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Application oriented R&D towards demonstrating feasibility of laser processing route for specific industrial applications; Research towards better scientific understanding of various processes; Job works of specialized nature; and Consultancy...
Research Areas
Laser Welding Laser Surface Treatment o Laser hardening o Laser cladding/alloying Laser Drilling Laser Cutting
Facilities
6 kW Diode Laser 3.5 kW CO2 Slab laser 400 W Avg Pulsed Nd:YAG Laser 9 kW CO2 Transverse Flow Laser
As far as the field of surface modification technologies are concerned, India has matured significantly in recent years. The conspicuous upward trend in the adoption of surface modification technologies by the Indian industry has also been catalysed by several initiatives taken by the Government of Indias Department of Science & Technology (DST). ARCI scientists have played a prominent role in piloting these initiatives and the organization has consistently tried to identify coating technologies of national relevance and consciously pursue those that are unavailable elsewhere in the country.
Over the years, ARCI has successfully projected itself as a leader in the field of surface modification. ARCI's Centre for Engineered Coatings has been engaged in developing a wide spectrum of appropriate surfacing technologies to assist the Indian industry in meeting the challenge of enhancing the durability and performance of components operating in adverse environments. The efforts of the Centre for Engineered Coatings have focused on eventually transferring relevant technologies to private entrepreneurs in a cost-effective manner. Several coating technologies are being simultaneously pursued by the Centre for Engineered Coatings in an effort to offer a range of quality and cost to the potential user industries. Some of these have matured and already successfully transferred to the industry while yet other exciting technologies are presently on the anvil.
Major Coating Technologies Established at CEC Detonation Spray Coating Cold Spray Coating Micro Arc Oxidation Electro Spark Coating Electron Beam Physical Vapour Deposition
Research Areas
Process: A method of coating, where an explosive high temperature flux of gas mixtures is used as a source for heating, accelerating and spraying the particles
Salient Features Excellent Adhesion < 1% Porosity High Microhardness Low Thermal Degradation Advantages Low Substrate Temperature Low Cost of Operation Less Gas Consumption Less Water Consumption Process Capabilities Thickness Buildup: 5-25 m/shot Coating Thickness Carbides/Cermets: 20-500 m Ceramics: 50-1,000 m Particle Velocity: 500 to 1000 m/s Particle Temperature: up to 4000oC Deposition Efficiency: 30 to 60% Porosity: 0.1 to 1.0% Less Electrical Consumption Less Down Time Less Work Scrap Low Oxide Content Good Tribological Properties High Coating Thickness Good Powder Efficiency
Metals & Alloys: up to few mm Coating Coverage: 0.5 to 1.0 m2/hr Type of Powders Sprayed
Metals, Oxides & Cermets, Carbides and Alloys Substrate Materials Metals, Alloys, Superalloys, Dielectric substrates, Plastics, Glass and Ceramics (Any substrate having hardness < 65 HRC can be coated by DSC) Examples of Powders Sprayed
Al2O3, Al2O3-TiO2, Cr3C2-NiCr, WC-Co, WC-Co-Cr, WC-17Co-8FEP, WC-10.5Co, WC10.5Ni, Ni-20Cr, CoCrAlY & NiCrAlY, SS316-Martensitic, Austenitic, Cr2O3, Aluminum bronze, NiCr-5Al, Stellite-6, Cr2O3-20 Al2O3, Ti(C,N)-38%(Ni, Co), Ti(C,N)- 38%(Ni, Co, Mo), Fly ash, AlN (from SHS), Fe-Al (with Al2O3, Cr2O3), Cr3C2-NiCr- TiB2, Fe-SiC, Al65Fe20Cu15, Fe, Ni, Cu and many pure metals.
DSC vs APS Higher bond strength (> 10000 psi) Denser microstructure (< 1% porosity) Reduced thermal degradation Controlled residual compressive stress Very thick coatings can be produced without delamination Very high melting point materials like Zirconia can not be sprayed
Smoother as-coated surface finish (1-4m Ra) DSC vs HVOF Coating properties nearly similar HVOF CANNOT SPRAY OXIDES HVOF has higher productivity DSC operating costs are much lower
Optimization of laser welding process on Ti-6Al-4V sheets to obtain defect free joints with required mechanical strength
Establishment of a new laser processing system based on a 6-kW Fiber-Coupled Diode Laser integrated with a 6-axis robot and turn-tilt table Laser hardening of crankshafts for reciprocating compressor Laser welding of tailor-welded blanks (TWB) in three steel combinations for formability testing
Facilities
1) Coating techniques
Pulsed Electrodeposition
2) Heat treatment
3) Characterization Facilities
Perthometer
People
Name - D. Srinivasa Rao Designation - Scientist-E & Team Leader
Qualification - MS (Mechanical Engineering) Areas of expertise - Surface Engineering, Industrial Applications of Coatings, Implementation of coating technologies for production eMail - raods@arci.res.in
Name - N. Ravi Designation - Scientist-D Qualification - MTech (Industrial Metallurgy) Areas of expertise - Diamond like Carbon Coatings and Material Characterization eMail - nravi@arci.res.in
Name - L. Rama Krishna Designation - Scientist-D Qualification - MTech (Materials &Metallurgical Engineering) Areas of expertise - Micro Arc Oxidization Coatings and Tribological Performance Evaluation eMail - lrama@arci.res.in
Name - G. Sivakumar
Designation - Scientist-C Qualification - BTech (Mechanical Engineering) Areas of expertise - Detonation Spray and Solution Plasma Spray Coatings eMail - gsivakumar@arci.res.in
Name - Nitin P. Wasekar Designation - Scientist-B Qualification - ME (Metallurgical Engineering) Areas of expertise - Pulsed Electrode Deposition and Micro Arc Oxidization Coatings eMail - nitin@arci.res.in
Name - Naveen Manhar Chavan Designation - Scientist-B Qualification - BTech (Metallurgy) Areas of expertise - Pulsed Electrodeposition eMail - naveen@arci.res.in
Designation - Technical Ofcer-C Qualification - Diploma in Mechanical Engineering Areas of expertise - Detonation Spray Coating and Electron Beam Physical Vapour Deposition eMail - dsen@arci.res.in
Advisors/Consultants
D Srinivasa Rao Scientist-E & Team Leader MS (Mechanical Engineering) Areas of Expertise: Surface Engineering, Industrial Applications of Coatings, Implementation of coating technologies for production eMail: raods@arci.res.in N Ravi Scientist-D MTech (Industrial Metallurgy) Areas of Expertise: Diamond like Carbon Coatings and Material Characterization eMail: nravi@arci.res.in L Rama Krishna Scientist-D MTech (material & Metallurgical Engineering) Areas of Expertise: Micro Arc Oxidization Coatings and Tribological Performance Evaluation eMail: raods@arci.res.in lrama@arci.res.in G Sivakumar Scientist-C BTech (Mechanical Engineering) Areas of Expertise: Detonation Spray and Solution Plasma Spray Coatings eMail: gsivakumar@arci.res.in Dr R Kavitha Scientist-C PhD (Solution Precursor Coatings) Areas of Expertise: Solution Precursor Based Coatings eMail: raods@arci.res.in kavitha@arci.res.in
Nitin P Wasekar Scientist-B ME (Metallurgical Engineering) Areas of Expertise: Pulsed Electrode Deposition and Micro Arc Oxidization Coatings eMail: nitin@arci.res.in P Sudharashan Phani Scientist-B BTech (Mechanical Engineering) Areas of Expertise: Cold Spray Coatings and Modeling Studies eMail: raods@arci.res.in spphani@arci.res.in Naveen Manhar Chavan Scientist-B BTech (Metallurgy) Areas of Expertise: Pulsed Electrodeposition email: naveen@arci.res.in D Sen Technical Officer-C Diploma in Mechanical Engineering Areas of Expertise: Detonation Spray Coating and Electron Beam Physical Vapour Deposition eMail: dsen@arci.res.in
Solution Precursor Plasma Spray (SPPS) is a thermal spray process where a feedstock solution is heated and then deposited onto a substrate. Basic properties of the process are fundamentally similar to other plasma spraying processes. However, instead of injecting a powder into the plasma plume, a liquid precursor is used. The benefits of utilizing the SPPS process include: the ability to create unique nanometer sized microstructures without the injection feed problems normally associated with powder systems and flexible, rapid exploration of novel precursor compositions.[1][2]
Contents
4 Costs 5 References
Background
The use of a solution precursor was first reported as a coating technology by Karthikeyan, et al.[3][4][5] In that work, Karthikeyan showed that the use of a solution precursor was in fact feasible, however, well adhered coatings could not be generated. Further work was reported in 2001 which refined the process to produce thermal barrier coatings,[6] YAG films,[7] and silicon ceramic coatings.[8] Since then, extensive research on the technology has been explored in large part by the University of Connecticut and Inframat Corporation.
The process
The precursor solution is formulated by dissolving salts (commonly zirconium and yttrium when used to formulate thermal barrier coatings) in a solvent. Once dissolved, the solution is then injected via a pressurized feed system. As with other thermal spray processes, feedstock material is melted and then deposited onto a substrate. Typically, the SPPS process sees material injected into a plasma plume or High Velocity Oxygen Fuel (HVOF) combustion flame. Once the solution is injected, the droplets go through several chemical and physical changes[9] and can arrive at the substrate in a several different states, from fully melted to unpyrolized. The deposition state can be manipulated through spray parameters and can be used to significantly control coating properties, such as density and strength.[2][10]
Research Areas
Back
Laser surface hardening is a selective surface hardening process wherein the desired metallurgical and mechanical properties are achieved by a defocused laser beam irradiated over the required area with average power density of 103 - 104 W/cm2 produced to desired case depth. Hardening is effected by transformation, remelting or shock hardening.
Moderate to rapid cooling rates resulting in fine homogenous structures Selectively localized area processing Controlled case depth Minimal distortion Chemical cleanliness Minimal post treatment High process flexibility Excellent reproducibility Ease of processing with CNC programming Faster production rates No quenchant requirement
Typical Applications
Steam turbine blades Crank shafts Cam shafts Forming dies Cutting tool edges
Crankshaft for a reciprocating compressor Piston spacers & rings for IC engines Two-wheeler cam shafts Crossings for rail roads
LASER CLADDING/ALLOYING
Laser surface cladding is a process of deposition of cladding material (alloying species) over a substrate to form a sound interfacial bond without diluting the clad with substrate. Laser surface alloying is a process similar to surface melting except that another material (alloying species) is injected into the melt pool. Typically an inexpensive base material is alloyed/cladded with an expensive alloying material, resulting in desired improvements in tribological properties of the alloyed region. Laser cladding has also progressed into direct laser casting (Direct Metal Deposition) for low volume 3D components.
Moderate to rapid solidification rates resulting in fine homogenous structures Desired coating depth with dilution Minimal distortion with low HAZ Controlled thermal profiles and shape
Good surface finish Selective alloying/cladding Minimal wastage of costly alloying material Precise control of alloy geometry Extremely versatile Excellent metallurgical bonding Reduced porosity Excellent coating homogeneity High deposition efficiency Faster processing rates
Typical Applications
Gas turbine blades Pump sleeves Engine valves Rotor shafts Ground rolls Temper mills Automobile pitons Ball and gate valves Friction discs Crane shafts Brake drums Casting molds Excavator blades
Valve seat cladding with stellite 6 Boiler burner tip baffle plates for erosion resistance Erosion resistant coating on turbine blades
LASER WELDING
Laser welding is a non-contact fusion welding process which involves melting and joining of two similar or dissimilar materials by the application of heat generated by a fine focused spot of laser beam. Laser welding usually employs a power density of 105-107 W/cm2 and hence, categorized as a power beam welding process. The welding can be done in conduction mode for thin sections and keyhole mode for thick sections. Generally, the welds are made autogenously but external addition of filler material to modify the microstructure is also feasible.
High power density o High depth of penetration (aspect ratios upto 20:1) o High welding speeds and low heat input Can weld wide variety of materials with varying thickness
Possibility to precisely focus the beam spot at desired location o Appropriate heat balance can be obtained while welding dissimilar materials or thicknesses Pulsed mode operation o Low heat input precision welding No vacuum requirement, unlike electron beam welding Can weld magnetic materials, unlike electron beam welding Non contact process and hence clean weld unlike Shielded Metal Arc Welding or Tungsten Inert Gas welding Some laser wavelengths can be sent through optical fiber and to weld inaccessible locations
Tailor-Welded Blanks (TWB) for Automotive bodies Gear assemblies in automotive transmission Stringer welding to skin of fuselage Sandwich panels for ship building Stainless steel equipment Hermetically sealed valves for solenoid applications
Tailor-weld blanks Welding of Ti-6Al-4V Thin section sensors to thick section structures made hardenable steels Dissimilar material joint Ti-SS Galvanised sheet steel Titanium parts for aerospace applications Micro welding of sensors to structures.
LASER DRILLING
Laser drilling involves material removal by vaporization and/or expulsion of molten material due to irradiation of high laser intensities. There are two types of laser drilling processes: percussion drilling (hole of diameter <1 mm) and trepanning (hole of diameter > 1 mm). Percussion drilling process involves a stationary beam and one or more pulses to penetrate the thickness of material. Trepanning involves contour cutting of the hole by moving the beam / workpiece to create the final dimensions of the hole.
Ability to produce small diameter holes with high aspect ratiosHoles can be drilled at shallow angles to the surface Optical fiber delivery possible Ability to process a wide range of materials High production rates Drilling of micron level holes to rock drilling Non-contact drilling (no tool wear or breakage, no material distortion) Highly accurate and consistent results
Precise control of heat input Flexibility to address different applications (for prototypes and low-volume, small-lot manufacturing)
Typical Applications
Cooling holes in gas turbine blades Aerofoil Laminar Flow Fuel Injection Nozzles Fuel Filters Inkjet Printer Nozzles PCB Via Interconnects Catheters MEMS
Laser Cutting
Laser welding is a non-contact fusion welding process which involves melting and joining of two similar or dissimilar materials by the application of heat generated by a fine focused spot of laser beam. Laser welding usually employs a power density of 105-107 W/cm2 and hence, categorized as a power beam welding process. The welding can be done in conduction mode for thin sections and keyhole mode for thick sections. Generally, the welds are made autogenously but external addition of filler material to modify the microstructure is also feasible.
High power density o High depth of penetration (aspect ratios upto 20:1) o High welding speeds and low heat input Can weld wide variety of materials with varying thickness Possibility to precisely focus the beam spot at desired location o Appropriate heat balance can be obtained while welding dissimilar materials or thicknesses Pulsed mode operation o Low heat input precision welding No vacuum requirement, unlike electron beam welding Can weld magnetic materials, unlike electron beam welding Non contact process and hence clean weld unlike Shielded Metal Arc Welding or Tungsten Inert Gas welding Some laser wavelengths can be sent through optical fiber and to weld inaccessible locations
Tailor-Welded Blanks (TWB) for Automotive bodies Gear assemblies in automotive transmission Stringer welding to skin of fuselage Sandwich panels for ship building Stainless steel equipment Hermetically sealed valves for solenoid applications
Tailor-weld blanks Welding of Ti-6Al-4V Thin section sensors to thick section structures made hardenable steels Dissimilar material joint Ti-SS Galvanised sheet steel Titanium parts for aerospace applications Micro welding of sensors to structures