUCTURAL STUDY OF A

NEW Ti2AlNb TITANIUM ALUMINIDEG. Sreenivasulu, P. Ghosal1, T.K. Nandy1,Vikas Kumar1, V.V. Kutumba Rao and

D. Banerjee2

College of Engineering, GITAM, Visakhapatnam 530045,1 Defence Metallurgical Research Laboratory,

Kanchanbagh, Hyderabad – 500 058,2 DRDO Sena Bhavan - B wing,

New Delhi 110011.

Phase transformation and microstructure of a Nb-rich O+B2alloy (Ti-20Al-25Nb-1Mo) is investigated following a varietyof heat treatments. A detailed phase identification andmicrostructural characterization involving optical, scanning /transmission electron microscopy and X-ray diffraction arecarried out and the results are discussed in relation to theavailable phase diagrams and existing literature.

COLD DEFORMATION TEXTURE ANDMICROSTRUCTURE DEVELOPMENTSIN SINGLE AND TWO PHASE Zr-BASED

ALLOYSM. Kiran Kumar, C. Vanitha, I. Samajdar,G.K. Dey1, R. Tewari1, D. Srivastava1 and

S. Banerjee1 IIT Bombay, Powai, Mumbai,

1 BARC, Trombay, MumbaiE-mail: [email protected]

The deformation texture development in single and two-phasezirconium based alloys has been studied. The texturemodifications in single-phase system could be captured by ‘onlyprismatic slip’. In two-phase, the texture developments in a

did depend on the apparent continuity/discontinuity of secondphase . A generalization of ‘in-plane rigid body rotation’ wasable to explain the observed lack of textural changes around acontinuous .

MICROSTRUCTURAL CHANGES IN AA2219 ALUMINIUM ALLOY UNDER

HIGH STRAIN RATEAbhay Kumar Jha, G.Naga Shiresha and

K. SreekumarVikram Sarabhai Space Centre (ISRO),

Trivandrum 695 022.

This experimental study was to evaluate the microstructuralchanges in AA 2219 Aluminum alloy under high strain rate.The Aluminum alloy welded plates were subjected to BallisticImpact using different projectiles traveling at 400-900 m/sec.The differences in the microstructures in the plates pierced andnot pierced by the projectiles are interpreted with respect tothe high strain rate deformation behavior of the material.

EFFECT OF MICRO ALLOYINGELEMENTS ON THE AGEING

BEHAVIOUR OF COPPER ADDEDHSLA STEELS

S. K. Ghosh, A. Halder1 and P.P.Chattopadhyay

BE College, Howrah, 1 Tata Steel, Jamshedpur

In the present study, an attempt has been made to study the Ti,B micro alloying addition on Cu added low carbon HSLAsteels to understand the transformation behavior of Austeniteand precipitation behavior of Cu in the transformedmicrostructure.

SLUGGISH TRANSITION OF COPPERTO BRASS TYPE TEXTURE INMETASTABLE AUSTENITIC

STAINLESS STEELB. Ravi Kumar, B. Mahato, P.K. De,

N.R. Bandyopadhyay1 and D. K. Bhattacharya2

National Metallurgical Laboratory, Jamshedpur- 831007 1 Bengal Engineering College, Howrah. 2 Central Glass

and Ceramic Research Institute, Kolkata.E-mail: [email protected]

The present work describes the transition of copper type textureto brass type in the austenite phase of the metastable austeniticstainless steel (SS), which is associated with mechanical twinsduring deformations process. However, the present study basedon texture measurements by x-ray diffraction method, has shownthe sluggishness in the texture transition. This is explained interms of strain induced martensite formation.

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EFFECT OF AGEING TREATMENT ONTHE CORROSION PROPERTIES OF

ALLOY 800R.S. Dutta, P. Sengupta, S.J. Sivaraman,

G.K. Dey, G.B. Kale and P.K. DeBhabha Atomic Research Centre, Trombay, Mumbai-

400 085.E-mail: [email protected]

Electron probe microanalysis revealed different extent of Cr-depletion adjacent to Cr-carbides for the samples of Alloy 800aged at 7000C for 5 and 10 minutes. Inferior corrosion resistancedisplayed by the sample aged for longer period as comparedto annealed one could be attributable to the Cr-depletionadjacent to Cr-carbides.

MICROSTRUCTURALINVESTIGATIONS OF LONG TERM

SERVICE EXPOSED ALLOY 800TUBES

S. Chowdhury, B. Misra, P. J. Potdar1 andM. Sundararaman1

Heavy Water Board, Mumbai-400094,1 Bhabha Atomic Research Centre, Mumbai-400085


In this paper, the results of a detailed investigation carried outon Alloy 800 tubes which have seen prolonged service life aspig tail in many heavy water tubes is presented. Detailed TEMexamination revealed that M23C6 type of carbide has extensivelyprecipitated in all the tubes but the volume fraction of carbideprecipitate is different for tubes supposed to have undergoneidentical service conditions.

DEFORMATION BEHAVIOUR OFLAMELLAR TITANIUM

ALUMINIDESJ.B. Singh, M. Sundararaman, A. Couret 1,

G. Molenat 1 and R. KapoorBhabha Atomic Research Centre, Mumbai-400 085,

1 CEMES – CNRS, BP 4347, 31 055, Toulouse Cedex 4,FRANCE


Deformation behaviour of two-phase TiAl based lamellar alloyshas been studied as a function of lamellar spacing at differenttest temperatures between 25ÚC and 600ÚC in compressionmode. Yield strength was found to decrease with increasingtemperature. The microstructure of the deformed alloy wasinvestigated using a transmission electron microscope.

EVOLUTION OF MICROSTRUCTUREOF LAMELLAR TITANIUM

ALUMINIDE ALLOYM. Sundararaman, J. B. Singh, Garima Sharma

and S. BanerjeeBhabha Atomic Research center, Mumbai-400 085.


The evolution of the lamellar structure has been studied indetail in a Ti-47.8%Al-2%Cr-0.2%Si alloy in which differentlamellar spacing have been created by suitably altering thecooling rate from the solutionizing temperature. The possiblemethods of formation of interfaces and small angle boundarieshave been identified and the mechanisms responsible for theformation of two phase lamellar structure and also the evolutionof lamellar boundaries have been discussed in this presentation.

MARTENSITES IN Zr-1Nb ALLOYS. Neogy, D. Srivastava and G. K. Dey

Bhabha Atomic Research Centre, Mumbai-400 085.

Zr-1Nb alloy is being used as cladding material in pressurizedwater reactors. The performance of this material is very sensitiveto microstructure and thermomechanical treatment. In thepresent work, martensitic transformation in this alloy has beenstudied with respect to the morphology, crystallographic aspectsand variant arrangements of the martensites.

TERMINAL SOLID SOLUBILITY OFHYDROGEN IN Zr-ALLOY PRESSURE

TUBE MATERIALSS. Mukherjee and R. N. Singh

Bhabha Atomic Research Centre, Mumbai-400 085.E-mail: [email protected]

The terminal solid solubility of hydrogen in the Zr-alloy sampleswas determined using dilatometry. The enthalpies of hydridedissolution and precipitation for Zircaloy-2 pressure tubematerial were 30-34.5 and 25.9-26.3 kJ/mol, respectively,whereas the corresponding enthalpies for Zr-2.5Nb pressuretube material were 35.44 and 17.5 - 22.8 kJ/mol, respectively.?

ATOMIC FORCE MICROSCOPICSTUDIES OF P/M ALLOYS

S.K.Tiwari, R.K. Gupta and A. UpadhyayaIndian Institute of Technology,

Kanpur-208016.E-mail: [email protected]

Atomic force microscopy (AFM) is a useful characterizationtool for surface topographical investigation of materials withatomic resolution. This study demonstrates the application of

A45

AFM to image morphology and interface of a range of systems,such as liquid phase sintered tungsten heavy alloys, supersolidussintered Cu-Sn and ODS-stainless steels; nano-SiO2 powders.

ELECTROCHEMICAL IMPEDANCESPECTROSCOPIC STUDIES ON A TYPE316 STAINLESS STEEL WITH BIOFILM

P. Muraleedharan, R. P. George andH.S. Khatak

Indira Gandhi Centre for Atomic Research, Kalpakkam,Tamil Nadu


In the present study, electrochemical impedance spectrographyhas been used to understand the time-dependent changes in afresh water bio film formed on Type 316 SS and its influenceon the passivity of the underlying material.

FATIGUE THRESHOLD OF FERRITEBAINITE DUAL-PHASE STEELSA. Kumar, S. B. Singh and K. K. Ray

Indian Institute of Technology, Kharagpur - 721 302.E-mail: [email protected]

The influence of bainite content on the tensile properties andfatigue threshold of a few ferrite-bainite dual-phase steels ofidentical chemistry has been examined. The hardness and yieldstrength of these steels increase, while their fatigue thresholdvalues initially increase and then decrease with increasingbainite content.

CHARACTERISATION OF FLOWBEHAVIOR OF Cu-STRENGTHENED

HIGH STRENGTH LOW ALLOY STEELS.K. Das1, S. Shivaprasad, S. Chatterjee1 and

S. TarafderNational Metallurgical Laboratory, Jamshedpur-831007,

1B.E. College (D.U.), HowrahEmail: [email protected]

[email protected],

This paper highlights the flow behavior of the Cu bearingHSLA steel subjected to different thermal treatment procedures.The flow behavior of steel is found to be greatly influenced bythe micro constituents mainly the Cu rich precipitates, revertedaustenite and new dislocated martensite formed after ageing athigh temperature.

FAILURE ANALYSIS OF CAST IRONRINGS IN TV GLASS PLANTS: AN IN-

DEPTH STUDYP.K.Shukla, S. Rajeswari and S. Sangal

Indian Institute of Technology,Kanpur-208016.

E-mail: [email protected]@iitk.ac.in

Ductile cast iron rings are used as mold parts in themanufacturing process of TV Glass parts. They come incontinuous contact with molten glass in the forming processand are subjected to high temperature and pressure conditions,resulting in the change in the morphology of the cast iron atthe interface. This is discussed in detail in the paper.

USE OF X-RAY DIFFRACTION IN THEDETERMINATION OF RESIDUAL

STRESS OF INDUSTRIALCOMPONENTS

B. Ravi KumarNational Metallurgical Laboratory, Jamshedpur - 831007


In this paper, the use of X-ray diffraction techniques is discussedwith suitable examples related to problems associated withresidual stresses in industries.

STRUCTURE-PROPERTYCORRELATIONS IN MICROALLOYED

HSLA STEEL PLATESMANUFACTURED THROUGH

CONTINUOUS CASTING ROUTEN. Venkateswara Rao, B.S. Bansal, K. Ankalu,

M. Srinivas, K. Muraleedharan,R. Balamuralikrishnan and G. Malakondaiah

Defence Metallurgical Research Laboratory,Kanchanbagh PO, Hyderabad

E-mail: [email protected] [email protected]

Plates of microalloyed HSLA steel with thickness varying from8mm to 18mm were manufactured through SAIL by controlledrolling of continuously cast slabs. Samples from these plateswere subjected to macro etching, microstructural investigationand mechanical testing. Differences in the microstructuralfeatures (between the different plates) that are likely responsiblefor differences in the observed sub-zero impact toughnessproperties between the thinner (8, 10 and 12mm thickness)and thicker (14, 16 and 18mm) plates will be presented.

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MICROSTRUCTURAL ANDMICROCHEMICAL INVESTIGATIONSOF Ti-5Ta-1.8Nb WELDMENTS USING

ANALYTICAL TRANSMISSIONELECTRON MICROSCOPY

Arup Dasgupta, T.Karthikeyan, S.Saroja,M. Vijayalakshmi and V.S.Raghunathan

IGCAR, Kalpakkam 603 102E-mail: [email protected]

Detailed microstructural and microchemical investigations usinganalytical TEM technique on weldments of a developmentalTi-5Ta-1.8Nb alloy will be presented here. In addition, theTemperature-Time profile at various locations of the weldmentis being simulated to predict the microstructure at any locationand compare these with experimental evidence.

MICROSTRUCTURE CONTROLTHROUGH DESIGN OF TREATMENTS

AND CONSEQUENT EFFECT ONPROPERTIES OF Ti-5%Ta-1.8%Nb

ALLOYR. Mythili, S.Saroja, M.Vijayalakshmi and

V.S.RaghunathanIGCAR, Kalpakkam 603 102E-mail: [email protected]

This paper describes methods for enhancement of corrosionand mechanical properties in a high corrosion resistant Ti-5%Ta-1.8%Nb alloy by microstructure control through designof treatments, based on commercial experience of a+b Ti alloys.The alloy when solution treated (1113K) and aged (823-873K)in the a+b phase field imparts high strength and ductility to thealloy.

MICROSTRUCTURALCHARACTERIZATION OF INTER

CRITICAL ZONE IN WELDMENT OFMODIFIED 9Cr-1Mo STEEL

V. Thomas Paul, S.Saroja, M.Vijayalakshmiand V.S.Raghunathan

IGCAR, Kalpakkam 603 102E-mail: [email protected]

This paper discusses the reasons for failure in Inter CriticalRegion in a modified 9Cr-1Mo steel weldment. The failureshave been attributed to the weak boundary between martensiteand soft ferrite Low defect density, fresh nucleation andcoarsening of pre-existing precipitates suggest over temperingof ferrite, typical of the temperature (Ac1-Ac3) experienced bythis region.

SERRATED YIELDING IN PRIORDEFORMED AND THERMALLY AGED

ALLOY D9K.G. Samuel, S.K. Ray and Baldev RajIndira Gandhi Centre for Atomic Research,

Kalpakkam 603 102.E-mail: [email protected]

Serrated yielding behavior of a fully austenitic 15Cr-15Nititanium modified stainless steel (D-9) is studied in a priordeformed condition after thermal ageing. The results arecompared with the behavior of a well annealed material.

FRACTURE BEHAVIOR OF AZ91MAGNESIUM ALLOY

A. Srinivasan, P. Prabhakar Rao,K. Sukumaran, U.T.S. Pillai and B.C. Pai

Regional Research Laboratory, Trivandrum- 695 019.E-mail: [email protected]

Even though the use of Mg alloys are in increasing trend, notmuch research work has been carried out on these alloyscompared to aluminum alloys to understand the microstructuralfeatures which influence the mechanical properties. ScanningElectron Microscopy (SEM) observations were carried out toexamine the fracture behavior and micro-fracture mechanismsof Si and Sb added AZ91 Mg alloy samples ruptured by tensileand impact tests. The effect of Si and Sb on the fracture modewas also studied in detail.

INVESTIGATION ONMICROSTRUCTURE AND HIGH

TEMPERATURE PROPERTIES OF SiAND Sb ADDED AZ91 MAGNESIUM

ALLOYA. Srinivasan, J. Swaminathan1, T. Soman,

S.G.K. Pillai, U.T.S. Pillai and B.C. PaiRegional Research Laboratory, Trivandrum-695019,

1 National Metallurgical Laboratory, Jamshedpur.E-mail: [email protected]

AZ91(Mg-9Al-1Zn-0.2Mn) magnesium alloy finds industrialapplications because of its improved room temperaturemechanical properties but its high temperature applications arerestricted because of its poor creep resistance. In the presentinvestigation, Si and Sb are added to AZ91 alloy to study itseffect on the microstructure and mechanical properties. Roomas well as the high temperature (1500C) mechanical propertiesand creep behavior are evaluated and they are correlated withthe detailed microstructure.

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EFFECT OF WELD BEADMORPHOLOGY ON THE

MICROSTRUCTURE OF COPPERBORON STEEL WELD

B. Basu, C.M. Omprakash, A. Lewis,A. Panday1, B.M. Singh, G. Rao and A.K. Shah

Naval Materials Research Laboratory, Mumbai,1 Govt. Engg. College, Raipur

Submerged arc welding of a high strength structural steel wascarried out to correlate the weld metal microstructure with theweld bead morphologies. The morphologies like nugget area,penetration, reinforcement and the parameters (NA/C1) wereobserved to have a very good correlation with the weldingparameters.

ASPECTS RELATING TO THEORIENTATION RELATIONSHIP OFNANOSCALE PRECIPITATES WITH

THE AUSTENITE MATRIX IN ALLOYD9

R. Divakar, A. Banerjee, S. Raju andE. Mohandas

Indira Gandhi Centre for Atomic Research, Kalpakkam,TN-603102.


Alloy D9 is titanium modified 316 austenitic stainless steel.The present work is an analysis of Moire fringes formed dueto the overlap of the austenite matrix and the TiC precipitatesand of the lattice images of the precipitates, matrixinterface.

DEVELOPMENT OF MAGNETICANISOTROPY IN Nd-Fe-B RING

MAGNETS. Prakash Narayan and H.S. Jain1

Regional Research Laboratory, Bhopal1BHEL corporate R&D, Hyderabad

In this paper, a study has been carried out for the preparationof radially oriented Nd-Fe-B ring magnets and a processoptimization has been done by varying die-punch, temperatureand applied force to develop magnetic anisotropy in the radialdirection.

FAILURE ANALYSIS OF STEAMPOWER PLANT EQUIPMENTSM. Sujata, M.A. Venkatasamy, M.A.

Parameshwara, M. Suresh Kumar, M. Madhan,S. K. Bhaumik and R.V. Krishnan

National Aerospace Laboratories, Bangalore-560 017.

In this paper, a few case studies on the failures of steam powerplant components made of steels are described. These includefailure of startup vent line tubes of boiler (mild steel), meroxoff gas line to crude heater (mild steel), superheated tube (mildsteel) and connecting pipe of the boiler feed water pre heater(austenitic SS). Various studies were conducted on the failedcomponents to arrive at the possible reasons for failures.Recommendations are made to avoid recurrence of similarfailures.

MECHANICAL BEHAVIOR

EVALUATION OF DAMAGE CAUSEDBY SODIUM FIRE ON MILD STEELN. Sivai Bharasi, H. Shaikh, S.Venugopal,

F. C. Parida, S.E. Kannan and H.S. KhatakIndira Gandhi Centre for Atomic Research,

Kalpakkam – 603 102.E-mail: [email protected]

Exposure to sodium fire caused the following effects in mildsteel: (a) high corrosion rates, (b) the ferrite + carbidemicrostructure remained stable, (c) increase in grain size withfire of increasing sodium inventory leading to drop in upperand lower yield points (d) no changes occurred in hardness,ductility and ultimate tensile strength.

CONTROL OF LAVES PHASE ININCONEL 718 ELECTRON BEAMWELDS THROUGH THE USE OF

DIFFERENT BEAM OSCILLATIONTECHNIQUES

A. Sambasiva Rao, G. Madhusudhan Reddy,C. V. S. Murthy1 and K. Prasad Rao2

Defence Metallurgical Research Laboratory,Kanchanbagh, Hyderabad-500 058.

1 Defence Research and Development Laboratory,Kanchanbagh, Hyderabad-500 058.

2 Indian Institute of Technology, Madras,Chennai- 600 036.

E mail: [email protected]

Inconel 718, has excellent weldability, however it has alimitation in the form of niobium segregation (laves phase)which leads to degradation of mechanical properties. A detailedstudy was taken up to reduce the niobium segregation in 718

A48

electron beam welds during welding stage itself. The SEM andEPMA analysis showed that there was significant reduction ofniobium segregation in the interdentritic regions and themechanical properties were found to be superior to oscillatedbeam weldments.

HIGH STRESS ABRASIVE WEARBEHAVIOR OF ALUMINIUM ZINC

ALLOY: EFFECT OF ALLOYCOMPOSITION

V. Rajput, D.P. Mondal and S.DasRegional Research Laboratory (CSIR), Bhopal-462 026.


This paper presents the abrasive wear behavior of Al-Zn alloywith Zinc concentration varying from 30-70%. Experimentalparameters such as load, abrasive size, distance etc. werecorrelated with materials parameters. It shows that smearing ofphases leads to lowering of wear rate during two-body abrasivewear.

EFFECT OF HOLD PERIOD ON LOWCYCLE FATIGUE BEHAVIOUR OF

NEAR -TITANIUM ALLOY IMI834 ATROOM TEMPERATURE

K.V. Sai Srinadh and Vakil SinghBanaras Hindu University, Varanasi-221005

E-mail: [email protected]@yahoo.com

Effect of hold period on Low Cycle Fatigue (LCF) behaviourof the near a-titanium alloy IMI834 has been studied, at roomtemperature. LCF tests were conducted at a constant strain rateof 0.008s-1. The deleterious effect of hold on fatigue life wasrelatively more for compressive hold than that for tensilehold.

EFFECT OF MINOR ADDITIONS ONSTRUCTURE AND PROPERTIESOF

FERRITIC STAINLESS STEELO.P. Sinha and M. Chatterjee

Mishra Dhatu Nigam Limited, Hyderabad

This paper deals with the effect of minor addition of Nitrogenand Ni on the microstructure and properties of conventionalAISI 430 ferritic steel under different heat treatmentconditions.

CREEP RUPTURE PROPERTIES OFINDIGENOUSLY DEVELOPED

MODIFIED 9Cr-1Mo STEAMGENERATOR TUBE STEEL

B. K. Choudhary, E. Isaac Samuel,K. Bhanu Sankara Rao and S. L. Mannan

Indira Gandhi Centre for Atomic Research, Kalpakkam,Tamil Nadu

E-mail: [email protected] ; [email protected]

The results obtained on the creep-rupture properties of modified9Cr-1Mo Steam Generator (SG) tube steel are presented in thepaper. The creep rate-rupture life relations of Monkman-Granttypes and the creep damage tolerance factor defining damagemechanism along with the comparison of rupture strength withthose available in the literature and the design code arehighlighted.

CREEP-FATIGUE INTERACTIONBEHAVIOUR OF A MODIFIED 9Cr-1Mo

FERRITIC STEELA. Nagesha, M. Valsan, V.S. Srinivasan,

K. Bhanu Sankara Rao and S.L. MannanIndira Gandhi Centre for Atomic Research, Kalpakkam,

Tamil NaduE-mail: [email protected]

[email protected]

Low cycle fatigue tests carried out at different strain rates overa wide temperature range revealed that fatigue life decreaseswith increase in temperature and decrease in strain rate. Creep-fatigue interaction tests conducted at 873K by introducingtensile hold times of different durations showed that life reducescontinuously with increase in the hold time, owing to oxidationeffects.

PROCESSING AND MECHANICALPROPERTIES OF MULTI-LAYER

COATINGS OF (TiN-AlTiN) ON STEELS. J. Suresha, R.Bhide1, K.Ravindranath1,

V. Jayaram and S. K. BiswasIndian Institute of Science, Bangalore,

1 Multi-Arc (India) Ltd., [email protected]

Multi layer TiN/AlTiN films with, bi-layer spacing as small as4 nm, have been produced by cathodic arc evaporation usingsample rotation. In addition, a complex set of microstructureswas found in which alternate layers of TiN and AlTiN areseparated, at the interface, by a finer banded microstructure.The mosaic of microstructures obtained under differentprocessing conditions had little influence on the hardeness andelastic modulus in comparison with those of monolayer TiNand Al TiN.

A49

FRACTURE MODE TRANSITIONSDURING INDENTATION OF TIN

COATINGS ON STEELS: THE ROLE OFFILM THICKNESS AND SUBSTRATE

PLASTICITYS. Bhowmick, K. Ravindranath1, V.Jayaram

and S.K.Biswas Indian Institute of Science, Bangalore,

1 Multi-Arc (India) Ltd., [email protected]

In this paper, TiN film coating on Al, mild steel, stainless steeland high speed steel are carried out and qualitative model isdeveloped to explain the fracture mode transition on the basisof competition between the ability of the film to slide and thedevelopment of significant plastic deformation.

EVALUATION OF IRRADIATIONEMBRITTLEMENT OF AISI 403

MODIFIED STEELU. K. Viswanathan, S. Anantharaman,K.S. Balakrishnan, S. Chatterjee and

K.C. SahooBhabha Atomic Research Centre, Mumbai-400 085

To monitor the extent of neutron irradiation inducedembrittlement, impact test specimens were irradiated in CIRUSreactor to a fluence of 1 x1019n/cm2 (E>1 MeV) at 290º ±10ºC. Based on the observed increase in the CV -41J transitiontemperature, the end fitting material is found to be safe forcontinued operation up to the end of life fluence of 6 x1019N/cm2 (E>1 MeV)

EVALUATION OF ULTIMATE TENSILESTRENGTH AND FRACTURE

TOUGHNESS OF ZIRCALLOYS BYSMALL PUNCH TEST (SPT)

B.N.Rath, R.S.Shriwastaw, V.P.Jathar,E.Ramadasan and K.C.Sahoo

Bhabha Atomic Research Centre, Trombay,Mumbai-400 085


Neutron irradiation degrades mechanical property of Zirconiumalloys used in nuclear reactors. Small Punch Test (SPT)technique which uses TEM size specimens (3 mm 250 mthick) is being developed to reduce man-rem exposure forevaluating mechanical property changes in irradiated Zircalloytube material at various temperatures.

EVALUATION OF FATIGUE CRACKGROWTH RATES OF DIFFERENT

FERRITIC STEELS USINGSTANDARD AND NON-STANDARD

SPECIMENS

Priti Kotak Shah and S. ChatterjeeBhabha Atomic Research Centre, Mumbai-400 085

This paper deals with the fatigue crack growth measurementusing K-Decreasing method during precracking of standard(CT specimen) and non-standard (Charpy, V-notch and 3-Pbend specimens) specimens of four ferritic steels namelyA533B, SA 333, Grade 6 and 20Mn-Mo-Ni55.

EVALUATION OF FRICTION WELDEDAISI 430 FERRITIC STAINLESS STEEL

JOINTS

P. Sathiya, S.Aravindan1 and A. Noorul Haq1

J.J. College of Engineering and Technology,Tiruchirappalli -620 009, Tamil Nadu,

1 National Institute of Technology,Tiruchirappalli -620 015, Tamil Nadu


Present study utilized a continuous drive friction-weldingmachine and ferritic stainless steel cylindrical specimens ofsimilar composition and shape (equal diameter and length)were subjected to friction welding. The processing parameterssuch as Friction Pressure, Friction Time, Upsetting Pressureand upsetting time were changed in order to understand therole of parameters on the strength related aspects of friction-processed joints.

EFFECT OF METAL SURFACETEXTURE ON METAL/ QUENCHANT

INTERFACIAL HEAT TRANSFER

K. Narayan Prabhu and Peter FernandesNational Institute of Technology Karnataka, Surathkal


The effect of metal surface texture on heat transfer rates duringquenching in various media was investigated. Heat transferanalysis, microstructure studies and hardness profiles showedthat the effect of metal surface roughness on quenching wassignificant for water and brine while its effect in high viscosityoils was marginal.

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THE EFFECT OF PRE-STRAIN ONDUCTILE FRACTURE BEHAVIOUR OF

INTERSTITIAL FREE STEEL

S. Majumdar* and K.K. RayIndian Institute of Technology, Kharagpur, *On study

leave from TISCO Pvt. Ltd. Jamshedpur

The critical void nucleation strain ( c) and dimple characteristicshave been estimated for a series of broken pre-strained tensilespecimens of interstitial free steel. The magnitude of c initiallyincreases and then decreases with increased pre-strain. But thedimple size is found to bear a proportional relationship with cand can be used to predict the later.

EVALUATION OF EMBRITTLEMENTON IRRADIATED COOLANT

TUBES

K.S. Balakrishnan, Priti Kotak Shah, andS. Chatterjee

Bhabha Atomic Research Centre, Mumbai-400 085

Assurance against leak before break (LBB) based on fracturetoughness data is a vital pre-requisite for the safe operation ofpressure tube (PT). Fracture toughness properties of fourirradiated PTs with Effective Full Power Years of operationranging from 3.5 to 9.5 and having hydrogen contents up to200 ppm were evaluated and analyzed vis-a-vis assuranceagainst LBB of PTs during reactor operation.

INTEGRITY ASSESSMENT OF RPVSTEELS THROUGH MASTERCURVE –A NEW APPROACH

S.Chatterjee and K.S.BalakrishnanBhabha Atomic Research Centre, Mumbai-400 085


The utilization of fatigue precracked Charpy impact type ofspecimens for the integrity assessment of pressure vessel (PV)steels through the Master curve approach, has been standardizedby participating in a round robin programme involving manyadvanced laboratories. The paper discusses the procedurefollowed in the standardization and the results obtained byusing two PV steels

EVALUATION OF TENSILE PROPERTYDATA ON TUBULAR COMPONENTS -

A CHALLENGE

K.S.Balkrishnan, A.B.Tamhne, S.Anantharaman,S.Chatterjee, and K.N. Mahule

Bhabha Atomic Research Centre,Mumbai-400 085, India


This paper brings out the results of irradiated ring tension testsconducted on irradiated nuclear reactor fuel element cladding(14 mm outer diameter and 0.89 mm wall thickness) at roomtemperature as well as on irradiated pressure tubes (90 mmouter diameter and 4.2 mm wall thickness) performed at varioustest temperatures.

ROLE OF BORON ADDITION ON THETOUGHNESS PROPERTIES OF

COPPER-PHOSPHORUS CONTAININGWEATHER RESISTANT STEEL

M.L. Narula and S.K. SenRDCIS, SAIL, Ranchi-834002


In the weather resistant steels, presence of phosphorous inducesbrittle fracture at the grain boundaries associated with itssegregation. This results in decrease in toughness properties ofthe steel and restricts its use to low temperature applications.The problem has been overcome by extensive laboratoryinvestigations by addition of boron. Results of the tensile,impact and metallography studies have been described in thispaper to propose a mechanism by which boron improvestoughness properties of high phosphorous steel.

HIGH TEMPERATURE TENSILE ANDLOW CYCLE FATIGUE (LCF)

BEHAVIOUR OF 9Cr-1Mo-1W STEELB.R. Panda and Vakil Singh

Banaras Hindu University, Varanasi – 221 005E-mail: [email protected]

The tensile behaviour of the 9Cr-1Mo-1W steel was studiedfrom RT-650OC. Dynamic strain aging is observed at 300OC.Uniform strain decreases with increase in temperature above300oC. The LCF behaviour of the 9Cr-1Mo-1W steel isinvestigated. The cyclic stress response behavior showed acontinuous cyclic softening up to failure. The fatigue lifedecreased as the temperature increased.

A51

FLAW ACCEPTANCE STANDARD INCODES: WORKMANSHIP VS FITNESS-

FOR-PURPOSEB.K. Shah

Bhabha Atomic Research Centre, Mumbai-400 085

The flaw acceptance clauses in various codes give the Non-Destructive Testing (NDT) methods to be used and themaximum size of flaws which can be tolerated. Specifiedacceptance levels for flaws are essentially based on ‘GoodWorkmanship’. There is a need to asses the significance offlaws with respect to Fitness-For-Purpose (FFP) which is basedon fracture mechanics. British Standard Institution has issuedBS 7910 (1999) ‘Guide on methods for assessing theacceptability of flaws in metallic structures’ which is beingused world wide for assessing acceptability of flaws with respectto fitness-for-service. This presentation will discuss themethodologies for assessing flaw severity and illustrate theconcept with some case studies.

STUDY OF THE STRAIN AGINGBEHAVIOUR IN ULTRA LOW CARBON

BAKE HARDENING STEELN. Bhagat1, 2, S. J. Baek2 and Hu-Chul Lee2

1 School of Materials Science and Engineering, SeoulNational University, South Korea,

2 Tata Steel, Jamshedpur, Jharkhand-831001

In the present work, the effect of tensile strain (0.5 - 4%) andsolute content (1.2 – 5.1 ppm) on the strain aging behaviourof ultra low carbon bake hardening steel has been studied. Theyield point elongation increased with the increase in deformationtill 4 %, whereas the “Y increased abruptly at 0.5 % with nomajor change at higher strain. Kinetics of the strain agingprocess was assessed using Cottrell-Bilby approach.

FATIGUE CRACK GROWTH BEHAVIOROF INDIGENOUS HIGH STRENGTHLOW ALLOY STRUCTURAL STEEL

FOR MARINE APPLICATIONSC.M. Omprakash, M. Nani Babu, K. Sridhar,

B. Basu and V.V. ModakNaval Materials Research Laboratory, Addl. Ambernath,

Anandnagar Po, Mumbai-421 506.

In our study, the indigenously developed high strength lowalloy structural steel has been tested for Corrosion FatigueCrack Growth Rate (CFCGR) at a load ratio of 0.1 and in therange of 1 to 5Hz frequency of both base and weld in presenceof air and 3.5% NaCl .

HOMOGENISATION AND AGEINGBEHAVIOUR OF COPPER BEARING IF

STEELSR. K. Rana, S. B. Singh and O. N. Mohanty

Indian Institute of Technology KharagpurE-mail: [email protected]

Ageing behaviour of IF steel containing 0.8 wt% Cu was studiedusing a variety of techniques including Thermo Electric Power(TEP). Excellent ageing response was obtained after properhomogenisation. Thermo Electric Power (TEP) measurementsshowed that Cu has a negative co-efficient of TEP in iron.

STUDY OF LOW TEMPERATUREANNEALING ON DEEP DRAWN STEEL

CARTRIDGE CASE FOR DEFENCEAPPLICATION

L.B.Singh and D.K.SarkarOrdnance Factory, Ambarnath-421 502


A study has been carried out to see the effect of low temperatureannealing at 350°C with 1¼ hours soaking time on finishedCartridge Case. Ten numbers of Cartridge Cases of the samelot having same chemical composition were subjected tohardness, tensile strength, elongation testing and microstructureanalysis before and after low temperature annealing. Theseproperties were tested at the points of 10mm, 50mm and 140mm from the mouth end of the Cartridge Cases.

MICRO-MECHANISMS OF HIGHTEMPERATURE FATIGUE CRACK

GROWTH IN IMI-834 NEARTITANIUM ALLOY

G.Nagalaxmi and Vikas KumarDefence Metallurgical Research Laboratory,

Kanchanbagh,Hyderabad –500 058


Effect of various parameters on high temperature fatiguebehavior of a near á titanium alloy has been investigated usingSingle Edge Notch Tension (SENT) specimen configurationon a computer controlled servo hydraulic MTS-880 test system.It is observed that higher temperatures, longer hold times andlower frequencies lead to high fatigue crack growth rates.Extensive SEM fractographic investigations revealed mainlycleavage features at lower K levels and striation types athigher K levels. Specimens corresponding to hightemperatures, low frequencies and large hold times showpresence of oxide features and cavitations.

A52

HIGH TEMPEREATUREMECHANICAL BEHAVIOUR OF

SUPERALLOY IN 718

K. Sisupalan, G.Venkata Narayana,V.M.J. Sharma, K. Thomas Tharian,

V. Diwakar and K. Sree KumarVikram Sarabhai Space Centre (ISRO),

Trivandrum 695 022,

This paper presents the high temperature deformation behaviorof IN 718 super alloy. Isothermal constant strain rate tensiletests were conducted at 873, 973, 1073 and 1173 K with initialstrain rates of 0.01, 0.1 and 1.0 s-1. The effect of hot deformationparameters such as strain, strain rate and deformationtemperature on strain hardening and flow stress properties wereanalyzed. The results are discussed in the light of themicrostructural and fractographic features.

WEAR STUDIES ON IRONALUMINIDE INTERMETALLIC

ALLOY

Garima Sharma and M. SundararamanBhabha Atomic Research Centre, Mumbai-400 085

Room temperature dry sliding wear behavior of DO3 basediron aluminides has been investigated using a pin on disk andball on plate wear tester. Tests were carried out for differentcomposition of iron aluminides and also with chromiumaddition at a range of load and sliding speed. The micromechanism responsible for wear was studied by SEM.

VARIATION IN STRUCTURE-PROPERTY OF PH 13-8 MoSTAINLESS STEEL UNDER

IDENTICAL HEAT-TREATMENTCONDITIONS

J. Mitra and P.K. DeBhabha Atomic Research Centre, Mumbai 400 085.


PH 13-8 Mo stainless steel samples from three different batchesof melt were subjected to identical heat-treatment. However,significant variation in the tensile and impact properties wasnoticed although, crucial elements were found in the specifiedrange. Change in the prior austenite grain size appearedresponsible for this variation.

STUDIES ON HEAT TREATMENTFIXTURES FOR FORMED

COMPONENTS

R.S.Amruth Kumar, N.S.Mahesh, R.R.Bhat1

and Subrahmanya Shastry1

M.S.Ramaiah Institute of Technology, Bangalore1 Hindustan Aeronautics Limited, Bangalore-560 017.


Commonly used fixture material is plain carbon steel owing toits cost. Warpage, deformation and scaling of plain carbonsteel fixtures were noticed due to repeated heating andquenching resulting in considerable decrease in the life of thefixtures. With this in view, an attempt has been made toinvestigate and recommend suggestions for increasing theworking life of heat treatment fixtures. The primary goal of thepresent work is to identify an alternative fixture material tosuit the conditions prevailing in heat treatment cycles.

STUDY OF WEAR BEHAVIOUR OFAUSTEMPERED DUCTILE IRON

Ritha Kumari and P. Prasad RaoNational Institute of Technology, Surathkal, Karnataka.


The present investigation is taken up to study the influence ofmicrostructure on the wear behavior of ADI. Wear test resultsshowed that a microstructure consisting of lower bainite andless retained austenite with high carbon content is alwaysbeneficial to wear resistance. At high austempering temperaturesthe retained austenite is instrumental in improving the wearresistance.

OPTIMIZATION OF HEAT TREATMENTPARAMETER OF Co-Cr-W-Ni

SUPERALLOY PLATES / SHEETS

R.K. Gupta, B.R. Ghosh, P.P. SinhaVikram Sarabhai space Centre, Trivandrum-695 022.


In the course of the development of the alloy extensive studieson the optimization of the heat treatment parameter of thisalloy was carried out. Experimental results and their analysiscould lead to the establishment of optimized heat treatmentparameters with respect to desired mechanical properties. Thispaper presents the experiments conducted and analysis of thedata evolved to achieve the desired properties.

A53

FATIGUE BEHAVIOUR OF IN718WELDMENTS

Sivaprasad Katakam, S. Ganesh SundaraRaman, C. V. Srinivasa Murthy1 and

G. Madhusudhana Reddy2

Indian Institute of Technology Madras,1 Defence Research and Development Laboratory,

Hyderabad,2 Defence Metallurgical Research Laboratory,

HyderabadE-mail: [email protected]

Techniques like pulsed current and arc oscillation in gastungsten arc welding reduce segregation of Nb in theinterdendritic region of IN718 welds and improve tensileproperties and stress rupture life of welds. The presentinvestigation deals with the fatigue behaviour of IN718weldments prepared using these techniques.

TRIBOLOGICAL CHARACTERISTICSOF ELECTRODEPOSITED

NANOCRYSTALLINE Ni-Fe-W ALLOYSK. R. Sriraman, S. Ganesh Sundara Raman and

S. K. SeshadriIndian Institute of Technology Madras,

Chennai-600036.E-mail: [email protected]

In this paper the deposition characteristics and tribologicalstudies of Ni-Fe-W poly alloy are discussed. The wear depthsof the coatings initially increased with lower hardness values,then showed a decreasing trend and then tend to increase.Maximum resistance to wear was observed at peak hardnessvalues. Beyond a critical amount of W in the coating thecrystallite size reduction reduced the hardness there by showingreverse Hall Petch behavior and thus this contributed toreduction in the wear resistance. The scanning electronmicrographs confirmed the effective material transfer from thepin to the counter disc there by confirming to mild adhesivewear mechanism.

EFFECT OF SUBSTRUCTURE ON THEWEAR BEHAVIOUR OF STEELV. Toppo, S. B. Singh and K. K. Ray

Indian Institute of Technology, Kharagpur-721302.E-mail: [email protected]

The effect of pre-strain on wear behavior of plain carbon steelhas been examined. The wear rate of the steel was found toincrease with increasing pre-strain up to a critical level. Theobserved variation in wear rate with pre-strain has beendiscussed using the dominance of delamination and oxidativewear.

A RE-EXAMINATION OF LUDWIGSONSTRESS-STRAIN RELATIONSHIP

K.G. Samuel and P. Rodriguez1

Indira Gandhi Centre for Atomic Research,Kalpakkam 603102.

1 Indian Institute of Technology, Chennai-600036.E-mail: [email protected]

This paper presents a re-examination of the Ludwigson relationand the often cited explanation for the Ludwigson type strainhardening found in stainless steels to a changeover from planarslip to cross slip. It is observed that the transition strain whichis about 25% in as received material still persists and is aslarge as 10-11% even after the material was given a prior coldwork of 24.7%. The results also reinforce the point that workhardening is a more appropriate parameter than stress or strainto describe the “hardness/strength /microstructural” state of aspecimen.

THE SCALING OF STRAIN-HARDENING INDEX AND STRAIN-HARDENING COEFFICIENT WITH

YIELD STRENGTH IN TYPE 316STAINLESS STEELS

K.G. Samuel, S.K. Ray and P. Rodriguez1

Indira Gandhi Centre for Atomic Research, Kalpakkam603102, India.

1 Indian Institute of Technology, Chennai 600036.E-mail: [email protected]

Strain hardening parameters (K and n) derived from the truestress true plastic strain relationship following Hollomonrelation in tensile deformation of three types of austeniticstainless steels, subjected to different thermo-mechanicaltreatments to vary its initial microstructure and yield strength,was investigated and the results are discussed.

DEPENDENCE OF STRAINHARDENING PARAMETERS WITH

STRENGTH AND ITS USEFULNESS TOASSESS THE TOUGHNESS OF THE

MATERIALK.G. Samuel, S.K. Ray and P. Rodriguez1

Indira Gandhi Centre for Atomic Research, Kalpakkam603102.

1 Indian Institute of Technology, Chennai 600036.E-mail: [email protected]

This paper presents the various possible dependence ofHollomon work hardening parameters K and n, derived fromthe true stress - true plastic strain data for tensile deformation,with the initial yield strength of the material. It is also shownthat these parameters can be used to assess the toughness ofthe material in terms of the plastic strain energy at the test

A54

temperature up to the onset of tensile instability. It is shownthat the suitability of a material in terms of its strength andtoughness at the temperature of its intended use can also beassessed with the knowledge of K and n from a simple tensiletest.

SHORT CRACK VIS-À-VIS LONGCRACK THRESHOLD IN STEEL

K. K. Ray and N. Narasaiah*

Indian Institute of Technology, Kharagpur - 721302.* Currently with National Metallurgical Laboratory,

Jamshedpur – 831007.E-mail: [email protected]

The short and long crack fatigue thresholds and the influenceof microstructure on the nature of short crack path have beenexamined for 0.003, 0.25 and 0.47% carbon steels using arecently developed technique. The ‘near long crack fatiguethreshold’ values obtained from short crack growth studies arein good agreement with the corresponding fatigue thresholdfor the long cracks.

INVESTIGATION AND CONTROL OFTRANSVERSE CRACKS AND

OTHER CONCAST DEFECTS FORCRNO-GRADES STEEL

AT RSP

Devasish Mishra, R.K. Patra, S.K. Acharya,U.C. Patra and U.K. Bhatacharya

Rourkela Steel Plant, Rourkela

Cold rolled non-oriented (CRNO) grades of electrical Steel isbasically a low carbon- Fe-Si alloy with large amount ofaluminium. Presence of silicon and aluminium contributes tothe elimination of allotropic transformation in Iron andconsequently these alloys can be annealed at high temperatureto obtain large grains, better watt-loss property. However,because high silicon and aluminium content, these grades arecrack sensitive and exhibit low ductility and strength at elevatedtemperatures along with columnar structures and low thermalconductivity, which make these grades of steel difficult forcontinuous casting. This paper describes in detail the mechanismof defects generation, corrective action taken, with specialemphasis on the prevention of “transverse cracks” in CRNOgrades.

MODELLING AND SIMULATION

MIXING TIMES AND CORRELATIONFOR DUAL PLUG STIRRED LADLE:QUANTIFYING THE ROLE OF AN

UPPER BUOYANT PHASED. Mazumdar

Indian Institute of Technology, Kanpur-208016.E-mail: [email protected]

Mixing times in water model ladles fitted with twin porousplugs were measured for various operating conditions. It wasshown that for a slag free situation, mixing times and operatingvariables (liquid depth, vessel radius and gas flow rate, Q)are related as: 0.256.038.0

%95, 15 RLQmix−−=τ . Then

the corresponding relationship in the presenceof slag is expressed through the equation:

0.27.033.03.0%95, 60 RLQmix

−−= ητ , inwhich, is the fractional slag depth (= L/L).

TRANSPORT PHENOMENA IN SPRAYDEPOSITION: A MATHEMATICAL

MODELS. Harikishore and S.C.Koria

Indian Institute of Technology, KanpurEmail : [email protected]

Transport phenomena play an important role in spray deposition.The microstructure and the mechanical properties of as-deposited material depend on thermal and solidification historiesof the droplets. Employing Langragian and Lumped-Heat-Capacity approaches and rapid solidification phenomenon tostudy the thermal and solidification behaviour of dropletsdevelops a mathematical model. The results of the calculationsare presented as a function of several process technologicalparameters.

PHASE DISTRIBUTIONS IN MCrAlYCOATINGS AND THEIR

INTERACTIONS WITH NICKEL BASEDALLOYS-THROUGH COMPUTIONAL

MODELLINGD. R. G. Achar

Indian Institute of Technology Madras.E-mail: [email protected]

Computational simulation modeling has been applied to followphase changes and inter diffusion processes in the temperaturerange between 950 and 1050o C in the MCrAlY coatingmaterials containing Co and Rhenium. Further, interdiffusionbetween NiCoCrAlY coating and a Ni-based superalloy

A55

substrate material at 1000oC has been simulated and resultscompared with the experimental findings.

MONTE CARLO SIMULATIONS OFMICROSTRUCTURAL EVOLUTION IN

MODEL Ni-Al-X (X = Cr, Co, Re)SYSTEMS

R. Sankarasubramanian andR. Balamuralikrishnan

Defence Metallurgical Research Laboratory,Hyderabad

Monte Carlo simulations of model ternary Ni-Al-X (X = Cr,Co, Re) systems, using pair-wise interatomic potentials, havebeen performed as a prelude to understanding the microstructureevolution in actual nickel base superalloys. The microstructuralevolution in terms of different order parameters, the partitioningof the ternary element into the ordered and disordered regions,and the sublattice occupancy within the ordered structure willbe presented.

STUDY OF PARTICLE SEPARATION BYFLUIDIZATION

A.K. Mukherjee and B.K. Mishra1

Tata Steel, Jamshedpur.E-mail: [email protected]

1 Indian Institute of Technology Kanpur. E-mail:[email protected]

Research work on fluidization indicates that particles of sizeratio below 0.2 and above 0.6 tend to either mix or segregate.Particles of intermediate size ratios behave either way dependingon the fluid velocity. Present study uses experimental data anda DEM based model to study the influence of fluid velocity onfluidization characteristics for all three types of particles.

VIRTUAL SENSORS IN RE-HEATINGFURNACE

K. Suresh Kumar, Anubha Prasad, AnuragAgnihotri and Navin Kumar

Tata steel, PuneE-mail: [email protected]

The side wall thermocouples in the furnace are used to controlthe zonal temperatures whereas, the thermocouples in the roofand hearth (Top/bottom) are used to deduce the slab temperaturewhich are prone to fail and difficult to maintain. The Top/bottom thermocouples have been replaced by virtualsensors.

EFFICIENCY ENHANCING SOLUTIONFOR HEAT TREATMENT OPERATIONS:MODEL BASED DESIGN OF OPTIMAL

PROCESS CYCLES

Satyam S. Sahay, Jeevan Jaidi andKarthik Krishnan

Tata Research Development andDesign Centre, Pune 411 013.E-mail: [email protected]

Heat treatment operations have significant bearings on plantproductivity, energy, quality and emissions. Nevertheless, theyare empirically designed in the plant, which results in sub-optimal operations. In this presentation, a formal approach ofdesigning optimal heat treatment cycles through processmodeling will be elaborated through successful industrial casestudies.

MONTE CARLO STUDY OFINTERFACIAL PROPERTIES OF

PHASE SEPARATINGALLOYS

Saswata Bhattacharyya, Ferdinand Haider 1

and T.A. AbinandananIndian Institute of Science, Bangalore 560012,

1 Institut fur Physik, Universitaet Augsburg, Augsburg,Germany

We have studied the interfacial properties of phase separatingbinary alloys using Monte Carlo (MC) simulation technique.The interfacial free energy is computed using directthermodynamic integration procedure. We have determined theequilibrium shapes of precipitates from the simulations andcompared them with the corresponding Wulf shapes.

VALIDATION OF PHASE FIELD MODELFOR STUDYING PRECIPITATION

GROWTH KINETICS

R.Mukherjee and T.A.AbinandananIndian Institute of Science,

Bangalore, 560012E-mail: [email protected]

In this paper an attempt has been made to demonstrate thecorrectness of a phase field model in a kinetic setting, byvalidating it against known results for precipitate growthkinetics.

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FINITE ELEMENT METHOD BASEDSIMULATION OF WATER COOLING OF

RODSRajeev Baskiyar

RDCIS, SAIL, Ranchi- 834002E-mail: [email protected]

Accelerated cooling of hot-rolled steels is being increasinglyused as a value addition tool. A predictive capability of thetransient temperature profile of the stock being cooled isnecessary for tailoring the required product properties. Thepaper deals with the approach for the development of amathematical model for water-cooling of rods using the FiniteElement Method (FEM) and discusses alternative coolingstrategies using the simulation results.

EFFECT OF STRESS TRIAXIALITY ONDUCTILE FRACTURE BEHAVIOR OFNEAR -TITANIUM ALLOY IMI-834 –A MICRO-MECHANICS APPROACH

Jalaj Kumar, B. Venkateswara Rao1, S. Padma2,B.Srivathsa and Vikas Kumar

Defence Metallurgical Research Laboratory, Hyderabad,1 Gandhi Institute of Technology and Management,

Vizag,2 College of Engineering, JNTU, Kakinada


The limitations of global fracture mechanics for assessment ofintegrity of critical structures / components in complexengineering situations has motivated the development of micro-mechanics based local fracture approaches. In the presentinvestigation, several micro-mechanics models have beenexplored to study the effect of stress triaxiality on ductilefracture behavior of near- Titanium alloy IMI-834 with thehelp of axi-symmetrically notched tensile round bars,experimentally and by finite element simulation.

SIMULATION OF MIXING ANDSEGREGATION IN TUMBLING MIXERS

THROUGH DEMV. Hema, S. Subasini, K. Usha, S.Savithri and

G.D. SurenderRegional Research Laboratory, Trivandrum-695019.


This work is directed towards the fundamental understandingof the mixing and segregation behavior in the simplest prototypeof the tumbling mixer-rotating cylinder. The theoreticalsimulation is based on discrete element method where eachindividual particle is tracked using Newton’s equation of

motion. The mixing and segregation patterns are quantified interms of the rotational speed, fill fraction, size ration, densityratio of the particles.

METAL FLOW INVESTIGATION ANDPREFORM OPTIMIZATION IN CLOSE

DIE FORGINGN.K. Singh and Gojamgunde Deepak Satish

National Institute of Foundry and Forge Technology,Ranchi-834003


In this work FEM software named DEFORM-3D is used forthe front axle beam (an automobile component) forgingsimulation. 3D models of dies and preform shapes have beenprepared and exported to DEFORM. Metal flow simulationshave been carried out for these dies and results for thesesimulations are analyzed. With the help of these resultsmodifications have been made in die design and perform shape.By detailed analysis of these results efforts have been made tofind out optimum die design which gives better metal flow,better yield, less load requirement and minimum stress on dies.

POROSITY DISCRIMINATION IN CASTMICROSTRUCTURES

Asim TewariGMTCI, Bangalore


An algorithm is developed to distinguish two kinds of porosities(shrinkage and gas) from each other based on their structure(shape and size) and spatial scatter. The algorithm usesmorphological transformations on gray scale images of themicrostructure. This technique will lead to a betterunderstanding and control of the solidification process tominimize the porosity formed in the solid.

SIMULATION STUDIES ON THEPARAMETERS THAT AFFECT THE

MATERIAL FLOW IN EQUALCHANNEL ANGULAR EXTRUSION

(ECAE) PROCESSI. Balasundar, M. Sudhakara Rao, T. Raghu

and G.G. SahaDefence Metallurgical Research Laboratory, Hyderabad


Simulation studies were carried out to understand the mechanicsof ECAE process and to evaluate the effect of variousparameters (die corner angle, friction, and material property)that affect material flow.

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ENGINEERING A DESIRED GRADIENTIN FGM BY MEANS OF COMPUTER

SIMULATIONPrem E. J. Babu, T.P.D. Rajan, S. Savithri,

U.T.S. Pillai and B.C. PaiRegional Research Laboratory, Trivandrum-695019.


A computer simulation is performed using a numerical techniquefor tailoring the composition gradient in a centrifugally castmetal-ceramic FGM. For the purpose, the motion of ceramicparticles in a viscous molten metal under a centrifugal force ismodeled and the gradient composition formation is thensimulated by considering the movement of each particle that issuspended in the viscous metal. The results of the simulationsare compared with the experiment results to validate theefficiency of the model in tailoring the composition gradient.

MEASUREMENT AND MODELLING OFTHERMOPHYSICAL PROPERTIES OF

TITANIUM STABILISED NUCLEARGRADE AUSTENITIC STAINLESS

STEEL (ALLOY D9)Aritra Banerjee, S. Raju, R. Divakar, and

E. MohandasIndira Gandhi Centre for Atomic Research, Kalpakkam

– 603 102.E-mail: [email protected]

In the present study, thermal expansion and enthalpy of AlloyD9 austenitic steel were measured and the experimental resultswere comprehensively modelled to obtain a complete set ofthermophysical properties, including high temperature bulkmodulus and Grüneisen parameter as a function of temperature.

ADVANCED MATERIALS ANDPROCESSES

THERMO-MECHANICAL TREATMENTOF SPRAY FORMED Cu-Ni-Si ALLOY

V. C. Srivastava and P. K. DeMetal Extraction & Forming Division

National Metallurgical Laboratory, Jamshedpur-831 007

The effect of various thermo-mechanical treatments on sprayformed Cu-2.4Ni-0.6Si alloy has been studied. The as-sprayformed alloy shows refined microstructure with increased solidsolubility giving better ageing response. The maximum hardnessis observed for solutionised and cold rolled alloy. The maximumelectrical conductivity is observed for only high degree of colddeformation but with rapid decrease in hardness during ageing.A combination of good conductivity and hardness is achievedafter cold rolling to 40% reduction followed by isothermal

ageing. The alloy shows interesting evidence of discontinuousprecipitation, which occurs primarily at the grain boundariesand deformation bands.

PREPARATION ANDCHARACTERISATION OF SmB6 BY

MOLTEN SALT ELECTROLYSISS.Devaki, A.Visuvasam, S.Angappan, L.John

Berchmans and C.O.AugustinCentral Electrochemical Research Institute.

Karaikudi-630006.Email:[email protected]

Rare Earth metals with Boron have recently been recognizedas promising materials, owing to their high melting point, highstrength and chemical stability in aggressive environments,which find application in many specialized areas. The presentinvestigation aims to synthesize Samarium Hexaboride bymolten salt metallurgy. SmB6 crystals were synthesized usingOxy-Fluoride melt at 8500C with Molybdenum cathode andGraphite anode at various current densities and characterized.The XRD patterns confirm the cubic crystal structure.

DUPLEX CASTING OF LEADEDALUMINIUM ALLOYS

J.P. Pathak, Sunil Mohan and S.N. OjhaCenter of Advanced study, Department of Metallurgical

EngineeringInstitute of Technology, Banaras Hindu University,

Varanasi-221005

Duplex casting s of Al-Cu-Pb alloys produced by melt stirringfollowed by its centrifugal casting are described. Variation inPb content is shown to be within 2% in the longitudinaldirection compared to 7% in the transverse direction of thecastings. The effect of process variables on microstructure andchemical homogeneity of the castings is discussed.

COMPRESSIVE DEFORMATIONCHARACTERISTICS OF CLOSED CELL

ALUMINIUM FOAM: EFFECT OFMATRIX MATERIALD. P. Mondal, and S. Das

Regional Research Laboratory (CSIR),Bhopal-462026, India.Email:[email protected]

This paper deals with the compressive deformation behaviorof Aluminium, Aluminium alloy and Al-SiC composite closedcell foam. The stress-strain diagrams of these foam materialswould be discussed paying particular emphasis to thedensification strain and plateau stress. Effect of SiC particleon the Compressive deformation behavior is studied.

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SYNTHESIS OF NiO NANOPARTICLESTHROUGH WATER-IN-OIL

MICROEMULSION TECHNIQUEPrakash. P and Ashok. M. Raichur *

Department of Metallurgy, Indian Institute of Science,Bangalore - 560 012

Email:amr @met.iisc.ernet.in

Nickel Oxide (NiO) nanoparticles were synthesized throughWater-in-oil microemulsion technique at high R-ratio (R ratiois the molar ratio of water to molar ratio of the surfactant)using n-heptane as the hydrocarbon phase, Aerosol-OT as asurfactant and nickel chloride solution as aqeous phase. It isfound that the nanoparticles synthesized within themicroemulsion region have narrow distribution compared tothe nanoparticles synthesized outside the microemulsion region.The synthesized nanoparticles were characterised using X-raydiffraction (XRD) and Transmission Electron Microscopy(TEM).

REFINED MOLYBDENITE AS ALUBRICANT ADDITIVE

Manoj Kumar*, T. R. Mankhand andP. M. Prasad**

* National Metallurgical Laboratory, Jamshedpur831007

Department of Metallurgical Engineering, Institute ofTechnology, Banaras Hindu University, Varanasi 221005

** Nonferrous Materials Technology DevelopmentCentre, Hyderabad 500058

Email:[email protected]

Refined molybdenite prepared from an indigenous low-grademoly concentrate has been tested for its suitability as a solidadditive to lubricant employing extreme pressure testingprocedure. Results indicate a vast improvement in all therequired tribological properties. Moreover, performance of ourrefined molybdenite has been found comparable with that ofan imported high-grade molybdenite.

SOME STUDIES ON STRUCTURALCHARACTERIZATION OF Ni-Mn-GaBASED FERRO MAGNETIC SHAPE

MEMORY ALLOYSR.P. Mathur*, P Ghosal*, V. Chandrasekaran*

and S.Ray***Defence Metallurgical Research Laboratory,

P.O. Kanchanbagh, Hyderabad 500 058** Department of Metallurgical & Materials Engineering

Indian Institute of Technology, Roorkee 247 667Email: raghumathur@rediffmail, [email protected]

Ferro-Magnetic Shape Memory alloys based on Ni2MnGacomposition have been prepared through Vacuum Arc Melting(VAM) using elemental constituents and the binary master alloys

as starting materials. The results of the micro-structural andchemical characterizations of these alloys are presented in thispaper.

RECENT ADVANCES IN P/M OF NON-FERROUS ALLOYS BY MICROWAVE

SINTERING Anish Upadhyaya

Department of Materials and Metallurgical EngineeringIndian Institute of Technology, Kanpur 208016, India


The present paper describes the sintering behaviour of bronzeand tungsten heavy alloys. Premixed 92.5W-6.4Ni-1.1Fe (wt.%)and 90Cu-10Sn alloys were sintered using both conventionalas well as microwave heating and their densification responseshave been compared. The study also includes the phase analysisand mechanical properties comparison of microwave sinteredcompacts vis a vis their conventional counterparts.

PROCESSING AND CHARACTERISA-TION OF W AND W + Os ALLOYS FORUSE AS DISPENSER CATHODES IN

MICROWAVE TUBES (118)N.C. Upadhyay

Dept. of Met. Engg., MNIT, Jaipur

The electromagnetic spectrum is rapidly getting congested atthe traditional Microwave frequencies with the increased useof terrestrial and space communication leading to an ever-increasing demand for still higher frequencies and power. Thishas led to a critical assessment of existing device technology,systems and innovations as well as improved materials. In themodern microwave tubes, one of the important constraints isthe electron Emitter, which has to provide higher emissiondensity at lower operating temperature, yielding long life. Inaddition the electron emitter has to provide uniform emissionacross its entire cross-section. Surface porosity, operatingtemperature and the quantity of Emission compound play asignificant role in uniform emission and longer life of theDispenser cathodes.

A METHOD FOR SYNTHESIS OFNANOSTRUCTURED ALUMINA &

ALUMINA BASED CERAMICSS.Senthil Kumar, K.V. Ramana Rao and

J.MukhopadhyayJawaharlal Nehru Aluminum Reasearch Development &

Design centreAmravati Road, Wadi, Nagpur


In the present communication the details of a low temperaturecombustion synthesis (LCS) used for the production of

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alumina nano-particles is presented. The process utilizes thein-built exothermicity of combustion of reaction system. Thisprocess also produces a compositionally homogeneous mixtureand enables the synthesis at lower ignition and combustiontemperature.

THERMAL CONDUCTIVITY OFNANOCRYSTALLINE Ti/Zr-BASED

METAL-HYDRIDES FORCOMPRESSOR DRIVEN

REVERSIBLE HEATING-COOLINGSYSTEM

S. Bera*, E. Prasad*, M. Ramgopal**,S. Bhattacharya** and I. Manna*

*Metallurgical and Materials Engineering Department,I. I. T., Kharagpur 721 302

**Mechanical Engineering Department,I. I. T., Kharagpur 721 302


The present study concerns synthesizing nanocrystalline AB2type (Ti,Zr)(Fe,Cr)2 quaternary alloys, characterizing theirmicrostructure, assessing thermal conductivity of the powdercompacts with or without graphite addition, and thermodynamiccalculations for determining enthalpy of hydride formation foruse of these nano-hydrides in pressure-driven reversible heating-cooling applications.

NANOFLUID FOR ADVANCED HEATTRANSFER APPLICATIONS

M. Chopkar*, S. Kumar*, P. K. Das**and I. Manna1*

*Metallurgical and Materials Engineering Department,Indian Institute of Technology

**Mechanical Engineering Department, Kharagpur,W.B. 721 302


Nano-fluid is a stable colloidal dispersion of solids in a fluidfor enhanced heat transfer. We have synthesised water-basednano-fluid by dispersing nanocrystalline Al-Cu/Al-Ag powdersand carried out appropriate conductivity measurements. Theinitial results reveal encouraging trend. Analytical modellingshows high aspect ratio of particle enhances thermal propertiesof the nanofluid.

DEVELOPMENT OF A DIAGNOSTICTOOL FOR INDUSTRIAL SCALE

GRINDING SYSTEMSB. Behera, B.K. Mishra, and C.V.R. Murty

Department of Materials & Metallurgical EngineeringIndian Institute of Technology Kanpur


The grinding efficiency of semi autogenous milling or ballmilling depends on the tumbling motion of the total chargewithin the mill. By proper monitoring of the charge motion theenergy efficiency of grinding mills can be increased. Theresearch work pursued here is to capture and interpret thevibration signals to predict the tumbling action of the charge.It is shown that this approach is very effective in monitoringthe charge profile in tumbling mills.

INVESTIGATION OF CONNECTINGROD FORGING DEFECTS AND THEIR

REMEDIAL MEASURESM.K.Agrawal* and P.Aiket**

* Deptt. of Met. Engg. & Mat. Sc, National Institute ofTechnology, Jamshedpur

** Tata Motors, Jamshedpur

Connecting rod, produced by close die forging, gives goodductility, toughness and lightness and is free from castingdefects. However, in forging process, number of rejections arevery large due to faulty design of die, wrong processingtechnologies, chemistry of steel etc. The present work dealswith the reasons for the rejection and its remedies to reducethe forging defects of connecting rods.

CONSOLIDATION ANDCHARACTERIZATION OF FIELD-ASSISTED SINTERED AND HOTPRESSED RAPIDLY SOLIDIFIED

HYPEREUTECTIC Al-Si-Fe-X ALLOYK.Y.Sastry*, L. Froyen*, J.Vleugels*, OmerVan der Biest*, Rolf Schattevoy** and Klaus

Hummert*** Department of Metallurgy and Materials Engineering

(MTM)Katholieke Universiteit Leuven (K.U.Leuven)

Kasteelpark Arenberg 44, B-3001 Leuven, Belgium**[email protected]

Powder Light Metals GmbH, Am Wiesenbusch 2D-45966 Gladbeck,Germany

[email protected]

Rapidly solidified pre-alloyed Al-17Si-5Fe-3.5Cu-1.1Mg-0.6Zr(wt%) powder was densified using hot pressing and field-assisted sintering (FAST) at 350, 400 and 450°C. It was

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observed that full density was reached at lower temperaturesand mechanical loads and also in very shorter time duringFAST when compared to hot pressing. FAST compacts exhibitedhigher hardness but similar microstructural features whencompared to hot pressed compacts.

CONTROLLED VACUUM LOWTEMPERATURE SINTERING OF UO2

PELLETSK.B. Khan, T.R.G. Kutty, A.K. Sengupta,

Arun Kumar, S. Majumdar and H.S. Kamath*

*Radiometallurgy Division,Nuclear Fuels Group,

Bhabha Atomic Research Centre,Trombay, Mumbai 400 085


A new process has been developed in Radiometallurgy division,called Controlled Vacuum Low Temperature Sintering (CVLTS)for the fabrication of nuclear fuel pellets. In this process bycontrolling the vacuum level in the furnace, it is possible toachieve good quality pellets with high density. This paper dealswith the vacuum sintering of UO2 and discusses the merits anddemerits of vacuum in the sintering.

STRUCTURAL ASPECTS OFELECTROLESS Ni-B AND Ni-W-B

ALLOY DEPOSITSM. Palaniappa and S.K. Seshadri*

Department of Metallurgical and Materials EngineeringIndian Institute of Technology Madras

Chennai – 600 036

This paper deals with synthesis and characterization of binaryNi-B and ternary Ni-W-B alloy deposits. Incorporation oftungsten results in reduction of boron content in the depositleading to a crystalline structure. Precipitation of borides isdelayed in the ternary Ni-W-B alloys when compared to thebinary Ni-B alloys. Incorporation of tungsten leads to athermally stable electroless deposits.

DISPERSION OF TaC IN Ni3Al MATRIXBY MECHANICAL ALLOYING

K. Satya Prasad, Vydehi A. Joshi,A.M. Sriramamurty and B.S. Murty*Defence Metallurgical Research Laboratory,

Kanchanbagh, Hyderabad*Indian Institute of Technology, Madras


Tantalum in superalloys, enhances creep through partitioningto the intermetallic phase gama prime (Ni3Al). It also formscarbide which is quite hard and compatible and strengthensthe alloy. An attempt is made to get a submicroscopic and

uniform distribution of TaC in Ni3Al by mechanical alloying.Elemental powders of Ni, Al, C and Ta-Al master-alloy weremilled in planetary mill from 10 to 40h. This paper presentsthe details of milling and the microstructural characterizationusing SEM and TEM.

PREPARATION OF NOVEL MIXEDMETAL OXIDE TUNGSTATES

S. Asha, K.V.O Nair and J JamesRegional Research Laboratory (CSIR),

Thiruvananthapuram-695 -19E-mail : [email protected]

The present paper reports the synthesis and characterization ofthree novel mixed metal oxide tungstates viz., Ba2SmWO6,Ba2EuWO6 and Ba2GdWO6 by conventional solid-state reactionroute. Experimentally obtaining their X-ray powder diffractionpatterns, theoretically calculating their XRD profile andcomparing and refining the data established the structure ofthese compounds as a perovskite structure. The variation ofdielectric properties with applied frequency indicate theirpotential for use as ionic conductors in sensors and SOFC etc.

STUDIES ON MELTING ANDPROCESSING NIOBIUM BASE ALLOYS

V.V. Satya Prasad and R.G. BaligidadDefence Metallurgical Research Laboratory,

Kanchanbagh PO, Hyderabad

Niobium base alloys command a great deal of attention becauseniobium has the lowest density of all refractory materials, aproperty which is of great significance for the deisgn of rotatingcomponents of aero engines. Preliminary experimental workhas been carried out by melting, processing and characterizationof three niobium based alloys, namely Nb – 1Zr, Nb – 1Zr –0.1C, Nb – 10Hf – 1Ti. This paper discusses the salient featuresof the aforementioned experimental study.

THE EFFECT OF NbC PRECIPITATESON THE SHAPE MEMORY BEHAVIOUR

OF Fe-Mn-Si-Cr-Ni SHAPE MEMORYALLOYS

Bikas C. Maji, Madangopal Krishnan andA. Biswas

Materials Science Division, Bhabha Atomic ResearchCentre, Mumbai – 400 085.


Shape memory effect (SME) in Fe-Mn-Si-Cr-Ni alloys isassociated with to martensite transformation. These alloyssuffer from incomplete SME due to permanent deformation oflow strength matrix. Nb and C have been added to strengthen

by precipitation of coherent NbC phase. The improvementof SME due to NbC precipitation strengthening will bediscussed.

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EXPERIMENTAL STUDY OF BRAZINGOF Al2O3 WITH GRAPHITE

K. Bhanumurthy*, P. Sengupta*, G.B. Kale*,P. K. De* V. Srivastava**, A.K. Chopra**,

J. Krishnan*** and D. Joyson***

*Materials Science Division, Bhabha Atomic ResearchCentre, Mumbai-400 085

**Central Electronics Engineering Research Institute,Pilani-333031

***Centre for Design and Manufacture, Bhabha AtomicResearch Centre, Mumbai-400085Email:[email protected]

Graphite and C/C composites are basically brittle and need tobe combined with structural ceramics like Al2O3 for specificspace applications. The preset work focuses on joining ofcommercial grade alumina (Al2O3) to graphite by conventionalbrazing and also by active metal brazing in the temperaturerange 900-10000C.The SEM/EPMA studies indicated that goodbonding could be achieved by both brazing process mentionedabove and the specimens brazed at optimised conditions passedHe-leak test.

3-D RECONSTRUCTION OF THE PORE-STRUCTURE OF NiTi PREPARED BY SHSAniruddha Biswas and Madangopal Krishnan

Materials Science DivisionBhabha Atomic Research Centre

Mumbai-400085

Superelastic porous NiTi is a promising bone prosthesismaterial. In the current work, porous and single phase NiTiwas prepared by thermal explosion by combining with a post-reaction heat-treatment. A reconstruction technique based onserial sectioning was adopted to build the 3-D pore structureand estimate the actual surface area of the specimen.

PREPARATION OF POROUS NiTi BYTWO DIFFERENT MODES OF SHS

Aniruddha BiswasMaterials Science Division

Bhabha Atomic Research CentreMumbai-400085


SHS is a unique technique that can create prosthesis-qualityopen and interconnected pores covering the required range ofsizes and volumes. The current work describes the preparationof porous NiTi from the elemental powder mixture of Ni andTi using two different modes of SHS namely, Plane WavePropagation and Thermal Explosion.

DEVELOPMENT OF Al-Al3Ti ALLOYTHROUGH MECHANICAL ALLOYING

(MA)G.P. Khanra, S. Girikumar, Gangadhar De and

K. Suseelan NairSpecial Materials Division

Materials and Metallurgy GroupVikram Sarabhai Space Centre, Trivandrum


In the present study, the alloy was prepared through mechanicalalloying in an attritor mill using elemental Al and Al-Ti masteralloy powders. The mixed powder was subsequently sinteredand hot extruded. XRD analysis revealed that Al3Ti is formedin the alloyed powder only after heat treatment at 5000 C. Hotextruded Al-10wt%Ti alloy exhibited good retention of hardnessup to 400 0C. The presence of stable uniformly dispersed finecoherent Al3Ti phase in Al matrix is found to be responsiblefor contributing attractive mechanical properties.

SYNTHESIS OF METAL FOAM:PRESENT STATUS AND FUTURE

PROSPECTSSunil Banerjee, Himanshu Kelkar, S.Das and

DP MondalMetal Composite Group

Regional Research Laboratory (CSIR) BhopalEmail:[email protected]@hotmail.com

In this present paper, a detailed comparison of the processesalready developed for making foams by various researchers,technologists and industries will be presented. Additionally theparameters which control the processing and stability of foamformation will be correlated and will be discussed during thepresentation. This presentation will also bring out the processesbeing used by RRL, Bhopal for making metal foam.

DEFORMATION AND FRACTUREBEHAVIOR OF ALUMINIUM ANDALUMINIUM COMPOSITE FOAM

Himanshu Kelkar, Sunil Banerjee,S. Das and DP Mondal

Metal Composite Group,Regional Research Laboratory(CSIR), Bhopal

Email: [email protected] ; [email protected]

This paper basically deals with the study of fracture behaviorof Aluminium and Aluminium Composite closed cell foam incompressive and tensile deformation conditions. Efforts havebeen made to correlate the factors such as cell geometry, materialcomposition with stress-strain diagram.

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PALLADIUM BASED HYBRIDHETEROGENEOUS MATERIALS:

SYNTHESIS ANDCHARACTERIZATION

Sobhi Daniel, P. Prabhakara Rao,M. Nandakumar and T. Prasada Rao*

Regional Research Laboratory (CSIR), Trivandrum.E-mail: [email protected]

The synthesis of hybrid heterogeneous palladium based catalystmaterials was accomplished in a straight forward, two stepreaction using solid phase extraction (SPE). This involvesfunctionalization of solid inorganic sorbents such as Al2O3,silica gel and TiO2 with organic chelate, i.e. dimethyl glyoxime(DMG). The above functionalized materials were transformedinto palladium ion sorbed DMG functionalized materials bySPE. All the synthesized materials were characterized by FT-IR, TGA, DTA, XRD, UV-visible, SEM, EDS and N2adsorption surface area and pore size measurements. One ofthe best synthesized materials was used for the catalyticevaluation using Heck reaction

SYNTHESIS ANDCHARACTERIZATION OF NANO

–BRASS ALLOYS AFTERMECHANICAL MILLING

D. Mukherjee, R. Manna, I. Manna*, andN.K. Mukhopadhyay

Department of Metallurgical Engineering,Institute of Technology, Banars Hindu University,

Varanasi – 221005*Department of Metallurgical and Materials

Engineering, I.I.T Kharagpur, E-mail :[email protected]

The Cu-Zn alloy (g-brass phase) obtained after conventionalmelting and casting was employed for mechanical milling, anovel technique for producing nanocrystalline phases, at variousmilling intensity and milling time ranging from 5h to 40h. Themilled and un-milled samples were then characterized forunderstanding the evolution of the phases. The aim of thepresent investigation is to optimize the process parameters inorder to obtain the nanocrystals of -phase and to understandthe stability of this phase.

STRUCTURAL DEFECTS INALUMINIUM FOAMS AND THEIR

LIKELY CAUSES

S.N. Sahu, B. Sudhakar, V.K.W.R. Kulkarni,N. Ramachandra Rao, Venkataswamy and

Amol A. GokhaleDefence Metallurgical Research Laboratory,

Kanchanbagh P.O. Hyderabad 500 058Email:[email protected]

Aluminium foam experimental ingots 95 mmdiameter and 0.2-0.4 relative densities were producedusing a recently established apparatus. The cells werepolyhedral, closed in general and of 3-5 mm size.Integrity, scale and uniformity of the cell structure weresensitive to the raw materials used, and foaming andsolidification

DEVELOPMENT OF HIGHSTRENGTH AND STRONGLY

CUBE TEXTUREDNi ALLOY SUBSTRATES

FORCOATED CONDUCTOR

APPLICATION

V. Subramanya Sarma*, J. Eickmeyer**

L. Schultz **and B. Holzapfel**

*Department of Metallurgical and MaterialsEngineering, Indian Institute of Technology, Madras,

Chennai-600 036, India** Leibniz Institute for Solid State and Materials

Research (IFW), Helmholtz street 20,Dresden, 01069, GermanyE-mail: [email protected]

We report on the development of thin (80 thickness)Ni-4.5%W/Ni-10%W composite substrates with strongcube texture, high strength (yield strength > 200 MPa)and reduced magnetisation losses for coated conductorapplication. The strong cube texture was obtained throughan optimised two-step annealing following heavy coldworking.

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DEVELOPMENT ANDCHARACTERISATION OF A Ni50Fe37Co13

SOFT-MAGNETIC ALLOY FORAPPLICATION IN THE MAGNETIC

SWITCH OF DIVERSE SAFETY RODDRIVE MECHANISM (DSRDM) OF

PROTOTYPE FAST BREEDERREACTOR (PFBR)

P.V. Sivaprasad*, R. Nagarajan*,R. Veeraswamy**, G. Markandeyulu****,

S. Raju*, M. Krishnaiah***,M. Venkatakrishnan*** and Baldev Raj*

*Metallurgy and Materials Group,***Engineering Development Group

***Chemistry Group, Indira Gandhi Centre for AtomicResearch, Kalpakkam

****Department of Physics, Indian Institute ofTechnology, Chennai


The paper discusses the development of a sensor material witha Curie temperature in the range 625–630°C for application infast breeder reactors. Ni50Fe37Co13 was identified to possessthis Tc based on trial melts and characterisation of the thermalproperties of this alloy. The problems faced during thermo-mechanical processing are discussed.

CRYSTALLITE SIZE EFFECT ONNANO-FERROELECTRICS BY

MECHANICAL ALLOYING

S. K. S. Parashar, R. N. P. Choudhary andB. S. Murty*

Department of Physics and Meteorology, IndianInstitute of Technology, Kharagpur, 721302*Department of Metallurgical and Materials

Engineering, Indian Institute of Technology, Madras,Chennai-600036


Nanoferroelectrics prepared by mechanical alloying exhibitexceptionally high dielectric constant. X-ray diffraction (XRD)studies shows PZT compound has new cubic phase in milledcondition and tetragonal on annealing. Detail studies ofdielectric properties of nano-ferroelectric as a function oftemperature shows that Tc, decreases with the decrease incrystallite size and diffusivity increases with increase in millingtime

ALLOYED NICKEL BASE SUBSTRATETAPES FOR COATED

SUPERCONDUCTOR APPLICATIONSP.P. Bhattacharjee, R.K. Ray and A. UpadhyayaDepartment of Materials and Metallurgical Engineering

Indian Institute of technology KanpurIndia – 208016


The current work investigates the possibility of preparing singlelayer and multi layer substrate materials of Ni, Ni/Ni-W andNi/Ni-Mo through P/M route for coated superconductorapplications. The tapes developed very sharp cube texture after95% cold rolling and annealing and also had good mechanicalstrength, suggesting that P/M route can be very well suited asa potential method for preparing such tapes.

SYNTHESIS OF COPPER TANTALUMALLOYS BY MECHANICAL ALLOYING

M.Sudhakara Rao, T. Raghu and G.G.SahaDefence Metallurgical Research Laboratory,

Kanchanbagh, Hyderabad-500 058Email:[email protected]

A study has been taken up to synthesize Cu-5Ta system bymechanical alloying. Milling of elemental powders has beencarried out in a high- energy planetary ball mill for differentmilling conditions. As milled powders have been characterizedfor their particle size, particle shape, morphology,microstructure, X-Ray diffraction (XRD) patterns and hardness.XRD data has been further analyzed to estimate latticeparameter and crystallite size of both copper and tantalum.Results have been examined to evaluate the extent of non-equilibrium solid solubility in the system during mechanicalalloying. The results obtained from these experiments were bepresented and discussed in this paper.

NANOCRYSTALLINEPHOTOCATALYTIC TITANIUM OXIDE

FOR CATALYSTS, SELF-CLEANINGAND ANTI ALGAL COATINGS

Pradeepan Periyat, K.V.Baiju, C.P.Sibu,P.Perumal, P. Krishna Pillai, P. Mukundan and

K.G.K. Warrier*Ceramic Technology Division, Regional Research

Laboratory (CSIR), Industrial Estate,Trivandrum – 695 019


Photocatalytic titanium dioxide finds promising applicationsas self-cleaning and anti soiling coatings on various substratessuch as glass, metal, plastics and ceramics. The synthesis ofhigh surface area photoactive titania from titanyl sulphateprecursor through a colloidal process is presented. The titania

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is modified by incorporation of certain dopants that increaseabove properties and is better in activity compared to certaincommercial counterparts. Nanocoatings were developed onvarious substrates and further characterized by microscopy,contact angle measurements and photocatalytic activity.Transparent coatings were obtained and they also exhibitexcellent capacity to prevent growth of algae on exposure toenvironment.

NANOCRYSTALLINE RARE EARTHPHOSPHATE FOR ELECTRICAL AND

HIGH TEMPERATURE APPLICATIONSR. Rohith, K. Rajesh, .P. Mukundan and

K. G. K. Warrier*Ceramic Technology Division, Regional Research

Laboratory (CSIR), Trivandrum – 695 019Email: [email protected]

Photocatalytic titanium dioxide finds promising applicationsas self-cleaning and anti soiling coatings on various substratessuch as glass, metal, plastics and ceramics. The synthesis ofhigh surface area photoactive titania from titanyl sulphateprecursor through a colloidal process is presented. The titaniais modified by incorporation of certain dopants that increaseabove properties and is better in activity compared to certaincommercial counterparts. Nanocoatings were developed onvarious substrates and further characterized by microscopy,contact angle measurements and photocatalytic activity.Transparent coatings were obtained and they also exhibitexcellent capacity to prevent growth of algae on exposure toenvironment.

ULTRA LOW DENSITY SILICAAEROGELS FOR VARIOUS

APPLICATIONS IN FUEL GASSTORAGE, NANO POROUS MICRO

SPHERES AND AS ELECTRONICSUBSTRATES

S.Smitha, S. Abhijit, P.R. Aravind, P.Shajesh,P.Krishna Pillai, P. Mukundan and

K.G.K.WarrierCeramic Technology Division, Regional Research

Laboratory (CSIR), Trivandrum – 695 019Email: [email protected]

Synthesis and properties of ultra low density mesoporous silicaaerogels as candidates for various applications are reported.High surface area (750m2g-1) silica-alumina mixed oxideaerogels have been synthesized from Tetraethoxysilane(TEOS)and boehmite for possible gas storage application. Silicamicrosphere was prepared from TEOS by emulsifying the sol

with cationic surfactants. Surface modification withtrimethylchlorosilane resulted in hydrophobic silicamicrosphere. Contact angle of microspheres was found to be850. Organic-silica aerogel hybrid was prepared through sol-gel reaction between TEOS and 3-glycidoxy-propyltrimethoxysilane (GPTS) which is proved to be a goodnetwork forming agent. The dielectric constant of the samplesvaried between 2.2 and 2.86 (at 13MHz).

SYNTHESIS ANDCHARACTERIZATION OF NOVEL

CERAMIC VANADATESL.Shamla, S. Senthil Kumar, K.V.O Nair and

J.JamesRegional Research Laboratory (CSIR),

Thiruvananthapuram –695 019Email: [email protected]

The preparation of four mixed metal oxide vanadate compoundsviz., Mg2NdVO6, Mg2PrVO6, Mg2YVO6 and Mg2CeVO6 ascoarse-grained particle by solid-state reaction and asnanoparticles by combustion method is reported. ExperimentalX-ray diffraction, theoretical profile calculation and profilefitting establish the structures of these compounds. Thecompounds Mg2NdVO6, Mg2PrVO6 and Mg2YVO6 have atetragonal zircon structure and Mg2CeVO6 have a cubicpyrochlore structure. The dielectric properties (dielectricconstant, dielectric loss and conductivity) of the coarse grainedpowder based sintered pellets and the nanoparticle sinteredpellets are compared.

METALS AND ALLOYS FORBIOMEDICAL IMPLANTS

Swati Sinha and P.K.ShrivastavaDept. of Metallurgical Engineering, Govt. Engineering

college, Raipur (C.G)Email:[email protected]

Superior combination of biocompatibility, corrosion resistanceand mechanical properties makes titanium and its alloys one ofthe best materials for biomedical applications. However,inadequate bonding between the implant surface and thesurroundings bone structure, coupled with gross mismatch inmechanical properties between titanium andnatural boneseverely limits the long term performance of conventionaltitanium bone replacements.The use of different materials asbiomedical implants not only requires a detailed knowledge oftheir individual behaviour in a biological environment, butalso an understanding of the processes occurring in the contactregions between the selected material couples. In this paperproblems such as contact and crevice corrosion are taken intoconsideration.

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NEW RUTILE-SPINEL MIXTUREDIELECTRICS FOR MICROWAVE

SUBSTRATE APPLICATIONSK. P. Surendran and M. T. Sebastian

Ceramic Technology Division, Regional ResearchLaboratory, Trivandrum 695 019Email : [email protected]

The dielectric loss phenomena of ZnAl2O4 spinels is exploredin an effort to develop a suitable material for microwavesubstrate applications. The dielectric properties of this spinelwas tailored by preparing mixtures with TiO2 to tune theirtemperature coefficient of resonant frequency close to zero. Itwas found that a low dielectric constant material 0.83ZnAl2O4-0.17TiO2 has excellent dielectric properties for possibleapplications in microelectronic packaging. The substratecharacteristics of the new temperature stable low loss material0.83ZnAl2O4-0.17TiO2 which is even advantageous overalumina, have been investigated.

PROCESSES, PRODUCTS ANDTECHNOLOGIES IN THE TITANIUM

INDUSTRIAL SECTORK. Gopinathan Nair

Travancore Titanium Products LimitedThiuvananthapuram 695 021

E-mail : [email protected] / [email protected]

In the ‘Gods own country’ – Kerala, the richest mineral resourceis undoubtedly the black sand- Ilmenite. Titanium, its alloysand the versatile pigment TiO2 form part of the value addedmaterials from this rich mineral. This paper covers thedevelopment of compounds of titanium with special referenceto titanium dioxide rutile grade in TTP. The emerging trendsin synthesis and application of titanium compounds are alsodiscussed.

INFLUENCE OF MILLING MEDIA ONKINETICS OF CuO/Cu2O REDUCTIONBY Al DURING HIGH-ENERGY BALL

MILLINGT. Venugopal, K. Prasad Rao and B. S. Murty

Department of Metallurgical and Materials Engineering,Indian Institute of Technology Madras,

Chennai 600 036

CuO/Cu2O and Al have been reactively milled in a high-energyplanetary ball mill to produce Cu-Al2O3 nanocomposites withthe crystallite size of about 15 nm. The effect of milling mediaon reaction kinetics has been studied. The reaction kineticshave been correlated to the energy imparted during milling.

COMPOSITES

EROSION BEHAVIOUR OF CAST ANDROLLED ALUMINIUM BASED METAL

MATRIX COMPOSITES. Chatterjee*, T. K. Pal*, R. M. Pillai** and

B. C. Pai*** Metallurgical Engineering Department, Jadavpur

University, Kolkata – 700 032** Regional Research Laboratory,Thiruvananthapuram – 695 019

Email : [email protected]

The purpose of this paper is to compare the erosion behaviourbetween cast and rolled AlMMCs reinforced with 15% siliconcarbide particulates. Solid particle erosion tests of cast androlled Aluminium Metal Matrix Composite (AlMMCs) with15% Silicon Carbide particulate were carried out at differentimpingement angles e.g. 300, 600 and 900. The erosion testswere performed using 210-300 µm quartz sand particles witha particle feed rate of 5 g/min and particle velocity of 30 ms-

1. A stand-off distance of 10 mm was maintained for all thetest. Eroded surfaces of rolled and cast AlMMCs samples wereobserved under SEM to study the micro-mechanisms of materialremoval.

EFFECT OF INTERFACECHARACTERISTICS ON RESPONSE

OF 2124 Al-SiC AND XD Al-TiCCOMPOSITES TO HEAT TREATMENTS

AND THERMAL CYCLINGSharmilee Pal*,R. Maiti*, R. Mitra* and

V.V. Bhanuprasad***Department of Metallurgical and Materials Engineering

Indian Institute of Technology, Kharagpur – 721302,West Bengal

**Ceramics and Composites Group,Defence Metallurgical Research Laboratory,

P.O. Kanchanbagh, Hyderabad – 500 058, A.P.Email: [email protected],

[email protected]

The particle-matrix interfaces of a powder metallurgy (P/M)processed 2124 Al- 5, 15 or 25 vol.% SiC composites, in as-extruded, solution treated or artificially aged conditions havebeen studied with emphasis on alloy segregation and its effecton aging kinetics. While interfaces in ex-situ 2124 Al-SiCcomposites show reduced microhardness due to cracking onrepeated thermal cycles between 500oC and 0oC, those of in-situ pure Al-TiC composites show work hardening withincreased density of dislocations. However, interfaces withbrittle reaction products in heat-treated Al-TiC composites showdecohesion.

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DRY SLIDING WEAR BEHAVIOR OFTHE Al2219/SICP-GRAPHITE METAL

MATRIX COMPOSITESS.Basavarajappa and G. ChandramohanDept. of Mech. Engineering, PSG College of

Technology, Coimbatore-641 004Email:[email protected]

Al2219 alloy was used as a matrix material and SiCp, Graphiteare used as reinforcement. The composite was fabricated usinggravity casting technique. Results reveal that the wear rates ofthe composites were lower than that of the matrix alloy andfurther decreased with the increase in the reinforcement content.Increase in the applied load increased the wear severity bychanging the wear mechanism from abrasion to particle crackinginduced delamination wear.

HIGH TEMPERATURE OXIDATIONBEHAVIOR OF STAINLESS STEEL

COMPOSITESS.S. Panda, S.C. Soni and A. Upadhyaya

Department of Materials and Metallurgical Engineering,Indian Institute of Technology, Kanpur 208016


This work investigates the oxidation behavior of stainless steel-YAG composites. Oxidation studies of these steel compositeswere conducted between 700 to 1100°C for varying time (1-10 hrs) under a controlled dry air. The high-temperatureoxidation behavior of P/M stainless steel reveals remarkabledifference from their wrought counterparts. Varying amountsof YAG (up to 10 wt.%) were added to both ferritic andaustenitic stainless steel and the compact was solid-state sinteredat 1200°C for 1h. Addition of YAG led to significantenhancement in oxidation resistance. The oxidation mechanismsin these stainless steels have been correlated to themicrostructure.

INTERMETALLIC BONDED TUNGSTENCOMPOSITES FOR ORDNANCE

APPLICATIONSMayadhar Debata and Anish Upadhyay

Department of Materials & Metallurgical EngineeringIndian Institute of Technology, Kanpur


This study investigates the sintering behaviour of Ni3Al andFe3Al intermetallic bonded tungsten composites (IWC). Theprime goals of this study are to understand the densificationand microstructural characterization. Sintering of the IWCswas carried at 1500°C. Microstructures of the sintered alloyswere characterized by optical and scanning electron microscopy.Both Vickers bulk and microhardness of IWCs were measured.Compared to conventional W-Ni-Fe alloys, IWCs exhibit refinedmicrostructure and enhanced mechanical properties in bothstatic as well as dynamic conditions.

SYNTHESIS AND CHARACTERISATIONOF (Ti,V)C/ (Ti,W)C– REINFORCED

IRON MATRIX COMPOSITESPRODUCED BY COMBUSTION (SHS)

PROCESSO.P. Modi and A. Chrysanthou*

Regional Research Laboratory (CSIR), Bhopal – 462 026* Dept. of Aerospace, Automotive and Design

Engineering, University of Hertfordshire, Hatfield,Herts AL 10 9 AB, UK


This investigation reports on the combustion synthesis of in-situ iron matrix composites containing solid solution monocarbides of (Ti,V)C and (Ti,W)C.

FRETTING WEAR OF Mg-SICPCOMPOSITES: A SYSTEMATIC STUDY

B. V. Manoj Kumar and Bikramjit BasuLaboratory for Advanced Ceramics; Department of

Materials and Metallurgical Engineering, IndianInstitute of Technology, Kanpur–208016.

Email: [email protected], [email protected]

The objective of the present research is to analyze the role ofapplied load (2 to 10N) and test duration (100 to 5000 cycles)on the fretting wear of Mg-SiCp composites, having differentamounts of SiCp content (0 to 26 wt.%) against bearing steel.The fatigue cracks were also observed on worn Mg. Based onthe SEM observations and Raman spectroscopy results, it canbe concluded that the soft, viscous triboproducts (dense hydrousmagnesium silicate, DHMS) smear on the worn surfaces.

FABRICATION ANDCHARACTERIZATION OF Zr BASEDBULK METALLIC GLASS/ W FIBRE

COMPOSITEA. Mukherjee, S. Neogy, D. Srivastava,

R.T. Savalia, G.K. Dey, N. Venkatraman** andP.K. De

Bhabha Atomic Research Centre, Mumbai 400 085**Defence Metallurgical Research Laboratory,

Kanchanbagh, Hyderabad 500 058, IndiaEmail: [email protected]

The present work describes the fabrication and characterizationof bulk metallic glass composite reinforced with W fibres.Zr52Ti6Al10Cu18Ni14 (at%) alloy was used to make the bulkmetallic glass matrix. Various combinations were used to createcomposites. These composites were characterized by differentmicroscopy techniques and their mechanical properties wereestimated.

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EFFECT OF GRAPHITE ADDITION TOAN OIL LUBRICANT ON THE WEAR

RESPONSE OF A ZINC-BASED ALLOYAND ITS COMPOSITE

B.K. Prasad and O.P. ModiRegional Research Laboratory (CSIR),

Bhopal-462026Email:[email protected]

In this investigation, the role played by graphite particles,when suspended in an oil lubricant, towards controllingthe sliding wear response of a zinc-based alloy has beenexamined. The influence of reinforcing silicon carbideparticles in the alloy matrix was also studied onsimilar lines. The study shows that mere presence of asolid lubricant like graphite in oil may not be beneficialalways and that maximum benefit in terms of betterwear performance could be realized only through a criticalquantity of the solid lubricant. Also, factors like theformation, stability and rupture of the lubricatingfilm/layer play a dominant role in governing the overallwear behaviour of the samples.

RANDOMISATION OF TEXTUREDURING HOT WORKING OF Al-SiC

COMPOSITES

Sandip Ghosh Chowdhury, P.K.De,B.Ravikumar, Swapan K.Das and B.Munda

Materials Science & Technology Division,National Metallurgical Laboratory,

Jamshedpur, 831007E-mail: [email protected]

In the present paper, the evolution of texture during coldrolling of Al-based metal matrix composites hasbeen investigated. The matrix is 2124 Al-alloy with asubstantial amount of intermetallic precipitates of size5-10mm. The material has 10% by weight SiC particulate;the size of the particulates is ~10mm. The composite was cast into 38mm thick slab by adopting vortexmethod and then solution-treated at 550oC by givingT6 treatment. The slab was deformed upto ~50% byhot forging; finally the slab was hot rolled at 450oCto unidirectionally from a plate thickness of 20mm to6mm, resulting in total ~85% deformation. It has beenobserved that the changes in bulk texture on rolling were foundto be insignificant, although there is minute change in thetextural components after large deformation.

EFFECT OF PARTICULATE TYPE (Al2O3AND ZrSiO4) ON MICROSTRUCTUREAND AGING BEHAVIOUR OF Al-4.5CuMATRIX COMPOSITE SYNTHESIZED

BY STIR CASTING ROUTESanjeev Das, Karabi Das and Siddhartha Das

Department of Metallurgical and Materials EngineeringIndian Institute of Technology, Kharagpur – 721302


Microstructure and aging behaviour of Al2O3/ZrSiO4 particulatereinforced Al-4.5wt%Cu matrix composite, produced by stircasting route, was studied in the present investigation. It wasfound that both the composites showed acceleration in agingcompared to the monolithic alloy. However, the Al2O3 reinforcedcomposite showed more acceleration compared to the ZrSiO4reinforced composite.

EFFECT OF BERYLLIUM ADDITION INAl-7Si-0.3Mg / SiCP COMPOSITESK.R.Ravi, V.M.Sreekumar, R.M.Pillai

and B.C.PaiMetal Processing Division, Regional Research laboratory,

Thiruvananthapuram - 695 019.Email: [email protected]

The present work investigates the effect of beryllium additionon the microstructural characteristics of Al-7Si-0.3Mg / 15 %SiCp composites. Varying amounts of beryllium (0.005, 0.05,0.1 and 0.2 wt %) were added using Al - 5% Be master alloy.Microstructures have been characterized using opticalmetallography, image analysis and SEM/EDS.

EFFECT OF HEAT TREATMENT ONEXPLOSIVELY CONSOLIDATED 2124

Al-20 Vol.% SiCP COMPOSITESK. Siva Kumar, V. Balasubrahmanyam and

T. Balakrishna BhatDefence Metallurgical Research Laboratory,

Hyderabad-500 058Email:[email protected]

2124 Al alloy reinforced with 20 vol.% silicon carbideparticulate has been consolidated using explosive compactiontechnique. The composites have been fabricated by usingexplosive pad thickness of 8, 14 and 20 mm. The effect ofprocessing conditions on density, hardness and microstructureof the compacts has been studied. After explosive compactionthe composites have been solutionized at 4950C for 75 minutesfollowed by water quenching. The solutionized compacts havebeen aged at 1800C for 6 hours. The resulting microstructureand hardness have been compared with those of compacts inas-compacted condition.

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PRODUCTION OF FUNCTIONALLYGRADED MATERIALS BY

CENTRIFUGAL CASTING TECHNIQUET.P.D. Rajan, K.R. Hafiz, K.S. Shibu,

L. Sindhu, V. Antony, R.M. Pillai and B.C. PaiMetals Processing Division, Regional Research

Laboratory, CSIR Trivandrum – 695019Email: [email protected]

Functionally graded materials exhibit gradual transitions in themicrostructure and/or the composition in a specific direction,the presence of which leads to variation in the functionalperformance within a part. The present study describes theproduction and characterisation of functionally gradedaluminium matrix composites of aluminium-silicon alloys(LM25 and LM13) reinforced with SiC and graphite particlesand hyper eutectic aluminium-silicon alloys using bothhorizontal and vertical centrifugal casting method.

FINE GRAINED ALUMINUM TITANATEAND ALUMINA MATRIX COMPOSITE

FOR LOW THERMAL EXPANSION ANDTHERMAL SHOCK APPLICATIONS

M. Jayashankar, S. Ananthakumar, P.Mukundan and K.G.K. Warrier

Ceramic Technology Division, Regional ResearchLaboratory (CSIR), Trivandrum-695 019


We have synthesised fine grained Aluminium Titanate (AT)and AT-Al2O3 composite by colloidal method from AlOOH andTiCl4. AT phase was formed at 1379oC. 98% density wasobtained on sintering at 1550 oC. The average grain size ofaluminium titanate was 1-2 mm. Composites had low thermalexpansion, and excellent thermal shock properties. Themechanical strength of composite containing 5wt% aluminiumtitanate is ~135 N/m2 and that of pure alumina is ~76.92 N/m2

at 600 oC.

DYE INTERCALATED NATURALLAYERED ALUMINO SILICATES-

EMERGING ECOFRIENDLYCOMPOSITE NANO PIGMENTS

A. Asif, P. Krishna Pillai, P.Perumal andK.G.K. Warrier*

Ceramic Technology Division, Regional researchlaboratory (CSIR)

Industrial Estate, Trivandrum-695019Email:[email protected]

We report here the synthesis and UV stability of methyleneblue intercalated montmorillonite clays (2:1). Effects of monoion exchange, substitution under stirring, ultrasonication,

refluxing and aging at different temperatures on the extent ofintercalation were studied. A range of colours have beenprepared and their stability towards UV light as against puredye has been compared. Extent of intercalation was found tobe influenced by time for mechanical methods. Intermediateexchange did influence the intercalation of methylene bluepositively.

CORROSION & SURFACEENGINEERING

ELECTROCHEMICAL STUDIES ON P/MAUSTENITIC STAINLESS STEEL

DISPERSION STRENGTHENED WITHGARNETS

Shashank M Tiwari and Anish UpadhyayaDepartment of Materials and Metallurgical Engineering

Indian Institute of Technology, Kanpur 208016E-Mail: [email protected]

This study correlates the electrochemical response of sinteredstainless steel (SS) and SS-garnet (YAG) composites withporosity, microstructure and interfacial chemistry chemistry.The corrosion rate was measured in a 0.1N H2SO4 and 0.1NHCl solution using DC potentiodyanamic polarization tests.The effect of sintering temperature (solid-state and supersolidus)and YAG addition on the corrosion rate, passivation and pittingbehavior is critically examined.

THE INFLUENCE OF REPAIR WELDINGON THE STRESS CORROSIONCRACKING (SCC) BEHAVIOR OF AA2219ALUMINUM ALLOY WELDMENTS IN

3.5% NaCl SOLUTIONA. Venugopal, V. Diwakar and K. Sreekumar

Material Characterisation division, Materials andMetallurgy Group,

Vikram Sarabhai Space Centre, Indian Space ResearchOrganisation (ISRO), Trivandrum 695 022


Comparison of the SCC resistance of repair welded Aluminiumalloy AA2219 with that of virgin weld made of auto AC-TIGwelding process is made. Pitting susceptibility using 3.5%NaClsolution was examined on various sections of the weldmentsuch as weld nugget, weld + fusion zone and HAZ to identifythe weakest zone of the weldment. SSRT at a strain rate of 5x 10-7s-1 to evaluate UTS, YS, %E and time to failure wereobtained on base metal and repair welded samples both in airand 3.5% NaCl. Fracture morphology of the failed sampleswas examined in SEM for all the samples.

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CORROSION AND WEAR BEHAVIOUROF AN UNMODIFIED AND MODIFIED

Al-Ni EUTECTIC ALLOYM.K. Rajak, K. Banerjee, A.K. Chakrabarti

and U. K. ChatterjeeDepartment of Metallurgical and Materials Engineering

IIT Kharagpur 721302Email: [email protected],

[email protected]

Magnesium modified Al-6%Ni eutectic alloy has shown a higherresistance to general corrosion in NaCl, H2SO4 and NaOHsolutions and also a higher resistance to stress corrosioncracking in NaCl+ LiCl+ H2O2 solution than the unmodifiedalloy. The modified alloy has also shown a higher wearresistance. A structural correlation has been presented.

AQUEOUS CORROSION BEHAVIOUROF DUCTILE IRON AND DUCTILE

IRON CONTAINING COPPERA.O.Surendranathan, K.R.Hebbar and

H.V.Sudhaker NayakMetallurgical and Materials Engineering Dept.,

NITK, SurathkalSrinivasnagar (D.K.) – 575 025


This paper describes the corrosion behaviour of alloyedspheroidal graphite irons containing 0.5% and 1.0% copper innatural sea water, dilute sulphuric acid and dilute sodiumhydroxide solutions and compares it with that of unalloyedductile iron. The study has been made in the ascast, annealedand cold worked (upto 28% reduction in thickness) conditionsat three different temperatures. Since the alloying additionbrings changes in the proportion of phases, in spite of alloyingaddition being small, the corrosion behaviour of the materialin the three conditions was different, indicating corrosionbehaviour to be structure sensitive.

CORROSION BEHAVIOUR OF A HEATTREATED 6Mn-5Cr-2Ni-1.5Cu WHITE

CAST IRONC.P. Sharma

Department of Metallurgical Engineering, MalaviyaNational Institute of Technology, Jaipur –302017


Fe- 6 Mn- 5 Cr- 2 Ni- 1.5 Cu white cast iron was studied toinvestigate the effect of microstructure on the corrosionbehaviour in a 5% NaCl solution. Microstructures comprised

of mostly austenite were found to be better than those comprisedof martensite from the point of view of corrosion resistance.

LOCALIZED CORROSION OF AMAGNESIUM ALLOY, AZ91

R.K. Singh RamanSchool of Physics and Materials Engineering

Bldg 69, Monash University (Melbourne), Victoria,3800, Australia

Email: Raman.Singh@spme. monash. edu.au

Micro-galvanic corrosion of magnesium alloys due to formationof cathodic intermetallic phases is reported in the case of oneof the most common Mg-alloys, AZ91. Ageing producessecondary -phase (Mg17Al12) in addition to the primarymicrostructure, Mg-Al-Zn solid solution ( phase). The

-phase, which shows considerably more corrosion resistanceis cathodic to the phase, and hence the two phases in contactcause galvanic corrosion. The phase is some 300 mV positiveto the phase.However, contrary to the common view on therole of -phase in facilitating galvanic corrosion, there are alsoreports suggesting improved corrosion resistance duedevelopment of a passive layer over the -phase. This paperpresents examination of localized corrosion in the region of

phase and surrounding eutectic a in a magnesium alloy AZ91,and the possibility of improving corrosion resistance by surfacemodification.

EFFECT OF HYDROGEN ONCORROSION BEHAVIOR OF PIPELINE

STEEL IN CO2/H2S ENVIRONMENTG. S. Das and A. S. Khanna

Corrosion Science & EngineeringIndian Institute of Technology Bombay

Powai, Mumbai-400076Email:[email protected]@yahoomail.com

Few experiments have been carried out in high temperatureand high pressure in a closed autoclave system. Thetemperatures and partial pressure of CO2 were varied from 30-120oC and 50-300 psi respectively. The corrosion rates of steelincreases up to 90oC due to formation of porous iron carbonatefilm on the metal surface. The small addition of H2S (0.4 ppm)severely increases the corrosion rate because it poisons therecombination reaction of hydrogen evolution, resulting inatomic hydrogen entering the metal surface and developingpressure. This results in initiation and formation of cracks. Thecorrosion products formed on the metal surface were observedby using scanning electron microscope and X-ray diffractiontechnique.

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OPTIMIZATION OF PROCESSINGROUTE FOR IMPROVED CORROSION

RESISTANCE IN Ti-5%Ta-1.8%NbALLOY

R. Mythili, S.Saroja*, M.Vijayalakshmi andV.S.Raghunathan

Materials Characterization Group, IGCAR, Kalpakkam603 102

Email: [email protected] ; [email protected]

A series of Thermo Mechanical Processing stages produced anequiaxed microstructure with inter and intra-granular nodularb, essential for possessing good corrosion resistance in a Ti-5%Ta-1.8%Nb alloy. This paper discusses the mechanism offormation of such a microstructure based on which, theprocessing route for this alloy has been finalized.

CORROSION BEHAVIOR OFTHERMOMECHANICAL TREATED

AND CORROSION RESISTANT STEELSS.R.Raval and K.B.Pai

Faculty of Technology and EngineeringM.S.University of Baroda

Vadodara – 390001Email: [email protected]

In the present work an attempt has been made to study thecorrosion behavior of a thermo-mechanically treated steel andthermo-mechanically treated corrosion resistant steel, bycarrying out electrochemical studies. These studies throw lighton both, the corrosion behavior of the steels as well as thecharacteristics of passive films formed on the surfaces of steel.It has been found out that in case of thermo-mechanicallytreated corrosion resistant steel the corrosion resistance is morethan two and a half times in comparison to thermo-mechanicallytreated steel. Likewise the electrochemical impedance valuesof thermo-mechanically treated steel is three to twenty twotimes less than that of thermo-mechanically treated corrosionresistant steel. Thus, much superior type of film is generatedon the thermo-mechanically treated corrosion resistant steel,which imparts high corrosion resistance to this type of steel.

STUDIES ON EFFECT OF Al AND PbADDITIONS IN GALVANIZING BATH OF

SHEET STEELU. V. Vala*, R. K. Singh**and K. B. Pai

Metallurgical Engg., Deptt., M. S. University of Baroda*Mechanical Engg., Deptt., SVIT, Vasad

** Steelco Gujarat Ltd., Palej.Email:[email protected]

The applications of Al – Zn coatings on steel has grownsubstantially in recent times on account of its apparentadvantages over galvanized sheets. The alloy coatings are

obtained by a continuous process of immersion of the steelsheet in a bath containing the molten coating.This paper presentsthe result of a study aimed at understanding the corrosionmechanization of Al – Zn coating on steel and a comparisonwith the behaviour of galvanized sheets. Research has beencarried out in different types of Industrial environments. Unlikethe Galvanized coating, which suffers a generalized attack ofits surface. The Al – Zn coating undergoes a localized type ofattack, which commences in the inter-dendrite regions of thematerial. Analysis performed by SEM on samples in thedifferent industrial environment, makes it possible to proposea mechanism to explain the successive stages in the corrosionprocess of Al – Zn coating up to attack of the base steel.

INFLUENCE OF RAPID SOLIDIFICA-TION ON CORROSION BEHAVIOUR OF

Li CONTAINING Al-Zn-Mg ALLOYSA.K.Bhattamishra

National Metallurgical Laboratory,Jamshedpur-831007Email: [email protected]

[email protected]

Literature on corrosion behaviour of ribbons of lithiumcontaining Al-Zn-Mg alloys in aggressive chloride media isscanty. The objective of the present paper is to study on thecorrosion behaviour of lithium containing Al-Zn-Mg , Al-Zn-Mg-Mn alloys and Al-Zn-Mg-Cu and Al-Zn-Mg-Cu-Cr alloysin 3.5% NaCl solution and natural sea water collected frombay of Bengal. The aluminium alloys were produced in theform of thin ribbon in a rapid solidification unit Model 2M ofMarko Materials (USA). It is found that corrosion rate of thealloys increases as concentration of NaCl increases and lithiumaddition improves corrosion resistance of Al-4.2Zn-1.8Mg-0.28Mn (T6) alloy ribbons. Further, corrosion resistance ofAl-5.6Zn-2.5Mg-1.3Cu-0.4Li (T6) alloy ribbons is superior toAl-5.6Zn-2.5Mg-1.3Cu-0.2Cr-0.4Li (T6) alloy ribbons inotherwise identical conditions of experimentation.

INFLUENCE OF Mo ALLOYING ON THECREVICE CORROSION BEHAVIOUR

OF TITANIUMKulandaivelu Ravichandran and Toshiyasu

NishimuraCorrosion Resistant Design Group, Steel Research

center,National Institute for Materials Science (NIMS),1-2-1,

Sengen, Tsukuba, baraki, 305-0047, JapanEmail: [email protected]

Crevice corrosion of titanium in different concentrations ofNaCl were investigated at 100 °C with the aid ofmicroelectrodes. Based on the crevice corrosion data a modelcrevice environment was simulated The influence of Moalloying over Ti and molybdate addition in the simulated creviceenvironment on pure titanium, towards cervice corrosion werestudied with help of electrochemical studies.

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WEAR BEHAVIOR OF PLASMANITRIDED H11 TOOL STEEL

Ms.Y.N.Pawar*and P.R.Abhyankar*

*Department of Metallurgical Engineering, PuneInstitute of Engineering & Technology, Pune 411005.

E-mail: [email protected]@meta.coep.org.in

A comparative study of microstructural, mechanical &tribological properties of hardened, gas & plasma nitrided ToolSteel H11 is presented here. Specimens were characterized bySEM to understand wear mechanism. Adhesion in hardenedwhile delamination in nitrided specimen was the modes ofwear. Plasma nitriding decreased the adhesive wear substantially.

PROPERTIES OF ALUMINA FILMSDEPOSITED BY FLAME PYROLYSIS

R. Kavitha and V. JayaramDepartment of Metallurgy,

Indian Institute of Science, BangaloreEmail:[email protected]

Alumina films have been successfully deposited on amorphoussilica and stainless steel substrates by flame pyrolysis. Thefilm properties, including roughness, hardness and themicrostructure, were investigated. The as-deposited films areamorphous and post-deposition annealing converts them toalpha alumina. A comparison of the hardness values showsthat alpha alumina is twice as hard as the amorphous aluminafilm.

STUDIES ON WEAR AND EROSIONPROPERTIES IN LASER COMPOSITE

SURFACED ALUMINIUM WITHSILICON CARBIDE AND ALUMINA

J. Dutta Majumdar*, B. Ramesh Chandra*,A. K. Nath**, R. Kaul** and I. Manna*

*Department of Metallurgical and MaterialsEngineering, Indian Institute of Technology, Kharagpur,

WB-721302**Laser R &D-Block B, Centre for Advanced

Technology, Indore – 452 013Email:[email protected]

In the present study, laser composite surfacing of commercialAl with SiC and TiB2 has been carried out by pre-placing thesaid powders and subsequently, melting it using a 2 kWcontinuous wave CO2 laser. The effect of process parameterson the microstructure and microhardness was studied in detail.Finally, the kinetics and mechanism of wear were investigated.

LASER SURFACE MODIFICATION OFMARTENSITIC STAINLESS STEEL

Vamsi Chaitanya Bommi*,M. Krishna Mohan**

*Dept. of Metallurgical & Materials Technology, IIT-Roorkee, Roorkee, -247667.

**Dept. of Metallurgical Engineering, NIT–Warangal-506004. Email:[email protected]

[email protected]

Surface modification using laser beam is a prominent processto improve hardness characteristics at specific locations to makethe component functionally more efficient. In the present work,surface treatment of a Martensitic stainless steel using a CWCO2 laser has been carried out to study the effect of processvariables on hardening characteristics.

CATHODIC CALCIUM PHOSPHATECOATING ON Ti-6Al-4V

R.Narayanan and S.K.Seshadri*

*Department of Metallurgical and MaterialsEngineering

Indian Institute of Technology, MadrasChennai – 600 036


Natural bone contains calcium phosphate mineral called hydroxyapatite. Titanium surface containing hydroxy apatite coatingshave good adhesion with natural bone. In this study, hydroxyapatite was cathodically deposited on Ti-6Al-4V surface. Thecoatings were analyzed for corrosion in physiological solutionby immersion and electrochemical polarization.

ANODIC OXIDE COATING ON Ti-6Al-4VIN PHYSIOLOGICAL SOLUTION

Sraboni Datta, R.Narayanan and S.K.Seshadri*


Indian Institute of Technology MadrasChennai – 600 036


Anodic oxidation of Ti-6Al-4V was carried out in 1N H3PO4for different current densities and times. Porosity of the coatingswas studied in great detail. Corrosion of the coatings wasstudied in physiological solution simulating body condition byimmersion and by electrochemical polarization. The results arecorrelated with porosity levels.

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STUDIES ON LASER MODIFIEDSURFACE OF ELECTROLESS Ni-W-P

ALLOY DEPOSITSB. Ashwini*, M. Palaniappa*, R.V. Subba

Rao**, S.K. Seshadri*, P. Shankar** & R.K.Dayal**


Indian Institute of Technology MadrasChennai – 600036, Tamilnadu

**Materials Characterisation GroupIndira Gandhi Center for Atomic Research

Kalpakkam – 603102, TamilnaduEmail: [email protected]

This paper discusses the effect of laser surface modification onelectroless Ni-W-P deposit. Mild steel coupons were used assubstrate for deposition. Parameters like power density anddwell time were varied. It was noted that increased laser powerdensity or preheating time led to surface melting. Optical andelectron microscopic observations were used to interpret thechanges in structural properties of the modified surfacelayers.

MICROSTRUCTURALCHARACTERIZATION OF THIN FILMS

OF DOPED CERIUM OXIDEGROWN BY PULSED LASER

ABLATIONP. Kuppusami, K. Muthukumaran*, R. Divakar,

E. Mohandas and V. S. RaghunathanPhysical Metallurgy Section, Indira Gandhi Centre for

Atomic Research,Kalpakkam-603 102,Tamilnadu.

*Department of Physics, Anna University, Chennai-600025


In this paper, we report the formation of 5 mol% Gd2O3 dopedcerium oxide (GDC) films deposited by pulsed laser ablationon oriented silicon (Si) and sodium chloride substrates over abroad range of temperature, pressure and energy. We haveinvestigated these films because of their application in solidoxide fuel cells and in gas sensors. This material is an oxygenion conductor with oxygen deficient fluorite structure and hasa higher oxygen ion conductivity than the conventional zirconiabased electrolytes. High thermal shock resistance, chemicalresistance to reactants and reasonable phase stability are otherkey properties of this material.

ENVIRONMENT ANDRECYCLING

REMOVAL OF HEAVY METAL IONSFROM CONTAMINATED WATER BYMANGANESE NODULES LEACHED

RESIDUEN. N. Das and R. K. Jana


The potential of manganese nodule leached residue as adsorbentfor removal of heavy metals from contaminated water bodieshas been examined. Leached residues, collected from the seanodules Pilot plant operated at Hindustan Zinc Limited, ismostly amorphous and contains fine particles (d50=18.5 m) ofoxide/oxyhydroxides of Mn, Fe, Si and Al along with otherminor metal constituents. Adsorption of different heavy metalions (Pb2+, Cu2+ and Cd2+) from their aqueous solution andsimulated water matrix with varying experimental parametersby batch adsorption method revealed the adsorption is fairlyrapid and more than 80 % adsorbed in first 15 minutes.

CEMENTATION OF SILVER FROMWASTE DOMESTIC BUTTON CELLS

N.SathaiyanCentral Electrochemical Research Institute,

Karaikudi-630 006

Waste domestic silver oxide button cells used in watches wereprocessed to recover around 95% of silver. These button cellswere cut open to liberate the active materials having mainlysilver and zinc. This active material was leached with nitricacid and zinc powder was employed to cement out silver in theleach solution and the purity level of silver was 96.2%. Theeffect of silver ion concentration, pH, agitation and temperaturewere investigated on cementation and discussed.

VALUE ADDED OXIDES FROMMETALLURGICAL WASTES

R.John Felix Kumar, S.Raman ShankaraNarayanan

Department of Metallurgical EngineeringNational Institiute of Technology

Thiruchirappalli-620 015Email:[email protected], [email protected]

Value added products such as pure oxides could be producedfrom the large quantities of metallurgical wastes generatedduring smelting/ refining. The effort made towards theseparation of iron oxide and silica is briefly described in thispaper. The relative yields and purity of products are alsodiscussed.

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CURRENT TRENDS IN THEENGINEERING AND MANAGEMENT

INTERVENTIONS TO COMBATENVIRONMENTAL STRESSES IN

ALLOY & SPECIAL STEEL ROLLINGMILLS

S Ramachandran* and R Baskar*Dept. of Chemical Engineering,

Kongu Engineering College, Erode, Tamil NaduEmail:[email protected]

Modern rolling mills complexes pose a radical challenge tothe environmental engineer due to the diverse nature of thepollutants emitted by them. An integrated approach to overcomethese environmental stresses is necessary to make themenvironmentally sustainable. This paper critically reviews thedifferent methods and techniques available to the environmentalengineer for successful abatement of environmental problemsassociated with a rolling mill complex.

RED MUD NEUTRALIZATION /TREATMENT AND ITS UTILIZATION

AS LOW COST ADSORBENTIN REMOVAL OF ARSENIC,

ZINC, CADMIUM AND COPPERMETAL IONS FROM THEIR

AQUEOUS SOLUTIONS

T. K. SenDepartment of Chemical Engineering

National Institute of Technology, Rourkela-8E-mail:[email protected] ; [email protected]

Bayer process red mud has a high pH, and high ironoxide content which makes it highly effective in removalof metal ions from their aqueous solutions. The overallaim of this research work is to develope a neutralisationprocedure that involve the conversion of basicity(mainly sodium hydroxide) and soluble alkalinity(mainly sodium carbonate) into alkalinity, and to developcost-effective unconventional sorbents i.e. neutralised /treated red mud in removal of highly toxic arsenic,zinc, cadmium and copper metal ions from their aqueoussolution.

RESPONSE OF Fe-TIC AND COBALT-BASED HARDFACED MATERIALS IN

EROSIVE-CORROSIVE ENVIRONMENTO.P. Modi, B.K. Prasad, A. K. Jha,V.P. Deshmukh* and A.K. Shah*Regional Research Laboratory (CSIR),

Bhopal – 462 026* Naval Materials Research Laboratory, Ambernath,

Shil-Badlapur Road, Addl. Ambernath, Distt.Thane – 421 506


The present investigation reports the observations relating tothe erosion-corrosion behaviour of the Fe-TiC and cobalt-basedhardfaced layers separately deposited on an En 31 steel in3.5% NaCl aqs. environment. Sample rotation method wasadopted for conducting the erosive-corrosive tests at a lineartraversal speed of 4.47 m/s over varying test durations of 8-32hrs. The study shows that the wear loss was strongly dependenton test duration and the nature of the test samples. Thehardfaced layers exhibited substantially reduced wear rate ascompared to that of the substrate. Further, the cobalt basedmaterial performed the best.

A NOVEL METHOD FOR DISPOSAL OFTAR DECANTER SLUDGE

A. J. Chaudhuri, A. K. Das, Y. Singh andD. Mukerjee

RDCIS, SAIL, Ranchi-834002E-mail: [email protected]

At Bokaro Steel Limited, about 10 t / day tar decanter sludge(TDS) is generated during settling of coal tar in the decanters.This material is considered as a toxic and hazardous wasteproduct, creating problem for its disposal. RDCIS, SAIL hasdeveloped a novel system for effective disposal of TDS bymixing it with coal blend prior to carbonization in the cokeoven batteries. Addition of TDS in coal blend has proved to bean effective waste disposal measure, when equivalent quantityof coal is saved, resulting in financial benefit of Rs. 1.50Crore per annum.

SOLID WASTE MANAGEMENT INMETALLURGICAL INDUSTRY

B.G. Reddy(Dy. Chief Manager Systems)

Visakhapatnam Steel Plant, VisakhapatnamEmail: [email protected]

A Metallurgical industry generates a number of solid wastesand many of them contaminate environment. A case study has

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been made in Visakhapatnam Steel Plant on Management ofsolid by-products. Of the solid wastes generated, more than35% are re-used reducing the input cost. They are also soldwhich earn good revenue or stacked in addition to re-cycling.A number of initiatives are taken for design modification. Waysfor further improvement are suggested.

DEINKING OF INDIAN NEWS PAPERBY AGGLOMERATE FLOTATION

D.K. Sengupta and R. Bhima RaoRegional Research Laboratory,

Bhubaneswar 751 013E-mail: [email protected]

In this study, , the newspapers are pulped prior to flotation andfurther processing is generally done by (a) heating at atemperature between 45 °C and 65 °C, (b) adjustment of pulpdensity to 5% (c) addition of sodium silicate of 2-3%, sodiumhydroxide of 1%, hydrogen peroxide of 0.7-1.0% and surfactantof 0.4- 3%. Calcium ion is also used as activator for adsorptionof anionic collectors such as oleic acid (Hornfeck, 1987). Thechemicals used for deinking pose a number of problems inboth deinking plant as well as in subsequent operations due tofoam formation. While calcium chloride is added as an activator,calcium may deposit as carbonate whereas chloride ion maylead to corrosion problems

UTILISATION OF STEEL PLANT SOLIDWASTE IN SINTRING

B.N.Roy*, S.N.Sinha** and U. S. Yadav****Department of Metallurgical Engineering, B.I.T.

Sindri, Dhanbad**Department of Met. Engg. & Material science, N.I.T.

Jamshedpur***Research and Development Division, Tata steel.


All integrated steel plants generate large amount of wastematerials in the iron making and steelmaking processes. Thesewastes materials are basically different type of ferroginiousoxides and fluxes. Most of these materials contain high iron,carbon, calcium and magnesium values and can, therefore, berecycled.

LIFE PREDICTION OF PIPELINESTEEL IN CO2/H2S ENVIRONMENT

G. S. Das and A. S. KhannaCorrosion Science & Engineering

Indian Institute of Technology BombayPowai, Mumbai- 400076

Email:[email protected] ; [email protected]

API grade low carbon steels are generally used in the petroleumindustries for the transportation of crude oil and gas. These

steel suffers from the corrosion in carbon dioxide and hydrogensulphide medium. The service life of these steels can bepredicted by determined corrosion rate in these corrosivemedium. Four types of steels API X-52, API X-56, API X-60and L-80 were used for the corrosion studies in 3.5 % NaCl.The severity of their corrosion rates were measured in thelaboratory scale by with simulating actual field conditions ina closed autoclave loop system with liquid flow rate of 2.5 m/s. It has been observed that as temperature and partial pressureof CO2 increases the corrosion rate increases. The performanceof API X-60 grade steel shows better corrosion resistance whencompared to all the steels used. The corrosion products formedon the metal surface were analyzed by SEM and XRDtechniques.

PHASE-PURE ANATASE TiO2NANOCRYSTALS FROM MULTI-METAL

WASTE CHLORIDE LIQUORS BYSOLVENT EXTRACTION COMBINEDWITH HYDROTHERMAL SYNTHESIS

Jesty Thomas, M.L.P Reddy and G.D SurenderProcess Science & Engineering Division, Regional

Research Laboratory, CSIRThiruvananthapuram - 695 019, India.


A novel process for the synthesis of phase-pure anatase TiO2nanocrystals from multivalent metal chloride solutions has beenproposed by solvent extraction combined with low temperaturehydrothermal synthesis. The process comprises the steps of i)Selective extraction of TiCl4 from multivalent metal chloridesolutions by solvent extraction using tributylphosphate as anextractant; ii) Precipitation of amorphous titania from the loadedsolvent; iii) Separation of amorphous titania, dispersion indeionized water and adjustment of the pH; iv) Hydrothermalsynthesis by using the above precursor; v) Separation of thesynthesized products by filtration, drying and characterization.The results demonstrate that phase-pure anatase nanocrystallites(5-20 nm) possessing photocatalytic activity can be synthesizedhydrothermally at relatively low temperatures and reactiontimes.

4-ACYLBIS(1-PHENYL-3-METHYL-5-PYRAZOLONES) AS HIGHLY

SELECTIVE EXTRACTANTS FORVANADIUM(V) FROM TITANIA WASTE

CHLORIDE LIQUORSP.N. Remya, Rani Pavithran and M.L.P. ReddyIon-specific Separation Science & Technology Group

Regional Research Laboratory, CSIRThiruvananthapuram-695 019Email:[email protected]

The more our economy recovers and recycles useful metalsfrom its wastes, the less mining will be needed and less

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environmental damage will result from waste disposal. Hence,in the present study efforts have been made for the recoveryof vanadium from waste chloride liquors of titania industry byemploying 4-acylbis(1-phenyl-3-methyl-5-pyrazolones) asextractants. The extraction behavior of Mg(II), Al(III), Ti(IV),V(V), Cr(III), Mn(II), Fe(II) and Fe(III) has been studied usingvarious 4-acylbis(1-phenyl-3-methyl-5-pyrazolones) fromhydrochloric acid solutions. The results demonstrate that V(V)is selectively extracted into the organic phase leaving behindall the other associated metal ions in the raffinate. It can beconcluded from these investigations that 4-acylbispyrazolonescan be used as selective solvent extraction reagents for theseparation and recovery of vanadium from the waste chlorideliquors of titanium minerals processing industry.

IMPROVEMENTS IN PREBAKEDANODES AND CO2 EMISSIONS IN

ALUMINIUM ELECTROLYSIS CELLR.N.Jena, M.K.B.Nair and Binuta Patra

Smelter Plant, National Aluminium Co.Ltd,Angul (Orissa)

Prebaked anodes emit green house gases while they areconsumed in the Aluminium electrolysis process. These gasesare being considered harmful for global environment. Tominimize the CO2 emissions, carbon consumption in pots is tobe reduced by improving anode quality. This paper relates thecarbon anode quality and emission of CO2 gas.

THIN LAYER CHROMATOGRAPHICSEPERATION AND QUANTITATIVE

DETERMINATION OF COEXISTING Al,Fe AND Ti IN BAUXITE AND RED MUD

P.A. Mohamed Najar, J.U. Jeurkar andK.V. Ramana Rao

Jawaharlal Nehru Aluminum Research Developmentand Design Centre Amaravati Road, Nagpur-440 023

Thin layer chromatographic (TLC) separation of the three majormetallic constituents viz. Al, Fe, Ti and silicon in bauxite andred mud were presented in an attempt to develop rapid analyticalprocedures for bauxite and red mud. Quantitative determinationsof these separated species were carried out by couplingchromatography using appropriate analytical techniques suchas spectrophotometry and titrimetry.

RECYCLING OF METALLURGICALWASTES AT ROURKELA STEEL PLANT

A.L.Kundu and B.RaiR&C Lab, SAIL, RSP,Rourkela-769011

Rorkela steel plant consumes large quantities of raw materialsand generates substantial quantities of solid and other wastematerials during iron and steel making. Presently, RSP is verykeen to improve solid waste management as businessopportunity and all round efforts have been made to reuse andrecycle them gainfully. The paper deals with how RSP hasbeen able to use LD slag (fine & lump). Nut coke, BF fluedust, Mill scale and BOF sudge for various metallurgicalapplications inside the plant.

Documents

Indian Institute of Metals