date: 25-26 april 2019 venue: hotel crowne plaza, mayur ......- idris peerzade, fluor daniel,...

Date: 25-26 April 2019 Venue: Hotel Crowne Plaza, Mayur Vihar, New Delhi

Annual Conference and Exhibition

Souvenir

“Steel, Industrial Materials & Non-Metallics”

&“Welding &

Fabrication Technology”

Materials‘19 WeldFab’19

Organizer

Media PartnersSpecial Acknowledgement

Tea/Coffee Partner University PartnerExhibitors

Knowledge Partners

Dignitaries of Inaugural Session

Mr. Puneet KansalJoint Secretary, Ministry of Steel

Govt. Of India

Dr. Mukesh KumarDirector, SRTMI, Ministry of Steel

Govt. of India

Mr. K. K. PahujaPresident, ISSDA

Mr. Ashish AgrawalDirector, Jindal Stainless Steelway

Warm Welcome to all the Participants

“Steel, Industrial Materials, Welding & Fabrication” are the essential part of everyday life and their application is

extensive in today’s technological development. With the launch of the ‘Make in India’ initiative by the Government of

India, to transform India into a global design and manufacturing hub, developments in the Material development &

production, Welding & fabrication Industry is the need of the moment to make Indian products globally competitive.

The agenda of the Conference covers a wide range of very interesting topics emphasizing on the Make in India Concept

help us to re-think about various approaches that can escalate the Concept among the young engineers. The subject

conference is going to bring together experts from Industries, academia, research & development organizations

and professional societies for sharing of knowledge, expertise, new technologies/developments, Innovations and

experience in the emerging trends related to Steels, Advanced Materials, Welding & fabrication techniques for the

Industry.

We have received extensive support from OP Jindal University, Steel Research & Technology Mission of India

(SRTMI, Under the Aegis of Ministry of Steel), Indian Stainless Steel Development Association (ISSDA), Indian

Welding Society (IWS), India Lead Zinc Development Association (ILZDA) along with co-operation from Indian

Institute of Welding (IIW), Indian Institute of Metals (IIM Delhi Chpater), Indian Society for Non-Destructive

Testing (ISNT Delhi Chapter) for organising Materials & WeldFab 2019 Conference. We are extremely grateful to

all the Dignities, Invited Guests, Academicians, Scientists, Researchers & participants for their active participation, co-

operation and support extended to us. We are thankful to all the sponsors/ Branding Partners for their participation

and co-operation not only financially but also technically. We hope that the conference is going to be technically

enrich and successful with all the supports and blessings from all.

Thanks a lot

Dr. Ashok Kumar Srivastava

Convenor & Chief of Technical Committee

Assistant Dean, Center for Reserach Excellence (CRE)

Professor & Head, Metallurgical & Materials Engineering

OP Jindal University, Chattisgarh

Ms. Jaya Ray

Chief of Organizing Committee

Managing Director, Matcorr, New Delhi

Materials’19 & WeldFab’19 || 01

Welcome Message

Session 4: Metallurgy of Weldingt 16.00 – 17.30 hours

Keynote Lecture: “3D Computed Tomography (CT) – Efficacy in Identifying Materials”-Dr. C. Muralidhar, Scientist – ‘G’, Director, DAINDE, Defence Research & Development Laboratory (DRDL)

“How Advances in Welding and Metallurgy has Helped the Industry to Improve Their Machine Availability”-Mr. Rajendren S, General Manager-Technical Services & Exports, Wearresist Technologies

“Flexible and Robust Plastic Welding for the Future, Today!”-Mr. Anubhav Gupta, Director, ARTEK - Bielomatik

“Producing Dual-Phase Microstructure in Friction Stir Welding/Processing of Medium Carbon low Alloy Steels”-Md. Anwar Ansari, Research Scholar, Dept. of Mechanical Engineering, Patna, IIT Patna

Networking Dinner 18.30-20.30 hours

Day 2: 26th April 2019

Morning Snacks & Tea 09.00 – 09.30 hours

Session 5: Advances in Welding Technology 09.30-11.00 hours

“Resistance Spot Welding of Aluminum 6061 Alloy for Gas Turbine Application”- Mr. A. Manjunath, Scientist-’F’, GTRE, DRDE

“Resistance Projection Welding”-Dr. Girish P. Kelkar, Consultant, Owner – WJM Technologies

“Resistance and Laser Welding for Micro Joining Applications”-Dr. Girish P. Kelkar, Consultant, Owner – WJM Technologies

“Coupled Thermo-Mechanical Modeling on Dissimilar Metal Plates of Friction Stir Welding Process with Polygon Tool Pin Geometry”-Mr. Rahul Kesharwani, Research Scholar, Dept. of ME, IIT Patna

Tea /Coffee Break 11.00 – 11.30 hours

Session 6: Corrosion Resistance Alloys & Welding 11.30-13.00 hours

Keynote Lecture: “Material Selection for Corrosion Protection”- Prof. A. S. Khanna, Chairman, SSPC

“Seamless FCWs for Welding of High Strength Steels”Mr. Ankit Jindal, Deputy Manager, Voestalpine Bohler Welding India Technology

“Investigation of Directional Anisotropy in Friction Stir welded/ processed Aluminum Alloys”-Ms. Sweta Saroj, Research Scholar, Md. Anwar Ansari, Dept. of Mechanical Engineering, Patna, IIT Patna

Panel Discussion: Industrial Application of Stainless Steel/Advanced Materials in the Industry & related Welding Technology

Lunch 13.00-14.00 hours

Session 7: Foundry & Fabrication Technology 14.00-15.30 hours

Keynote Lecture: “State of P91 Steel Fabrication in Indian Industries”-Mr. D. D. N. Verma, General Manager – Quality Management (Welding & NDT) , DEE Piping Systems

“Stresses in Sand Casting – Analysis and Optimized Solutions for Improved Casting Designs and Product Quality”- Mr. Muni Raj M, Manager – Ferrous Applications, MAGMA Engineering Asia Pacific

“Automatic Virtual Optimization of Ingot and Continuous Casting Processes”- Mr. Muni Raj M, Manager – Ferrous Applications, MAGMA Engineering Asia Pacific

“Achievement in New Technology Introduction for PU (Production Units) & Repair Units”-Mr. Ashish Kumar Apte, Segment Manager, Fronius India

Networking Tea /Coffee Break 15.30-16.00 hours

Session 8 Closing Remarks & Way Forward 16.00-17.00 hours

Open Question/ Answer Session & Way Forward

Note: Technical agenda is tentative and there might be last minute changes or due to any unavoidable situation.

Day 1 (25th April 2019)

Registration with Morning Snacks & Tea 09.00-09.30 hours

Session 1: Inauguration and Opening Ceremony 09.30-11.00 hours

09.30 - 11.00 Inauguration & Opening Ceremony• Lamp Lighting Ceremony • Welcome address by Chief Technical, Dr. Ashok K Srivastava, Director, Center for Steel Technology and Product

Development, Professor and Head, Dept. of Metallurgical and Materials Engineering, OP Jindal University, JSPL• Address by Inaugural Dignity, Mr. K. K. Pahuja, President, ISSDA• Address by Guest of Honor, Mr. Ashish Agrawal, Director, Jindal Stainless Steelway• Address by Guest of Honor, Dr. Mukesh Kumar, Director, SRTMI, Ministry of Steel, Govt. of India• Address by Chief Guest, Mr. Puneet Kansal, Joint Secretary, Ministry of Steel, Govt. Of India• Vote of Thanks by Mr. A. Mukherjee, Director, Matcorr• Opening of the Exhibition with Ribbon Cutting

Tea /Coffee Break 11.00 – 11.30 hours

Session 2: Steel, Advanced Materials- its developments & applications 11.30 – 13.00 hours

Keynote Lecture: “Introduction to Stainless Steel & Good Fabrication Practices”-Mr. Ashish Agrawal, Director, Jindal Stainless Steelway

“Advanced Materials”- Prof. A. S. Khanna, Chairman, SSPC

“To Study the Fracture Toughness (CTOD) of HSLA Steel Welded with Multi Wire Submerged Arc Welding”-Mr. Hitesh Kumar Desai, Associate Manager, Welspun, Dahej Facility

“Material &Welding Consideration for Stainless Steel Components”- Mr. Idris Peerzade, Associate Design Engineer III, Fluor

“Alternate Materials & Next Generation Technologies (Oil & Gas) for Environment friendly space & AIM”-Mr. R. N. Verma, Consultant, Ex-IOCL

Lunch 1300 – 1400 hours

Session 3: Advances in Welding & Fabrication Technology 14.00-15.30 hours

Keynote Lecture: “Creativity & Innovation in Selection of Material & Fabrication Process to Improve Productivity, Hygiene and Safety in the Industry” - Mr. Rajeev Gupta, General Manager- Marketing, Jindal Stainless

“Moving Along with Technological Innovations: Advancements in Welding Processes and Welding Equipment”-Mr. Ilhar Ul Hassan M S, Solution Engineer, Kemppi India

“Sub Merged Arc Welding on Critical Housing”-Mr. S. Shivashankar, Manager- Fabrication, Larsen & Toubro Rubber Processing Machinery

“Insight of Training needs for Personals for Certification for Welding Manufacturers”-Mr. Prashant Barodia, Partner, Techcellent Inspectorate

“Fabrication of Waveguide Run by Forming and Welding Technique Developed Innovatively for Space Use”-Mr. Rajan K. Mishra, Scientist/Engineer-‘SC’, SAC/ISRO

Tea /Coffee Break 15.30- 16.00 hours

Annual Conference & Exhibition on

“Steel, Industrial Materials & Non-Metallics”“Welding & Fabrication Technology”


Technical Agenda

Technical Agenda

02 || Materials’19 & WeldFab’19 Materials’19 & WeldFab’19 || 03

Participating Companies

Welcomes you to

Abstracts


www.materialssummit.co.in www.weldfab.co.inMaterials‘19 WeldFab’19

Date: 25-26 April 2019Venue: Hotel Crowne Plaza, Mayur Vihar, New Delhi

Media Partners

Participating Companies

Special Acknowledgement

Tea/Coffee Partner University PartnerExhibitors

Knowledge Partners


Title: “Advanced Materials”- Prof. A. S. Khanna, IIT Bombay (Retd.), Chairman SSPC India

Abstract:An advanced material is that which can perform one or more of the following functions without any failure:

•Microstructuralstability• GoodPhysicalProperties•HighMechanicalPropertiesIncludingcreepresistanceat

high Temperatures • Strong resistance tomaterial degradation at room and

high temperatures

The material classification starts from Metals & Alloys, Ceramics, Refractory Materials, Composites and Polymers. Many of these materials have either high strength or strong corrosion resistant but may be brittle or have poor ductile to brittle transition temperature. The most advanced metallic materials are those which possess high strength, have micro structural stability and are also strong corrosion resistance. Starting from steel, materials development occurs by addition of alloying elements which enhance strength as well as corrosion resistance. It also requires change of micro-structure which remains stable even at very high temperature. One set of such materials is known as super alloys which have sustained strength and excellent corrosion resistance. A systematic procedure how super alloys are developed and what makes them of super strength and strong corrosion resistance will be discussed.

Title: “To Study the Fracture Toughness (CTOD) of HSLA steel Welded with Multi-Wire Submerged Arc Welding”- Hiteshkumar Desai, T. S. Kathayat, Swatantra Joshi, Devendra Goyal, DhruvKumar Vavdiya, Surendar G., Welspun, Pipe Division, L-SAW Operation, Dahej, Gujarat, India.

Abstract:The Development and demand of high strength low alloy (HSLA) steel pipe for transmit oil and gas product into undersea service. Under Corrosive fluid flow, beyond extremely high external pressure and low temperature, the occurrence of defects on the pipe and weld ,which compromises the structural integrity of pipelines leading to catastrophic failures. For this reason the fracture toughness is most accomplishing in longitudinal SAW welded pipes.

This experiment attempt has been made to determine the effect of different welding consumables on fracture toughness (CTOD) on API 5L X 65 HSLA steel grade which were welded by multiple wire along with two run technique submerged arc welding(SAW). This investigation also includes Metallurgical and Mechanical behaviours of weld with respect to different welding consumables. Fractography (SEM & EDS) of CTOD specimen is been conducted to analyze the factors leading to degradation of fracture property. The obtained results indicate that the fracture properties of the weld influenced by the micro alloying elements.

Experimental plan has been made which is focusing to determine the welding wire & flux combination which influences to cause the desirable metallurgical changes in the weld metal and also how it enhances the fracture properties of welded line pipe. By Combined addition of micro alloying elements such as Titanium, Molybdenum and Boron in weld which instigate the formation of large volume of acicular ferrite which substantially improves the fracture toughness.

Title: “Material &Welding Consideration for Stainless Steel Components”- Idris Peerzade, Fluor Daniel, Gurgaon, India - Ameer Hamza, Mohammed Al Aseel, Sarah Zaki Al-Jishi, Fluor Arabia, Saudi Arabia

Abstract:Stainless Steel is a type of steel that withstands highly corrosive environment due to the presence of large content of Chromium. Theyare widely used in refinery, chemical, petrochemical, pharmaceutical, food and beverage industries due to their inherent nature and capability of combating corrosion with variety of services. Majority of stainless steel components are employed in high, moderate, low temperature, corrosive and purity service application. It is usually considered as a first choice in selection of material to mitigate the issue subject to corrosion and erosion wherever normal carbon steel material have shown significant failure or whenever certain service demands the application of additional requirements such corrosion allowance, PWHT, HIC, SOHIC, chemistry restriction, simulation, Hardness, NDE, WFMT and also where product purity needs to be maintained. Stainless Steel can be classified as Ferritic, Austenitic, Martens tic, Duplex and Precipitation Hardening (PH). The groups differ by its chemical composition which affects their mechanical properties. All the metals including stainless steel will undergo certain changes on the base material (BM) and heat affected zone (HAZ) during the process of welding. Stainless Steel material has been selected for optimum corrosion resistance. Hence to maintain these properties it is foremost and necessary to take extra measure for the material and the precaution during welding operation to minimize or prevent any effects that will lose the corrosion resistance properties and strength of this stainless steel material.

The improper application of welding and material requirements on stainless steel may result in serious challenges and issues during the operational and design life of these stainless steel components. This paper will address the most important factors that need to be taken in consideration on material and welding during the design and fabrication stage.

Title: “Moving Along with Technological Innovations: Advancements in Welding Processes and Welding Equipment”- Ilhar Ul Hassan M S, Solution Engineer, Kemppi India

Abstract:As the technology around us evolves and improves there is always a scope of advancement in every field. Welding being one of the major processes in the fabrication industry assimilate the scopes and innovates welding processes and equipment technologies. New processes and variants of the established processes are being developed and perfected to tackle the challenges from the industry. Welding equipment manufacturers are also developing and improving their equipment to boost its capabilities and deliver quality welding. Now the industry stands at a point where the welding systems are getting upgraded to embrace the wave of industry 4.0. A large share of welding practiced in the industry is still by arc welding processes. The timeline of arc welding equipment starting with the generator sets reached microprocessor-controlled inverter technology machines. The digitally controlled and programmable machines empower the development of application specific process variants and functions. Machines with multi-process capabilities are being manufactured. Pre programmed curves can be installed in current MIG/MAG welding machines to suit the material and the consumables to provide the best arc characteristics. Advanced controls are available even in SMAW machines for efficient starting and to avoid sticking of electrode to the work piece which will reflect in the productivity. The ability to precisely control the welding current wave form give raise to new welding process variants itself. Pulsed GMAW and GTAW are processes in which the current is switched between peak and base levels alternatively resulting in a lower heat input welding process. Multi wire welding processes are being used in the industry to increase the deposition rate and hence the productivity. Apart from the welding process variants geared and supported by the advancements in the welding equipment independent welding process variants have also emerged. ATIG, FBTIG are examples of such processes. Automation of the welding system brings in consistent quality along with productivity. In some processes automation becomes inevitable. With the integration of automation with a fully matured industry 4.0 will bring a new era in welding.

Title: “Merged Arc Welding on Critical Housing”- S. Shivasankar, Manger- Fabrication, L & T Rubber Processing Machinery

Abstract:L&T’s Rubber Processing Machinery manufactures and markets tyre curing presses and other equipments for the global tyre and rubber industry. The machines are produced at its facility in Kancheepuram, Tamil Nadu.

The state of the art Hydraulic Tyre Curing Press for truck tyres requires an Upper Housing having three piece constructions and subjected to tensile load of 600 tons. Three different materials namely forged steel flange of BS: 970 709M40,

rolled shell of E450 BR IS 2062(FE 570) and bolster of E250 IS 2062 are welded together. Being welding of dissimilar materials preheating to requied temperature is mandated. Root welding with SMAW process using E8018-B2 electrode was carried out followed by Flux Cored Arc Welding using E81T1-B2C wire plus 100% CO2 process was employed during the development of the prototype. The process was consuming more time for 1600mm shell and not producing 100% radiography acceptance level requiring huge reworks due to slag inclusions and minor cracks. Due to preheating environment, the operator fatigue also resulted in low productivity and inferior quality. In the mean while we have received a bulk order after successful field trials in the tyre industry for a similar tyre curing press.

Hence to improve the productivity and quality, we have planned to change the process to Sub Merged Arc Welding which can provide very high penetration, good quality welding and repeatability along with high productivity. To automate the process we have developed a special purpose machine with variable speed drive and multiple axis manipulators and a shell rotator. Laser beam was employed to track and ensure the weld bead.

The challenge was to establish the WPS, WPQR and QAP for achieving the consistence result along with high productivity. After conducting trials, the current, voltage and travel speed were established for various welding passes required to welding the J-groove welding between the shell and the flange.

Different parameters were arrived and charted for passes like narrow groove welding with lower current and voltage with higher travel speed over the root run, second and third passes with relative higher current and voltage at reduced speed to take care of the higher weld bead of the groove and ensure wall fusion. Next passes were done with the offset for double bead at a marginally reduced current and voltage. Finally cap welding with higher travel speed at a lower current and voltage was performed for multiple passes. Sufficient care was taken in cleaning the slag 100% during the passes.

The result was very encouraging with first time right radiography result and very high consistency on every work piece with four times higher productivity compared to FCAW process.

Abstracts Abstracts


Title: “Fabrication of Wave Guide Run by Forming and Welding Technique Developed Innovatively for Space Use Programme”- Rajan Kumar Mishra, Scientist / Engineer – SC, SAC/ISRO Jigish M Patel, Scientist / Engineer- G, SAC/ISRO

Abstract:Waveguide plumbing components are one of the most important and critical flight model (FM) hardware, are being used for propagation of Radio frequency (RF) waves, between two electronic packages. Basically, the waveguide is rolled semi-finished tubes of very thin walled (0.635 mm) having rectangular cross section in shape, made out of Al- alloy 6061- T6 material. In-house fabrication techniques are developed innovatively to form these above referred delicate straight tubes, into various complicated shapes called as Waveguide Runs, to be used in waveguide plumbing setup, to cater requirement of satellite panels. Primary requirement during fabrication of these waveguide runs is that, while forming it into various complicated shapes, the cross sectional dimensions and inside surface finish along the length of wave guide runs should change only up to defined stringent tolerance limits. Moreover, both the ends of the formed waveguide runs are to be joined with highly precise flanges through very sophisticated and Space Qualified Gas Tungsten Arc Welding (GTAW) to achieve leak proof permanent joints in Ultra high vacuum conditions. Since, the tubes are much thinned wall, internally having mirror finish and made with highly precise cross sectional dimensions, makes the whole fabrication process very challenging. However, through above briefed innovative space qualified fabrication technique developed In-house, a very significant progressive impact has achieved on aspects like; Assurance of quick delivery, enhancement of productivity, quick adaptability to the panel layout changes, high reliability and also substitution to the imports.

Title: “3D Computed Tomography (CT) – Efficacy in Identifying Materials” - Dr. C. Muralidhar, Scientist - ‘G’, Director, M. P. Subramanian and G. Chandrasekhar, DAINDE, Defence Research & Development Laboratory, Hyderabad

Abstract:Computed Tomography (CT) generates a thin cross-sectional (slice) image of an object, which represents point-by-point distribution of linear attenuation coefficients. CT images are free from interference of overlying and underlying areas of the object and are highly sensitive to small density differences (<1%) between structures. CT system with Linear Detector Array (LDA) generates cross-sectional images of the test object that can be stacked one over the other to create 3D volume of the object, where as Flat Panel Detector (FPD) can directly generate 3D volume from 2D X-ray projections (Digital Radiography). This 3D volume can be sliced in arbitrary planes to get the extent of internal features and measurements in 3 dimensions.

DRDL has developed 3D CT system using 450 kV X-ray source, 2D Flat Panel detector array, Mechanical manipulator and

cone beam reconstruction algorithm that can handle objects of 1000 mm diameter, 10 m height and 2000 kg weight for the first time in India. 3D CT provides 360 X-ray projections i.e., Digital Radiographs (DR), cross-sectional images and generate 3D model of an object. The resolution of the CT system is 300 µm. The time taken for generating the full 3D model of an object is about 45 minutes, can be cut at an angle to view the internal details, defects in 3 dimensions and obtain their dimensions including inaccessible areas.

In the present paper, we have employed 3D Computed Tomography (CT) with 2D FPD on a jet vane assembly, whose internal parts are made of metal, Composite and Poly Urethane Foam (PUF). The purpose of this paper is to reveal internal details, identify and differentiate various materials of Jet vane assembly and also to identify, locate the defects and their extent in 3 dimensions.

3D CT facilitates 100% inspection obtaining Digital Radiographs (DR) over 3600 unlike limited angle X-ray Radiography and 3D model of Jet Vane assembly can be visualized for revealing internal details with dimensions and extent of defects in 3 dimensions. A significant change in attenuation coefficients/gray scale values at various window levels of Tomograms noticed for a range of materials of Jet vane assembly. Further, the details obtained in 3D CT are phenomenal as compared to that of Digital Radiographs and conventional Radiography. The density profiles plotted on Tomograms showed sharp fall in pixel values for defects as compared to intact regions; where no such sharp fall seen. 3D CT provides qualitative and quantitative measurements on Jet vane assembly as compared to other Non Destructive Evaluation (NDE) methods and its salient features are highlighted.

Title: “How advances in welding and metallurgy has helped the industry to improve their machine availability”- Pankaj Jain, Director, Wearresist Technologies

Abstract:Regular and uninterrupted availability of plant for production particularly in core sector industry like Power, Cement, Steel, Mining, Sugar, Paper etc has become critical by every passing day due to enormous cost of putting up such plants and also to bring economy of scale. It is not uncommon that maintenance engineers are spending sleepless nights fighting with challenges of the weak links in the process particularly due to wear and tear of equipment particularly in INDIA where the raw material like coal, limestone, slag etc are of the hardest kind in the world.

This paper envisages to share example of such case studies in the industry where multiple fold life has helped the industry to be able to now dream big after this turnaround unlike in past where they were always fire fighting for their maintaining production targets and machines availability.All this was achieved through newer chemistry in welding or by using composite metallurgy.

Title: “Flexible and Robust Plastic Welding for the future, Today”- Anubhav Gupta, Director, ARTEK – Bielomatik

Abstract:With the introduction of new variants in plastic and demand for high quality, high speed production comes the need for innovative and customized solutions for plastic welding. Bielomatik provides a wide range of options from the standard Vibration, ultra-sonic and hot plate welding to the latest Laser, Infra-red and automated welding solutions. With 4 global manufacturing facilities and over 70 years of industry experience, Bielomatik has provided state of the art welding solutions to hundreds of customers across the globe.

With fast changing market trends and designs today’s manufacturing needs to be flexible to reduce change-over time and cost of even limited volume production.

Title: “Producing Dual-phase Microstructure in Friction Stir Welding/Processing of Medium Carbon low Alloy Steels”- Md. Anwar Ali Anshari, Murshid Imam, Department of Mechanical Engineering, IIT Patna

Abstract:Micro structural evolution in steels during friction stir welding (FSW)/friction stir processing (FSP) is a more complex process than that in aluminium alloys due to the occurrence of phase transformations. The dominant parameters of thermal cycle that affect the micro structural evolution are peak temperature and cooling rate. In the present work, critical control of the welding conditions produced a fine ferrite–marten site/bainite duplex structure with varying volume fractions of marten site/bainite and ferrite within the stir zone. The developed micro structure provides the preferable combination of tensile strength and ductility. The findings were achieved to clarify the effect of the welding parameters on the weld ability. Additionally, process window is constructed to show the correlation between the range of welding parameters and the optimum condition of dual phase microstructure distributions. It is shown that FSW/FSP can be an effective tool for the development of dual phase steels which can offer an outstanding combination of strength and draw ability as a result of their high combination of strength and ductility, as well as their high strain harden ability which gives them good strain redistribution capacity.

Title: “Resistance spot welding of Aluminium 6061 alloy for Gas Turbine application”- A. Manjunath, Scientist’F’, K. M. Ashique, Scientist’E’, K. Parthiban, Scientist’H Gas Turbine Research Establishment, Defence Research and Development Organisation

Abstract:Aluminium 6061 T6 is widely used in the aircraft industry. This alloy has a very good corrosion resistance and finishing ability. T6 is the temper designation, it is solution heat

treated and artificially aged. Aluminium and its alloys have high thermal and electrical conductivity compared with steel and, as the spot welding process depends on resistance (Joule) heating, they require much higher welding currents. In addition, the surface contact resistance plays a major part in heat generation. Short weld times are employed to generate the heat quickly and thus minimise the heat lost by conduction.

In order to conform to the requirements of specification for resistance welding for Aerospace applications AWS D17.2/D17.2M:2007 various tests are conducted. It is to determine if a particular machine, in combination with a specific weld procedure, will on a given set of material produce resistance welds meeting the standard.

Inlet nose a component made out of 1.2mm thick Al 6061 material called for 4 + 16 number of spot welds of 4mm spot diameter. In order to spot weld the job and meet the required aerospace weld quality standards the following were investigated:

• ResistanceSpotweldingmachine• Electrodematerial,designanddressing• Cleaning/preparationofsamples• Spotweldingparameters• Peelofftest• Non-destructive testing (Visual, Radiography and Dye

Penetrant Inspection)• Failureloadsin6061-T6aluminiumresistancespotwelded

joints were investigated. • Nugget size and microstructure characteristics were

quantified• Surfaceindentation

Title: “Resistance Projection Welding”- Dr. Girish P. Kelkar, Owner – WJM Technologies, Member – American Welding Society

Abstract:Resistance projection welding, a type of resistance welding process, offers many benefits by utilizing a projection geometry that ensures that the welding current and heat is focused at a specific location. During the welding process, the projection collapses and the weld contact area grows to required size, and typically produces a solid-state bond. Benefits of projection including localization of the weld, extended electrode life, improved heat balance, and the ability to produce multiple weld spots with a single electrode. Presence of projection also allows a lower melting plating to be squeezed out from the weld and results in cleaner weld metallurgy at the bond line. Projection welding does provide challenges with extra step to make a projection, special heads with good follow-up, and power supplies that can provide a rapid rate of energy delivery. Process development also can prove to be challenging since weld heat control is important in order to avoid melting and expulsion of the weld in form of weld flash. Projection designs can include single dome shaped projections for spot welding, linear rail projections, or annular projection to form a continuous hermetic

Abstracts Abstracts


weld. Rapid heating and cooling of the weld can result in excessive brittleness in the weld when welding carbon steel components. A secondary welding pulse can be employed to reduce weld hardness with a process of tempering. Both the welding and tempering pulses are fired in succession and the resulting weld can be strong yet not so brittle. Projection welding has found extensive use in wide variety of applications and industries including welding engine fuel rails, pressure sensors, air bag assemblies, and structural flanges.

Title: “Resistance and Laser Welding for Micro Joining Applications”- Dr. Girish P. Kelkar, Owner – WJM Technologies, Member – American Welding Society

Abstract:Resistance welding and laser welding are two commonly used welding processes to produce microscopic welds. Often these welds are made literally under a microscope as the parts are extremely small, usually less than a 0.5 mm, and require careful handling and positioning prior to welding. Such welds are quite common in the medical device industry making implantable for heart, spine, and vision applications. With rapid miniaturization of motors, sensors, batteries, and microchips, an increasing number of micro joining applications are coming to fore. Resistance and laser welding are unique processes that are able to make very focused welds in small components without causing any collateral damage to nearby components. While the two processes have similarities, they are also quite different. While laser welding is primarily a fusion welding process, resistance welding is more versatile and can produce all types of bonds including fusion, solid-state and solder/braze. One of the advantages of resistance welding is the electrodes push down on the parts being welded and able to hold the tiny parts in place. Resistance welding also offers direct feedback from the process that helps to gauge weld quality. In contrast, laser welding is a non-contact process that can be targeted into hard to reach locations and for parts not suitable for contact welding. Both processes are able to effectively deal with welding dissimilar materials, which is the norm in micro joining applications. This paper reviews the applications and capabilities of the two processes as they pertain to micro joining applications with real world examples.

Title: “Coupled Thermo-Mechanical Modelling on Dissimilar Metal Plates of Friction Stir Welding Process with Polygon Tool Pin Geometry”- Rahul Kesharwani, Chiranjit Sarkar, Murshid Imam, Dept. of ME, IIT Patna

Abstract:Friction stir welding (FSW) is a solid-state welding technique, it is the modified form of conventional friction welding, initially it was used for soft aluminium alloy and thin plates, but now it’s a huge application in the aerospace, automobile and thick plate welding etc. In the FSW process, the heat generation was the major impact on the tool failure and this

heat generation is purely depending on the contact area during welding. The probe of the FSW process experiences high temperature and it was the weakest component of the FSW tool. The tool geometry plays an important role in deciding the tool life criteria because of maximum temperature changes by changing the tool shape. In this work, the two dissimilar metals of aluminium and copper plate were selected with different polygon tool pin geometry such as a hexagon, triangle, pentagon, square and cylindrical to understanding the temperature and fluid flow behaviour during friction stir welding. From the computational results, the temperature, velocity, strain rate and dynamic viscosity values are found by coupled Heat transfer and material flow physics when two dissimilar welding was performed. Here we are discussed that the effect of temperature on the tool and work-piece of friction stir welding process when tool geometry changes with the help of simulation modelling. The coupled thermo-mechanical modelling was performed with the use of a Consol Multi physics software package. Welding was done on dissimilar metal plates of aluminium alloy AA-6061 and pure copper and the tool was made of H-13 steel. The probe was in tapered shape where outer radius for the top and bottom position of the probe was same for all the probe design. In this case, the triangular tool pin shows the highest temperature (816K) among all the tool pin geometry and cylindrical probe shows the lowest temperature (629K), the welding parameter and boundary conditions were same for all the cases.

Title: “Selection of Materials for Corrosion Resistance”- Prof. A. S. Khanna, IIT Bombay (Retd.), Chairman SSPC India

Abstract:Corrosion is the degradation of materials, leading to its metal loss, thereby loosing its load bearing capability, leading to catastrophic failure. Annual losses due to corrosion in India is estimated around Rs. 75000 to one lakh crore, which covers various sectors ranging from oil and gas, refineries, corrosion in transportation industry ranging from automobile, railways to ships and aircrafts, structures – bridge flyover, multi-storey buildings and real estate. Further corrosion takes place in various forms, uniform or localized, intergranular or transgranular, during welding or joining, due to stress or impact or due to micro-organisms. Further it must be understood that corrosion cannot be totally eliminated, it can only be minimized. Hence the whole game is how to minimize corrosion. Though, there are four methods to minimize corrosion:

•Selectionofbettermaterials•UseofCoatings•UseofanodicorcathodicProtection•Useofinhibitorswhichreducecorrosion

However, the crux of minimizing corrosion is by proper material selection. Material selection does not mean we select only costly materials that stainless in place of steel but it simply means proper chemical composition which can resist corrosion for a selected application. The paper will describe how several steels are modified to suit a particular

application, for example heat exchanger or underground pipelines, what is most corrosion resistant stainless and what is most corrosion resistant alloy.

Title: “Investigation of Directional Anisotropy in Friction Stir Welded/Processed Aluminium Alloys”- Sweta Saroj, Murshid Imam, Dept. of ME, IIT PATNA

Abstract:Friction stir welding (FSW)/friction stir processing (FSP) would results a beneficial effect on the properties due to physical interaction between the tool and work piece material. The developed microstructure is a strong function of both the temperature and strain rate. The local values of the relative velocities of the plasticized material within the shear layers are expected to vary significantly when a non-symmetric tool probe profile is used. Therefore, the main goal of the present work is to investigate the directional anisotropy within the stir zone (SZ) region. It is believed that in addition to grain structure, a crystallographic texture also plays an important role in causing anisotropic behaviour of SZ. The miniature tensile samples were tested along welding direction and transverse direction within the SZ (stir zone) region. Interestingly, it is observed that despite the micro structural refinement in SZ (stir zone), the SZ also exhibit directional anisotropy. Additionally, micro structural studies performed on these tensile samples revealed that crystallographic textures, precipitates morphology, and the thermally stable fragmented second phase particles are the main reason for this anisotropic behaviour. The present findings will help in selecting the appropriate stretching/loading directions of the processed/welded samples for forming applications.

Title: “State of P91 Steel Fabrication in Indian Industries”- D. D. N. Verma, General Manager – Quality Management (Welding & NDT), DEE Piping systems

Abstract:Steam-temperature & pressure exiting S/H of a high capacity boiler is ~ 570 °C - 600 °C & 170 - 230 bar respectively. The final S/H & Pipes carrying steam to turbine must withstand this extreme temperature & pressure. This necessitates the material constituting these tubes & pipes must possess very high strength properties & must be creep-resistant. P91, presently is one such heat & creep resistant material in power-industries.

PAYBACKS OF P91Equated to its predecessor, the grade P22, ‘Modified P91’ exhibits high strength up to ~ 600 °C in the range. It’s oxidation resistance confines are higher & authorizes plant designers to plan components like S/H coils, Headers and Steam Pipes with lesser thickness contributing a higher thermal fatigue life of ~ ten times. In addition to imparting enhanced operating parameters, it suits plants that operate on a cyclic basis like a combined cycle plants.

WHAT MAKES P91 ATYPICAL?A Cr content of 9% and Mo at 1% compared to 2.5 %Cr in the next best P22 enhances elevated temp. Strength of P91

and increases its oxidation resistance. Mo imparts creep-resistance. Ni & Mn, though present in small quantities contribute to its harden ability.

Micro structural-formations are more imperative than alloying elements in P91 steel. The steel is fashioned by normalizing at 1050 °C & air cooling down to ~ 100-200 °C. Its then is tempered by heating to 760 °C. The temperatures and cooling rates are critical to obtain the requisite microstructure & creep strength. Steel is absolutely intolerant to variations in its microstructure, unlike P22 or other grades. All heat treatment requirements must, therefore, be precisely followed to achieve the micro structural constituents & features.

Any working on the steel would necessitate a precise heat treatment in order to reinstate the lost microstructure back to its original conditions. Else, the steel may have properties much lower than its predecessor P22. Conclusively, in P22 and other low alloy steels, the effect of variations in heat treatment is not as violent as in P91.

JOINING P91Welding affects microstructure. Preheating, Inter-pass, and PWHTs are very critical for P91. Failure to follow the procedures will result in catastrophic failures. Thick walled pipes need use of an induction heating system. This gives better control, and uniform heating between the inner and outer diameters. In induction heating the coils themselves do not heat up. This is ideal for maintaining the inter-pass temperatures and carry out the welding. It’s worker-friendly & is ideal for complex shapes likes weld lets, Tees etc.The Nickel and Manganese content, even though in smaller percentages, have profound effects on the critical temperatures & all heat treatments. Because of this, the composition of the welding electrodes used should be in line with the parent material.

P91 weld has great affinity to Hydrogen leading to hydrogen induced cracking. PWHT must be executed as quickly as possible to avoid any contact with water. All joints must be post-weld heat treated prior to hydro test. Finally, since in spite of all challenges & confronts, the industry embraces P91, the use of this steel continues & will continue to continue its successful journey.This paper presents various aspects of P91 metallurgy & fabrication in Indian industries including the design of the steel, welding, Heat Treatment, effects of Delta ferrite, microstructure on the shop – floor, Type IV Cracking in the HAZ etc. etc..

Abstracts Abstracts


Title: “Stresses in Sand Casting – Analysis and Optimized Solutions forImproved Casting Designs and Product Quality”- Dr. Jesper Thorborg, Jörg Zimmermann und Dr. Corinna Thomser, MAGMA GmbH, Aachen

Abstract:Sand casting of metal parts is one of the most flexible manufacturing processes for differently Shaped and sized castings. The process is applicable for a wide range of alloys and the obtained material quality and dimensional tolerances can be controlled by modifying either the design of the part or the casting layout. The flexibility in design provided by the shaping sand material and the internal sand cores often leads to a complex cooling history, which highly affects the evolution of properties and defects. Many defects in the final part like e. g. cold cracks and hot tears are related to the stresses that build up during cooling. This article presents how MAGMASOFT® is used to analyze and optimize both the casting design and the casting process by combining the thermal analysis of the casting process with an integrated prediction of stress and distortion. It is shown how the thermal gradients, cooling time and constraints from the mold and core materials affect the risk of stress related defects and unwanted distortion. Methodological application on industrial examples show the significant advantages of being able to systematically analyze different designs and casting lay outs up front, to avoid quality problems in production and fulfil dimensional tolerance requirements.

Title: “Automatic Virtual Optimization of Ingot and Continuous Casting Processes”- I. Hahn, E. Hepp, M. Schneider, MAGMA Gießereitechnologie GmbH

Abstract:Simulation technology today makes it easily possible to carry out three-dimensional simulations of the teeming and solidification of ingots as well as of the flow and solidification in continuous casting processes. Quick and reliable virtual casting trials in the computer can be performed considering all relevant process parameters. During casting, numerous complex physical phenomena occur simultaneously that are

coupled with each other. Changes of one process parameter usually lead to a change of many quality-relevant properties of the product. A coupling of casting process simulation with statistical design of experiments allows the virtual exploration and evaluation of the effects of process changes on all relevant quality characteristics. Automatic virtual optimization, which is focused on the fulfilment of several targets at the same time, provides promising approach for defining robust casting processes and finding operating points that build a best compromise between competing objectives. This paper will show examples of the application of these methodologies for continuous and ingot casting processes and gives an insight into how process development benefits from them.

Title: “Achievement in New Technology Introduction for PU (Production Units) & Repair Units”- Ashish Apte, Segment Manager, Fronius India

Abstract:Fronius India with support from Fronius International GmbH introduced the concept of CMT (COLD METAL TRANSFER) in Indian Railways production & repair units for Rolling Stock.CMT Process with the Cold Metal Transfer (CMT) technology, Fronius has revolutionized the welding market. The technology, first unveiled in 2004, ushered in a new era that continues to this day.

This distinctive system has managed to position itself over time as a brand. Of course, not only high-quality welds were decisive for this development.

The Cold Metal Transfer stands for much more than just minimal welding spatters, a more stable “cold” process and high welding speeds. It is also the physical embodiment of the impossible made possible: the joining of steel and Aluminum to a high standard.

The focus of this process, the typical CMT application areas, is extremely varied.

With this technology, Fronius has not only succeeded in creating a unique selling point, but has also built upon its position as the technology leader.

Abstracts

12 || Materials’19 & WeldFab’19

a


Annual Conference & Exhibition on



Glimpses

Anual Conference and Exhibition on

4-5 June 2020, New Delhi

2020

In

“Steel, Industrial Materials & Non-Metallics”

&“Welding &

Fabrication Technology”

WeldFab’20Materials’20

Ansal Chambers, Bhikaji Cama Place, N. Delhi- 110066, IndiaMobile No.: +91 96673 17805; Phone No(O): 011-46545757Email: [email protected]; [email protected]: www.materialssummit.co.in, www.weldfab.co.in

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date: 25-26 april 2019 venue: hotel crowne plaza, mayur ......- idris peerzade, fluor daniel,...

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