MSRSAS - Material and Surface Modification

MSRSAS - Postgraduate Engineering and Management Programme - PEMP
Module Code Module Name Course Department
AMT2501 Materials and Surface Modification Processes M.Sc [Engg] in Advanced Manufacturing Technology Mechanical and Manufacturing Engg.
Name of the Student Reg. No Batch Module Leader
Shanmuga Raja .B BVB0912004 Full-Time 2012. Mr. K.N. Ganapathi
M.S.Ramaiah School of Advanced Studies

Postgraduate Engineering and Management Programmes(PEMP)
#470-P, Peenya Industrial Area, 4 <Materials and Surface Modification Processes> Phase, Peenya, Bengaluru-560 058 Tel; 080 4906 5555, website: www.msrsas.org
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POSTGRADUATE ENGINEERING AND MANAGEMENT PROGRAMME (PEMP)

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ASSIGNMENT
Declaration Sheet Student Name Reg. No Course Batch Module Code Module Title Module Date Module Leader Shanmuga Raja .B BVB0912004 M.Sc [Engg] in Advanced Manufacturing Technology FT 2012 AMT2501 Materials and Surface Modification Processes To 05/11/2012 08/12/2012 Mr. K.N. Ganapathi
Batch Full-Time 2012 .
Declaration The assignment submitted herewith is a result of my own investigations and that I have conformed to the guidelines against plagiarism as laid out in the PEMP Student Handbook. All sections of the text and results, which have been obtained from other sources, are fully referenced. I understand that cheating and plagiarism constitute a breach of University regulations and will be dealt with accordingly.
Signature of the student Submission date stamp

(by ARO)
Date
Signature of the Module Leader and date
Signature of Head of the Department and date
<Materials and Surface Modification Processes>
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Abstract ____________________________________________________________________________ Fuel crisis lingers in a great turmoil, pushing humans to reach out more the existing practices and quest for finding genuine natural alternatives. Billions of gallons of fuel are burnt everyday at the expense of destroying mother earth. Radical initiatives are in need, one such being advancing the fuel economy, i.e. more mileage with the best functional and safety rationale. Henry Ford, in his autobiography quoted Fat men cannot run as fast as thin men but, we build most of our vehicles as though dead-weight fat increased speed, eyeing the fuel consumption. New design and alternatives are brought to play to improve the fuel economy. The concept of dead weight is realized and finding alternative lighter substitutes are the talk every auto makers interest. Aluminium as a substitute to steel; is observed by many auto makers. But, steel is no longer gone, came up with the best rendition fighting aluminium eye to eye. An insight whether Aluminium can replace steel in body panel is been discussed.
Pelton wheel, a high efficient impulse water turbine goes under the scanner to determine the material characteristic of its major parts. The literature is reviewed to understand the basic function and service conditions of five parts. Material selection, starting with purpose and objective is not an intuition but, careful assessment of all the service parameters which endorse high efficiency. Parts are individually broken to analyze its inherent need and clear function. Material selection is done by justifying based on true properties aligned step by step. The scenario expedited in the process is systematic addressing the right need.
Pelton wheel Bucket, an aim behind every jet of water to strike, efficiently to take a spin generating a natural source of power, is assessed to select the best possible material. The subject is put to careful consideration and analyzed. Cambridge Engineering Selector, a modern digital software program, delivering all the possible solution of material selection is exploited to the address the every relative property of Pelton wheel bucket. Process ability and the cost are the other traits which drives the selection. The whole concurrent stream is necessary to determine the best available material, and also rate the equal best for alternate considerations.
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Contents ____________________________________________________________________________ Declaration Sheet .................................................................................................................. ii Abstract ................................................................................................................................ iii Contents .................................................................................................................................iv List of Tables .......................................................................................................................... v List of Figures .......................................................................................................................vi List of Symbols.................................................................................................................... vii
1. Aluminium versus Steel in Car body panel..................................................................... 1 1.1 Introduction ................................................................................................................ 1 1.2 Properties requirement of Panel material ................................................................... 1 1.3 Comparison of properties of AHSS and Al alloy for panels ...................................... 2 1.4 Manufacturability and Cost ........................................................................................ 2 1.5 Example for justification ............................................................................................ 3 1.6 Conclusion .................................................................................................................. 3 2. Pelton wheel ....................................................................................................................... 4 2.1 Overview .................................................................................................................... 4 2.2 Parts and Function of Pelton wheel ............................................................................ 5 2.3 Analysis of Material property of Pelton wheel .......................................................... 7 2.4 Material used for parts of Pelton wheel.................................................................... 11 2.5 Conclusion ................................................................................................................ 14 3. Material selection of Pelton wheel Bucket .................................................................... 15 3.1 Selection Overview .................................................................................................. 15 3.2 Pelton wheel Bucket ................................................................................................. 15 3.3 Selection of Bucket material using CES .................................................................. 17 3.3.1 Functional property ...................................................................................... 18 3.3.2 Process ability ............................................................................................... 20 3.3.3 Cost ............................................................................................................... 22 3.3.4 Resistance to Service environment .............................................................. 22 3.3.5 Material rating ............................................................................................... 24 3.4 Stainless steel characteristic comparison with alternatives ...................................... 24 3.5 Surface treatment ...................................................................................................... 25 3.6 Conclusion ................................................................................................................ 27 Learning Outcome ............................................................................................................... 28 References ............................................................................................................................ 29 Bibliography......................................................................................................................... 32
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List of Tables ____________________________________________________________________________
Table No. Table 1.3 Table 2.3a Table 2.3b Table 2.3c Table 2.3d Table 2.3e Table 3.3 Table 3.3.4 Table 3.3.5 Table 3.4
Title of the table Comparison between AHSS & Aluminium alloy Material property of Shaft Material property of Casing Material property of Nozzle Material property of Spear needle Material property of Penstock Requirement for Bucket material selection Material screening Material rating Steel comparisons
Pg.No. 2 9 9 9 10 10 17 23 24 24
List of Figures ____________________________________________________________________________ Figure No. Figure 1.2 Figure 1.3 Figure 1.5 Figure 2.1a Figure 2.1b Figure 2.2a Figure 2.2b Figure 2.2c Figure 2.2d Figure 2.2e Figure 2.2f Figure 2.2g Figure 2.3 Figure 2.4a Figure 2.4b Figure 2.4c Figure 2.4d Figure 2.4e Figure 2.4f Figure 3.2a Figure 3.2b Figure 3.3.1a Figure 3.3.1b Figure 3.3.1c Figure 3.3.2a Figure 3.3.2b Figure 3.3.3 Figure 3.3.4 Figure 3.4 Title of the figure Car Body panel Strength versus Elongation chart AHSS usage trend Schematic of Hydropower generation Assembly of Pelton wheel Construction of Pelton wheel Pelton wheel Shaft Runner with Bucket Water flow simulation Multi Nozzle arrangement Spear needle arrangement Penstock Spear needle cavitation Selection of material Shaft-Initial Selection of material Shaft-Final Selection of material Casing Selection of material Nozzle and Spear-Initial Selection of material Nozzle and Spear-Final Selection of Penstock Bucket Water displacement in Bucket Hardness versus Youngs modulus Fracture toughness Fatigue strength Formability versus Machinability Weldability Comparison of Cost price Durability conditions Surface treatment Pg.No. 1 2 3 4 4 5 6 6 7 7 8 8 10 11 12 12 13 13 14 16 16 18 19 20 21 21 22 23 25
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List of Symbols ____________________________________________________________________________
Symbol AHSS Al CES ULSAB
Description Advanced High Strength Steel Aluminum Cambridge Engineering Selector Ultra Light Steel Auto Body
Units
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PART-A CHAPTER 1 1. Aluminium versus Steel in Car body panel 1.1 Introduction: The world is said to run on wheels, the same is true. Automobiles have become an intrinsic part of day to day life from mass transport to personal transport, from need to luxury. On the practical stake, huge amount of fuel is burnt at the expense of deteriorating the environment. With no other alternatives government bodies are striving to regulate the raise of fuel economy standards. Fuel economy can be enriched by reducing the weight of the car in three ways (Stadolsky et al. 1995: 3) by reducing its size, optimizing design to minimum weight and replacing heavier material with the lighter one. Steel, being a best known engineering material from ages, where the vast background knowledge acquired, is molded to suit any application cost effectively. Modern materials like aluminium can be a strong counterpart offering better characteristic over less weight is merely a better substitute. Strength to weight ratio (performance model) alone is not sufficient to satisfy real value but, also ever growing need for high safety standards, the cost incurred and ability to repair or rework . Steel industry also catching the race with their own rendition through Ultra high strength steel, lowering weight and escalating strength as well as formability than traditional steels.
1.2 Properties requirement of panel material: Car body panel used are as shown in Figure 1.2, it forms the exterior profile body of the car. The panel material i.e. the closures, accounts to approx. 5% of the total body mass (Carlson et al. 2010).
Figure 1.2: Car body panel (Shop at India n.d.,) The body panels need to have certain properties like, less weight, corrosion resistance, since it is exposed to the environment, Strength and stiffness to absorb and withstand energy in crashes, good
formability and manufacturability per the requirement, dent resistance and rework ability, sustainability, Class-A surface quality and cost.
1.3 Comparison of properties of AHSS and Al alloy for panels: The strength to elongation relationship of AHSS and Al alloy is shown in Figure 1.3
Figure 1.3: Strength versus elongation chart (Billur, Mao and Altan 2012: 15) The general property comparison between AHSS (First generation) and Aluminum alloy is given in Table 1.3 AHSS High strength and low formability High spring back High stiffness and dent resistance Low strength to weight ratio low corrosion resistance Low weight due to lesser gauge thickness because of strength high wear resistance high crash worthiness Low rework / repair ability Inconsistent material property Al alloy low strength and low formability moderate spring back Low stiffness and dent resistance High strength to weight ratio high corrosion resistance Low weight by density low wear resistance low crash worthiness Moderate rework / repair ability Consistent material property
Table 1.3: Comparison between AHSS and Aluminum alloy 1.4 Manufacturability and Cost: AHSS (Billur, Mao and Altan 2012): Forming requires strong die material and coating. Due to high strength of steel more loading capacity of press required, which can be tweaked with the current infrastructure available. Springback is an issue with AHSS, holding on engage and re-striking with servo drive presses enhances cold forming. Hot forming can be used as a substitute, no issues with welding. Repairing
a strain hardened AHSS is a tedious activity may result in fracture. The cost of material as well as the processing is less, utilizing the same infrastructure built for conventional steel processing.
Aluminum alloy (Sever et al. 2012): Formability of aluminium is less compared to that of steel. Warm forming and hydro forming can be employed, which uses special setup and insulation as heat is involved. Lubricants are used to reduce friction. Welding flexibility is not as steel, but some of the aluminium grades can be welded easily. The cost of aluminium is high compared to steel, but one of the most sustainable materials. Manufacturing needs special setup, capital cost is high, only suitable for low volume production.
1.5 Example for justification: Honda, was the first to launch alternate material car, however the latest version is with AHSS intense. BMW launched aluminium version with 5 series, but recently switched to steel (Geck 2010). Price of car is a major driving concern, auto industry is rather cost oriented than the performance. Business target aim primarily on manufacturing and cost. Though high end cars rely on performance is produced in low volumes because of less demand. High volume production still sticks on to steel, with an already built vast infrastructure, by replacing with AHSS (Hall 2008). There will be a growth in AHSS usage in future years as shown in Figure 1.5 a new benchmarking is going to be achieved through Ultra Light Steel Auto Body (ULSAB) with no additional cost but with enhanced safety parameters with less weight (World auto steel n.d.,)
Figure 1.5: AHSS usage trend (Hall 2008: 28) 1.6 Conclusion: Aluminium can be a best substitute to steel, but the ongoing development in steel like ULSAB makes much more sense utilizing the current capabilities to its fullest. Considering cost barrier as a primary objective and characteristics next, it can be assessed as aluminum can replace steel only to a certain extent. But steel is competitively building its edge over ages to prove it is very capable.
PART-B CHAPTER 2 ________________________________________________________________________________ 2. Pelton wheel 2.1 Overview: The Pelton wheel, also known as Pelton turbine is a tangential flow impulse turbine; it is more efficient than any other impulse turbine. The pressure energy of the water is converted into kinetic energy (Bansal 2005: 851), when flown through a nozzle causing pressure amplification, hits the bucket mounted on a shaft causing rotation of the runner. It is named after an American engineer Lester Allan Pelton, who improvised the water wheel by splitting incoming jet provisioned through bucket making the wheel to run faster (Wikipedia 2012a). Pelton wheel is used in hydro-electric plants where high heads of water with low discharge. Pelton can be horizontally mounted or vertically designated with the shaft axis, single jet or multi-jet pelton wheel are available. Figure 2.1a shows the logical technology behind power generation using turbine, Figure 2.1b shows the assembly of pelton wheel turbine.
Figure 2.1a: Schematic of hydropower generation (Current generation 2011)
Figure 2.1b: Assembly of Pelton wheel (Wikipedia 2012b)

2.2 Parts and function of Pelton wheel: Construction of a pelton wheel hosts different parts offering unique function to drive the power. Figure 2.2a show the elements of construction.
Figure 2.2a: Construction of pelton wheel (Rajput 2005: 358) Pelton wheel consists of following parts and the function of the highlighted parts will be discussed. Shaft: The shaft is a rotating member keyed to the runner assembly. The shaft is coupled to the generator, power is determined from the rotation of the shaft. The circular and cylindrical run-out of the shat is a substantial criterion for its efficiency. Guide bearing block houses the shaft to maintain an unison rotation throughout the entire span. Figure 2.2b shows the picture of the shaft mounted with runner along on the bearing housing. Shaft Runner with buckets Casing Nozzle Spear needle Penstock
Figure 2.2b: Pelton wheel shaft (Fuchan industry n.d.,) Runner assembly: Runner is a circular wheel which is mounted on the shaft and keyed in. It consist number of hemispherical buckets, evenly spaced on its periphery. The buckets can be welded with the runner or fastened as an attachment or can be cast as an whole assembly. The bucket has a vane provision known as a splitter which breaks the incoming water gliding over the cup and departing. Two or more runner can be mounted on the shaft. Figure 2.2c shows runner assembly.
Figure 2.2c: Runner with bucket (Bright hub engineering 2012) Casing: Casing is not associated with any hydraulic function. It provides and enclosure to safeguard the turbulent water dragged out from the bucket. It act as a guide for water to discharge from to the tail race (Bansal 2005: 852). Figure 2.2d shows the fluid flow simulation within the casing.
Figure 2.2d: water flow simulation (HAP 2011: 11) Nozzle: Nozzle is a member used to direct the water discharge to the buckets. A convergent nozzle is used to build the pressure of the incoming water and direct over the bucket making it to rotate. A pelton wheel turbine can be built with a single or a set of nozzle depending on the head available to harness maximum potential. Figure 2.2e shows a multi nozzle arrangement
Figure 2.2e: Multi nozzle arrangement (Renew hydro n.d.,) Spear needle: Is a conical device used to control and direct a sharp flow of the water through the nozzle orifice. The velocity of the water impinging on the bucket is controlled by blocking and opening the spear needle. A handle can be rotated to push-in or push-out based on the requirement. Figure 2.2f shows the spear needle engage and dis-engage.
Figure 2.2f: Spear needle arrangement (Subbarao n.d.,: 18) Penstock: Penstock is a tubular duct which supplies water from the storage source into the nozzle via a distributor manifold. It can have gates to restrict the water flow. It is like a tube descending from storage source to the nozzle, the cross section can be uniform or divergent to proliferate the velocity of the flow. Figure 2.2g shows the penstock application in real site.
Figure 2.2g: Penstock (Qurren 2011)
2.3 Analysis of material property of Pelton wheel parts: The materials for the parts of pelton wheel are selected subjective to analysis based on the property which it need to wok i.e. the environment and to award the best possible efficiency. The material characteristics are discussed selecting each component and their requirement. Shaft: Shaft is a primary member, only whose rotation purely determines the output efficiency. It needs to bear some of the vital properties to ensure that. The property requirements based on the working analysis of shaft is shown in Table 2.3a Material property Stiffness Bending strength corrosion resistance Fatigue resistance wear resistance low co-efficient of friction Surface finish Requirement to withstand deformation, having high elastic modulus to withstand the weight of the runner assembly mount to resist fresh, salt and soil water conditions to withstand cyclic loads of combined torsional and bending stresses wear causing slippages and run-out of shaft, tribological concerns to maximize the output efficiency to enhance lubrication Table 2.3a: Material property of Shaft Casing: The rigid member, though need to perform some of the functions for a whole approach. The property which a casing has to offer is shown in Table 2.3b Material property Dampening Impact resistance corrosion resistance Surface finish Requirement to reduce vibration to withstand splashes from bucket to withstand fresh, salt and soil water conditions to guide water to tail race causing no counter impact to bucket Table 2.3b: Material property of Casing Nozzle: Nozzle an important jet guiding member has to withstand some of the impact caused by the jet with high velocity. Table 2.3c shows the material requirement. Material property Corrosion resistance wear resistance surface finish Impact resistance Requirement to withstand fresh, salt and soil water conditions due to the high velocities of water leading to worn surface guide water smoothly and impinge directly on the splitter to withstand back pressure from jet splashing bucket
Table 2.3c: Material property of Nozzle

Spear Needle: A conical needle, is an actuation member to control the flow of water jet. Table 2.3d shows the property requirement of the Spear needle. Material property Corrosion resistance Wear and abrasion resistance surface finish Impact resistance Requirement to withstand fresh, salt and soil water conditions preventing cavitation due to the high velocities of water leading to edge crack, silt erosion and uneven discharges, guide water smoothly as a concentrated jet to withstand the impact surges from rotating bucket Table 2.3d: Material property of Spear Needle An example of eroded spear is shown in Figure 2.3, where the tip has lead to cavitation, which is going to lead to uneven jet discharge.
Figure 2.3: Spear Needle corrosion (HAP 2011: 12) Penstock: Penstock is a hollow tube which connects the access of water from storage source to nozzle via a distributor manifold. The length of these may follow from several meters. Table 2.3e shows the material properties expected by these penstock. Material property Corrosion resistance fracture toughness elastic modulus Requirement to withstand fresh, salt and soil water conditions to withstand internal pressure (hoop stress) developed and crack able to draw to form tubular sections followed by welding Table 2.3e: Material property of Penstock
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All the parts coming in contact with turbulent water faces cavitation due to the suspended soil particle abrading the surface of the part. This is a major concern with water turbines.
2.4 Material used for parts of Pelton wheel: As discussed in section 2.3, the task can be put forth in selection of material to the intended use. Material selection can be done by Data hand books or Selection software.
Shaft: Cambridge Engineering Selector (CES), can be used to select the general material responsive to the cited requirement. Following steps are followed to assess the suitable method. CES, Lever -2 is chosen for selection. Material can be directly selected through option SELECT, instead of searching. Edu level 2: Materials with durability properties is defined. Limit is set with excelling in fresh, salt and soil water resistance. A Graph, is set considering fracture toughness versus fatigue strength, top 14 materials are selected as shown in Figure 2.4a Once again a Graph is set between the hardness and the cost (since INR was not available USD is used) as shown in Figure 2.4b Material selected are Bronze or Stainless steel for the application.
Stainless steel
100
Fracture toughness (MPa.m^1/2)
Nickel-chromium alloys
10
Bronze
0.1
0.01
Fatigue strength at 10^7 cycles (MPa)
10
100
1000
Figure 2.4a: Selection of material shaft-initial
11
1000
100
Hardness - Vickers (HV)
10
Bronze
1
Stainless steel
0.1
0.01
0.001 0.1 1 10 100
Price (USD/kg)
Figure 2.4b: Selection of material shaft-final Casing: Literature will be handy for selection. Since, dampening is the primary criteria; Gray Cast Iron can be used. The part could be simply cast as functionally casing doesnt add any value. CES can also be put to use to determine the right material. Limit is set as acceptable resistance to water. Process, Surface coating and painting is added to resist the impact of jet. Graph is plotted with castability against cost. Gray Cast Iron and SG Iron hold the top ranks as shown in Figure 2.4c
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Cast iron, ductile (nodular)

4
Cast iron, gray
Castability
1 1 10 100
Price (USD/kg)
Figure 2.4c: Selection of material Casing

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Nozzle and Spear Needle: These two parts more or less do hold the same working characteristics. So, the result can be assessed as consolidate. Limit is set for excelling fresh, salt and soil water condition. Tree is set with collection of Metals, Non-metals and ceramics, with surface treatment. Graph is plotted as Hardness versus Fracture toughness, top 14 materials are selected bidding the performance as shown in Figure 2.4d Graph is plotted to derive the inexpensive material. Bronze, Stainless steel and Silicon carbide are the material selected as shown in Figure 2.4e TiN coating can be applied to invoke wear resistance.
Boron carbide Silicon carbide
1000
Nickel-based superalloys
100
Hardness - Vickers (HV)
10
Bronze
Stainless steel
0.1
0.01
0.001 0.01 0.1 1 10 100
Fracture toughness (MPa.m^1/2)
Figure 2.4d: Selection of material Nozzle and Spear-initial
100
Silicon carbide
10
Stainless steel
Price (USD/kg)
Bronze
0.1
Figure 2.4e: Selection of material Nozzle and Spear-Final

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Penstock: Penstock, is an external part functioning to carry the water from source to destination. Earlier days steel pipes were used, later galvanized iron pipe. Other possibilities are explored with CES. Limit is set excelling water conditions fresh, salt and soil. Tree is set compiling joining and shaping process. Graph is plotted between fracture toughness and hardness. Graph is plotted again to derive the economical material. Concrete, PVC and Stainless steel can play as an optimal choice as shown in Figure 2.4f
Aluminum nitride Polyetheretherketone (PEEK) Nickel Polytetrafluoroethylene (Teflon, PTFE)
100
Stainless steel
10
Titanium alloys
Polyoxymethylene (Acetal, POM)
Polyvinylchloride (tpPVC)
Slate
Price (USD/kg)
Sandstone
0.1
Concrete
Figure 2.4f: Selection of material Penstock 2.5 Conclusion: The major five parts of Pelton wheel are selected. Shaft, Casing, Spear needle, Nozzle and penstock, whose properties are ascertained, respected to its functionality. CES is used to determine the material as, Shaft Casing Spear Nozzle - Stainless steel - Gray cast iron - Bronze, Stainless steel, Titanium carbide coating - Bronze, Stainless steel, Titanium carbide coating
Penstock - Concrete, PVC for medium head, Steel for low head
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PART-C CHAPTER 3 ________________________________________________________________________________ 3. Material Selection of Pelton wheel Bucket 3.1 Selection Overview: Material selection is a holistic decision making approach (Farag 2002: 4). As earlier days called as I design, you produce is mere irony limiting the scope of practical consideration. Concurrent engineering is the rave trend idealizing every available expertise across various functions of the organization and endorse optimization efficiently. (Farag 2002: 4-14) The selection entails three main steps, Initial screening, developing and comparing alternatives, selecting optimal solution. Initial screening is subject to primary evaluation for the group based on following consideration: Functional requirement Processability requirement Cost Reliability requirement Resistance to service environment
Once concern is diminished to selection availing above factors, weighing across agreeable features is done by: Weighted property method Digital logic method Performance index The ranked data is selected later to deliver optimal solution to the requirement. The data involved associating the process is immense and lead to obscure judgment. Computer guided referencing has opened new milestone to material selection. Cambridge Engineering Selector (CES) is one such software program which depicts data handbook contents customized with process capabilities and comparisons by property charts.
3.2 Pelton wheel Bucket: Bucket is what makes the pelton wheel distinguishable than other water wheel. The splitter which breaks the incoming water jet and provides an access to glide the water over two hemispherical cups with an impact causing it to rotate. These buckets in series around periphery of the runner are designed in such a way that the subsequent engaging bucket melds as a cycle without creating counter turbulence. Figure 3.2a shows the unique shape of the bucket used for operation Figure 3.2b shows the splitting of the jet tangentially into the cups.
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Figure 3.2a: Bucket (Cink n.d.,)
Figure 3.2b: Water displacement in bucket (Kennedy 1903)
Rotation of the shaft is totally relied on the bucket design and the jet flow. The design of the bucket to deliver maximum efficiency is the key criteria. Pelton wheel bucket is subject to lot of stress and other operating obstacles. Silt erosion and cavitation is a major threat posed by the bucket. The water flowing in to the turbine may contain sand and minerals which abrades the surface microscopically leading to loss of efficiency.
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3.3 Selection of Bucket material using CES: Cambridge Engineering selector (CES) is made use to select the material for Pelton wheel Bucket, requirements of the selection need to be framed, whose input can offer a whole lot of selection from diverse range of data. The general characteristic which substantiates bucket material selection are discussed in Table 3.3 Characteristic Corrosion resistance
Function
Requirement
to withstand fresh and salt water conditions preventing rusting to withstand deformation under consistent pressure, high Youngs Stiffness modulus Wear resistance to withstand slit erosion caused by sand and mineral mixtures Fatigue resistance to withstand the cyclic load acting on the cups Fracture toughness to resist crack propagation Impact resistance to withstand shock loads for high velocity water jet to guide the water along with distorting the turbulence, low co-ef of Surface finish friction Primary process able to cast or forge Secondary process able to machine, grind, weld Surface treatment to withstand tribological concern for the water sample mixture Material cost cost of material based on functional requirement Manufacturing cost cost of processing to exhibit best service condition Servicing cost cost incurrent on servicing as per the cycles of operation Table 3.3: Requirements for bucket material selection
Cambridge Engineering Selector (CES), is used to find the solution for Pelton wheel Bucket. Corrosion resistance is a surface property depending on serviceable environment. So as discussed in Section 3.1 Selection Overview, this service or surface property can be analyzed after ideal material selection based after function, process and cost since, surface treatment can add value to the material performance on subsequent stages. As expressed in Section 3.1 Selection Overview, step involved in Initial screening is with, Functional property Process ability Cost Reliability (Since, dependent on practical usage cycle; not considered here) Resistance to service environment
Cost
Process
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3.3.1 Functional property: Based on the material characteristic, CES is maneuvered to serve the need. Following are detailed steps associated with snapshot of CES Edupack 2009 program to input the design data.
Step-1: The primary functional criteria of the Pelton wheel Bucket is its stiffness, so a material with higher Youngs modulus to be selected. Stiffness can be related with the wear resistance property i.e. high hardness value. Italicized words are the options used in CES Level 2 is selected for finding, 98 material are available Select tab is used instead of Browse or Search Select from: Edu level 2 Materials with durability properties Graph is selected to plot mechanical properties, Hardness-Vickers (x-axis) versus Youngs modulus (y-axis) Ashby chart lists 89 materials out of 98 A Box selection is used to select top 40 results Figure 3.3.1a shows the selection, grayed out results are omitted.
Figure 3.3.1a: Hardness versus Youngs modulus

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Step -2: Fracture strength is a vital criterion for the effective performance of Pelton Bucket, a comparison of this property is done in the same file. Graph is selected to plot the mechanical property, Fracture toughness out from selected 40 materials A Box selection is used to select top 30 results Figure 3.3.1b shows the comparison of Fracture toughness.
Figure 3.3.1b: Fracture toughness Step -3: The next property of Pelton Bucket is Fatigue resistance, as the rotating cups are subjected to some cyclic load, the residual stress induced may lead to fracture. So the material is analyzed for its performance to withstand these loads. Graph is selected to plot the mechanical property, Fatigue strength out from selected 30 materials A Box selection is used to select top 20 results Figure 3.3.1c shows the comparison of Fatigue toughness. Fracture and fatigue strength could have been plotted as a whole, but due the dominant inherent characteristic the functional properties are organized and concluded.
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Figure 3.3.1c: Fatigue strength 3.3.2 Process ability: Only the functional attributes alone cannot be judged for selection, are the initial design functions are flexible for producing, need to be looked upon. Forging of Bucket are chosen than casting because of homogeneity, machining and welding capabilities need to be explored. Graph is selected to plot the process ability, Formability (x-axis) versus Machinability (y-axis) out from selected 20 materials A Box selection is used to select top 12 results Figure 3.3.2a shows the comparison of Formability versus Machinability.
Then one of the most important process to assemble runner and Bucket, which is welding is applied Graph is selected to plot the process ability, Weldability The same top 12 materials are compared Figure 3.3.2b shows the comparison of Weldability.
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Figure 3.3.2a: Formability versus Machinability
Figure 3.3.2b: Weldability
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3.3.3 Cost: The cost of the material and processing is a driving factor for its applicability. Optimum performance model with lower cost is the best practice in interest of any business. The selected 12 materials are compared for its cost Graph is selected to plot the cost price per kg, USD is used instead of unavailability of INR cost unit. Figure 3.3.3 shows the comparison of Cost price.
Figure 3.3.3: Comparison of cost price 3.3.4 Resistance to service environment: The selected material should be able to withstand the operating environment. For a Pelton wheel Bucket, it is of prime importance that it should not corrode with fresh, salt, silt water conditions. The necessary surface treatment can be carried to inhibit corrosion, though it is advisable to have a view whether materials directly suit the requirement. Following conditions are applied: Limit is applied to select the durability function with fresh, salt, soils and clay to be excellent. Figure 3.3.4 shows 8 materials listed for the purpose
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Figure3.3.4: Durability conditions Narrowed down by multiple stages, 8 materials are listed finally as shown in Table 3.3.4
Function Alumina Boron carbide Brass Bronze Cast iron, ductile (nodular) Commercially pure titanium High carbon steel Low alloy steel Low carbon steel Medium carbon steel Nickel Nickel-based superalloys Nickel-chromium alloys Silicon carbide Silicon nitride Stainless steel Titanium alloys Tungsten alloys Tungsten carbides Zirconia Process Brass Bronze Commercially pure titanium High carbon steel Low alloy steel Low carbon steel Medium carbon steel Nickel Nickel-based superalloys Nickel-chromium alloys Stainless steel Titanium alloys Environment Brass Bronze Commercially pure titanium Nickel Nickel-based superalloys Nickel-chromium alloys Stainless steel Titanium alloys
Table 3.3.4: Material screening

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3.3.5 Material rating: The selected materials are rated against their feature to become the Bucket material. The basis of rating is its functional, processability, cost and serviceability aspect. A Five scale rating is used for justifying individual judgment without biasing. Table 3.3.5 shows the rating
Function Material Stiffness vs hardness 3 2 2 4 5 4 5 4 Fracture toughness 2 2 2 4 4 4 5 3 Fatigue strength 2 2 3 3 5 3 4 4 Process Forming vs Machining 5 4 1 3 3 3 2 1 Welding cost Total
Brass Bronze Commercially pure titanium Nickel Nickel-based superalloys Nickel-chromium alloys Stainless steel Titanium alloys
4 4 4 4 4 4 5 4
5 5 2 3 3 3 4 2
21 19 14 21 24 21 25 18
Table 3.3.5: Material rating Stainless steel is the best material as a whole package for Pelton wheel Bucket scoring 25 out of 30 followed by Nickel.
3.4 Stainless steel characteristics comparison with alternatives: Stainless clearly won the whole requirement. But, other steels too were in a tight competitive comparison until cost and losing just because of its service environment i.e. Corrosion resistance. Since, surface treatment can get the other steels performing the same action; a comparison is carried out excluding surface condition. Table 3.4 shows the comparison of stainless steel with other steels.
Properties Youngs modulus (GPa) Hardness (HV) Fracture toughness (MPa.m^1/2) Fatigue strength at 10^7 cycles (Mpa) Formability rating Machinability rating Weldability rating Cost (USD /Kg) Low carbon steel 200 215 108 173 41 82 203 293 45 34 5 0.634 - 0.698 Medium carbon steel 200 216 122 565 12 92 229 600 45 34 5 0.671 - 0.738 High carbon steel 200 215 160 650 27 92 281 606 45 34 5 0.723 - 0.796 Low alloy steel 205 217 140 693 14 200 248 700 34 34 5 0.806 0.887 stainless steel 189 210 130 570 62 150 175 753 23 23 5 6.52 - 7.17
Table 3.4 Steel comparisons (from CES datasheet)

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It is notices that, Low alloy steel is the best competitor in every regard to Stainless steel. Having all the fair attributes better than that of Stainless steel, it can be concluded that Low alloy steel is the perfect material for Pelton wheel Bucket, with surface properties improved with coating.
3.5 Surface treatment: Low alloy steel is susceptible to corrosion, as it needs to perform well with the aqueous condition a surface treatment method is chosen to give the material the sustainability with following critical touchstones: Corrosion resistance (resist oxidation) Wear resistance (resist silt abrasion)
CES, is used to identify the surface treatments applicable to improve material characteristics, the steps are as followed: Level 3 is selected of CES Edupack 2009 Select from, Processes universe Surface treatment TREE is used to locate the material Low alloy steel from Material Universe. Limit is set to define the function of treatment, for corrosion and erosion resistance, with economic attributes: labor intensity, equipment and tooling cost as shown in Figure 3.4
Figure 3.4a: Surface treatment

25
Three surface modification process are listed based on functional and economic attributes Electroless (auto catalyst) process Flame spraying Hot-dip coating
Flame spraying is the best method being able to apply over large surface area with less overall cost. Flame spraying is a overlay coating technique done by arc wire thermal spraying, plasma arc spraying and powder flame spraying. The process parameters mainly depend on (Thapa et al. n.d.,) Coating material property Chemical composition Melting point Morphology Particle size distribution Shape
Spraying process control Flame temperature Gas pressure Powder flow rate Geometry of nozzle Spray distance Surface preparation and substrate
Case study conducted on the hydro erosion resistance of Kalingdaki hydropower plant is vital to justify the sustainability rendered by High Velocity Oxygen Fuel (HVOF) flame spraying. The coating can be applied to stainless as well as low alloy steel. The tungsten carbide ceramic coating shows better resistance to sediment laden water erosion. High abrasion resistance and increased fatigue resistance is offered by tungsten carbide coating (Alstom 2012). Vacuum plasma spraying has better properties than atmospheric spray (Kumar, Sapra, Bhandari 2011) Tungsten carbide and Cobalt chromium have an edge than any other coating.
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3.6 Conclusion: Stainless steel is the best material for Pelton wheel bucket based on performance, Low alloy steel is considered to be the cost effective substitute whose surface characteristics improvement makes a close competitor to stainless steel. Flame hardening is the surface treatment best suited for corrosion and abrasion resistance of the material. Tungsten carbide and Cobalt chromium raises the standard of performance of these materials against sediment laden particles.
27
Learning Outcome ________________________________________________________________________________ Aluminium is replacing the Steel entirely in car body panel; a scintillating topic put forth. As simple the issue looks, more deceiving it is. Every piece of literature gives it own right. The topic aided to realize the circumstance to select the best material aiming a global cause and also understand the limiting factors, why it is hard for a switchover. Material property has an intrinsic value, alone which cant be justified unless related to the cost. The rationale behind using the performance model and cost model is learnt. Either way the benefit can be reaped, by Improvisation or substitution. Business excellence is driving the research; every need of customer is expected to be the best but at no additional expense, a tricky part. Opinion should not be biased, but the numbers should speak the fact, it is understood.
Perplexed that, what I learn from Part-B? As it speaks the material selection of major Pelton wheel parts, I gained the clarity behind the notion. Every assessment should start from the mechanism behind it. Pelton wheel is a whole mechanism being simple, the major parts contributes to its overall functioning. The art of initial screening, without any technical input is made known with this. The analysis can be purely judgmental if the right properties are assessed. The process of listing the characteristic based on function is made known. I was able to relate material science and engineering beholding the classification.
Pelton wheel Bucket selection is made easy only with knowing the function behind, which was dealt in Part-B. Though Part-B was an overview classification and selection. Part-C was a discrete initiative to select the material with much more precision by increasing the degree of input. CES is a thoughtful medium, the screening, comparison and selection is made available saving enormous time. The problem, helped to find a concise systematic way for solution. How best a material could be explored is learnt. Defining the performance index to suit the requirement is understood. Assisted to gain the confidence in selecting material for any real time situation. The mode to distinguish and apply consideration in various method is understood.
28
References ________________________________________________________________________________ Alstom (2012) Pelton hydro turbines [online] available from <http://www.alstom.com/power/renewables/hydro/hydro-turbines/pelton-turbines/> [06 December 2012] Bansal, R.k. (2005) Fluid mechanics and Hydraulic machines [online] 9th edn. Delhi: Laxmi publications available from <http://books.google.co.in/books?id=nCnifcUdNp4C> [03 December 2012] Billur, Erren. Mao, Tingting. Dr, Altan, Taylan. (2012) Forming of AHSS and Al Alloys, Part I Advanced High Strength Steels [online] available from < http://nsm.eng.ohio-state.edu/cpf/Forming_of_AHSS_and_Al_Alloys.pdf> [30 November 2012] Brighthub engineering (2012) Hydraulic Turbines: The Pelton Turbine [online] available from <http://www.brighthubengineering.com/fluid-mechanics-hydraulics/26777-hydraulicturbines-the-pelton-turbine/> [30 December 2012] Carlson, Blair. Krajewski, Paul. Sachdev, Anil. Schroth, Jim. Sigler, David. (2012) Challenges and opportunities relative to increased usage of Aluminum within the Automotive industry [online] available from <http://www.tms.org/meetings/annual10/PDFs/presentations/verbrugge.pdf> [30 November 2012] Cink (n.d.,) Pelton [online] available from <http://www.cink-hydro-energy.com/galerie/turbiny/galerie/pelton/pel8_big.jpg> [05 December 2012] Current generation (2012) Information [online] available from <http://currentgeneration.co.nz/INFORMATION/ABOUT+RENEWABLE+ENERGY/MIC RO-HRDRO+WATER+TURBINE.html> [30 December 2012] Farag, M. Mahmood. Kutz, Myer (ed.) (2002) Handbook of Materials Selection. New York: John Wiley & Sons, Inc., Fuchan industry (n.d.,) Products [online] available from < http://www.fuchunind.com/product_show.asp?bid=&tid=130&id=4> [03 December 2012]
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Geck, Paul. (2010) Advanced High-Strength Steels Add Strength and Ductility to Vehicle Design [online] available from < http://machinedesign.com/article/advanced-high-strength-steelsadd-strength-and-ductility-to-vehicle-design-0503> [01 December 2012] Hall, N. Jody. (2008) 50 year Perspective of Automotive Engineering Body Materials and an Analysis of the Future [online] available from <http://www.steel.org/~/media/Files/Autosteel/Great%20Designs%20in%20Steel/GDIS%2 02008/06%20%2050%20year%20Perspective%20of%20Automotive%20Engineering%20Body%20Mater ials%20and%20an%20Engineering%20Body%20Materials.pdf> [01 December 2012] HAP (2011) Best practice catalog : Pelton turbine [online] available from < http://hydropower.ornl.gov/HAP/BestPracticeCatComp.pdf> [03 December 2012] Kennedy, Rankin (1903) Pelton wheel water turbine, nozzle and bucket (Rankin Kennedy, Electrical Installations, Vol III, 1903) [online] available from <http://commons.wikimedia.org/wiki/File:Pelton_wheel_water_turbine,_nozzle_and_bucket _%28Rankin_Kennedy,_Electrical_Installations,_Vol_III,_1903%29.jpg> [05 December 2012] Kumar, Adarsh. Sapra, Pawan kumar. Bhandari, Sanjay. (2011) A Review paper on slurry erosion of Plasma and Flame thermal sprayed coatings [online] available from <http://ptuconferences.com/digitallibrary/aftmme2011/62.pdf> [06 December 2012] Qurren (2011) Kokuto III power station penstock [online] available from <http://commons.wikimedia.org/wiki/File:Kokuto_III_power_station_penstock.jpg#file> [04 December 2012] Rajput, R.K (2005) Elements of Mechanical Engineering [online] Delhi: Laxmi publications available from <http://books.google.co.in/books?id=CtT0fzwkMvUC&dq=pelton+wheel&source=gbs_nav links_s> [03 December 2012] Renew hydro (n.d.,) Pelton wheel [online] available from <http://www.renewhydro.com/index3B.html> [03 December 2012] Sever, Nimit kardes. Balachenderan, Madhumitha. Billur, Erren. Dr, Altan, Taylan. (2012) Forming of Aluminum Alloy Sheets for Automotive Applications [online] available from < http://nsmwww.eng.ohio-state.edu/CPF_Al_forming.pdf> [01 December 2012]
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Shop at India (2012) [online] available from < http://www.shopatindia.com/price/Tata-Nano-LXBS-III-Car> [30 November 2012] Stadolsky, F. Vyas, A. Cuenca, R. Gaines, L. (1995) Life-Cycle Energy Savings Potential from Aluminum-Intensive Vehicles [online] available from < http://www.transportation.anl.gov/pdfs/TA/106.pdf> [28 November 2012]
Subbarao, R.V.M (n.d.,) Analysis of Intake System for Modern Pelton Wheel [online] Delhi: IIT Available from <http://web.iitd.ac.in/~pmvs/mel346/mel346-16.ppt> [03 December 2012] Thapa, Bhola. Dahlhaug, G. Ole. Timsina, Madan. Upadhyay, Piyush. Basnet, Ranjil (n.d.,) HVOF coatings for erosion resistance of hydraulic turbines:Experience of Kaligandaki A Hydropower Plant [online] available from <http://www.drukgreen.bt/library/Documents/CPSU/6.05.%20Thapa%20B.pdf> [06 December 2012] Wikipedia (2012a) Lester Allan Pelton [online] available from <http://en.wikipedia.org/wiki/Lester_Allan_Pelton> [03 December 2012] Wikipedia (2012b) Pelton wheel [online] available from < http://en.wikipedia.org/wiki/Pelton_wheel> [03 December 2012] World auto steel. (n.d.,) ULSAB Programme Report [online] available from < http://www.worldautosteel.org/projects/ulsab/ultralight-steel-auto-body-ulsab-programme/> [01 December 2012]
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Bibliography ________________________________________________________________________________ Soboyejo, Wole`. (2002) Mechanical properties of Engineered materials. New York: Marcel Dekker Inc. Callister, Jr.D.William. Rethwisch, G. David. (2012) Fundamentals of materials science and engineering : an integrated approach. 9th edn. New York: John Wiley & Sons, Inc., Kutz, Myer (ed.) (2002) Handbook of Materials Selection. New York: John Wiley & Sons, Inc.,
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MSRSAS - Material and Surface Modification

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MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Module Code Module Name Course Department

Name of the Student Reg. No Batch Module Leader

Shanmuga Raja .B BVB0912004 Full-Time 2012. Mr. K.N. Ganapathi

M.S.Ramaiah School of Advanced Studies

POSTGRADUATE ENGINEERING AND MANAGEMENT PROGRAMME (PEMP)

Batch Full-Time 2012 .

Signature of the student Submission date stamp

Signature of the Module Leader and date

Signature of Head of the Department and date

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

List of Tables ____________________________________________________________________________

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

List of Symbols ____________________________________________________________________________

Symbol AHSS Al CES ULSAB

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Figure 2.1a: Schematic of hydropower generation (Current generation 2011)

Figure 2.1b: Assembly of Pelton wheel (Wikipedia 2012b)

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Figure 2.2g: Penstock (Qurren 2011)

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Table 2.3c: Material property of Nozzle

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Fracture toughness (MPa.m^1/2)

Fatigue strength at 10^7 cycles (MPa)

Figure 2.4a: Selection of material shaft-initial

<Materials and Surface Modification Processes>

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Hardness - Vickers (HV)

0.001 0.1 1 10 100

Cast iron, ductile (nodular)

Cast iron, gray

Figure 2.4c: Selection of material Casing

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Hardness - Vickers (HV)

0.001 0.01 0.1 1 10 100

Fracture toughness (MPa.m^1/2)

Figure 2.4d: Selection of material Nozzle and Spear-initial

Figure 2.4e: Selection of material Nozzle and Spear-Final

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Polyoxymethylene (Acetal, POM)

<Materials and Surface Modification Processes>