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ERADICATION OF CORROSION AND

IMPREGNATION OF OXIDE ON METAL COMPONENT

IN STEAM TREATMENT PROCESS

A PROJECT REPORT

Submitted by

SHARAN.R(21110114099)

THIRUMALESH.G(21110114320)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

RAJALAKSHMI ENGINEERING COLLEGE, THANDALAM, CHENNAI

ANNA UNIVERSITY: CHENNAI 600 025

MARCH 2014

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ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report ERADICATION OF CORROSION

AND IMPREGNATION OF OXIDE ON METAL COMPONENT IN STEAM

TREATMENT PROCESS is the bonafide work of THIRUMALESH G who

carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr.S.P.Srinivasan Mr.N.VINOTH BABU

HEAD OF THE DEPARTMENT SUPERVISOR

Associate professor

Mechanical engineering Mechanical engineering

Rajalakshmi engineering college, Rajalakshmi engineering college,

Chennai. Chennai.

This project report is submitted for viva voce examination to be held on

INTERNAL EXAMINER EXTERNAL EXAMINER

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ACKNOWLEDGEMENT

I thank God Almighty for enabling me to complete my project. My sincere

thanks to the Chairman, Mr.S.Meganathan for his sincere endeavor in educating

me in his premier institution.

I like to express my deep gratitude to beloved Chairperson Dr. & Mrs.

Thangam Meganathan for her enthusiastic motivation in completing this project.

I thank our Principal Dr. G.Thanigaiarasu, for his kind support and the facilities

provided to carry out my work.

I am extremely grateful to Dr. S.N.Murugesan, Vice Principal,

Rajalakshmi Engineering College, Dr.P.S.Mani, Dean, Department of

Mechanical Engineering, Rajalakshmi Engineering College,and Dr.

S.P.Srinivasan, Head of the Department, Department of Mechanical Engineering,

Rajalakshmi Engineering College, for their approval and encouragement for

the project work.

I express my sincere thanks to my project supervisor, Dr. N.Vinoth

babu, Associate Professor, Department of Mechanical Engineering,

Rajalakshmi Engineering College, for his valuable guidance.

I express my truthful thanks to my industrial project supervisor, Mr.

R.Ravichandra, Assistant General Manager, TVS Sundaram Fasteners Ltd.,

Powder metallurgy plant, Aviyur, Madurai , for his valuable guidance.

Last, but not the least, I wish to express my thanks to staff members,

parents, friends, classmates and others, who helped me either directly or

indirectly, for the successful completion of the project work.

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ABSTRACT

The main objective of our project is to reduce the corrosion in the steam

treatment process and to reduce the time of cleaning after the process in the

powder metallurgy plant. In this plant we did the project on ERADICATION OF

CORROSION AND IMPREGNATION OF OXIDE ON METAL

COMPONENT IN STEAM TREATMENT PROCESS. Basically, steam

treatment process is used to improve tribological and mechanical properties of

ferrous compacted products in powder metallurgy approach.

In our project, we have selected the product SPROCKET SUPPORT

LEVER and have analyzed the causes for the corrosion and have tried to reduce

the causes by one experimenting we done and hence arrived of method to reduce

corrosion. We calculated the drying time of the product, and then the dryness

fraction of the steam at the entrance of the furnace. We have also observed the

whole process and made the changes of the process values which was implemented

so as to reduce the corrosion and also the time for cleaning the corroded products.

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TABLE OF CONTENTS

Chapter No Title Page no

Abstract vi

List of Figures

xi

List of Abbreviations xiii

List of Table xiv

I INTRODUCTION 1

1.1 Objective 1

1.2 Powder metallurgy 1

1.2.1 General steps in p/m process 1

1.2.2 Metal powder 2

1.2.2.1 Particle shape 2

1.2.2.2 Fineness 3

1.2.2.3 Particle size distribution 3

1.2.2.4 Flow rate 3

1.2.2.5 Chemical properties 3

1.2.2.6 Compressibility 3

1.2.2.7 Apparent density 4

1.2.2.8 Sintering ability 4

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II

LITERATURE REVIEW

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2.1 Compacting 5

2.2 Sintering 6

2.3 Drying 8

2.4 Barreling 10

2.5 Steam treatment 12

2.6 Inspection 15

2.7 Powder metal advantage 15

III COMPANY PROFILE 16

3.1 TVS Sundaram Fastener Ltd 16

3.2 High tensile fasteners 17

3.2.1 Operational excellence 17

3.3 Powder metal parts 18

3.3.1 Operational excellence 18

3.4 Awards 19

3.4.1 Customer 19

3.4.2 Government 20

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IV PROBLEM IDENTIFICATION 21

4.1 Corrosion 21

4.1.1 Types of corrosion 21

4.1.1.1 Dry corrosion 22

4.1.1.2 Wet corrosion 22

4.2 Causes and effect diagram 23

4.3 Brain storming of ideas 24

V CALCULATIONS 25

5.1 Percentage of corroded components(before) 25

5.2 Cleaning time(before) 25

5.3 Dryness fraction 26

5.4 After experimentation(expected value) 31

5.5 Cleaning time calculation 31

5.6 Design changes 32

VI RESULTS 36

6.1 Percentage of corroded components 36

6.1.1 844 Sprocket rocket lever 36

6.1.2 924 Piston 38

6.1.3 966 Connecting rod 40

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6.1.4 658 Valve plate 42

6.2 Result chart 44

VII PHOTOGRAPHS 46

VIII CONCLUSION 46

BIBILOGRAPHY 47

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LIST OF FIGURES

Fig No Description Page No

1.1 Morphology Of Powder Particles 2

2.1 Compacting 5

2.2 Powder Conversion 6

2.3 Sintering Machine 7

2.4 Sintered Component 8

2.5 Drying Machine 9

2.6 Drying Output 9

2.7 Barreling 11

2.8 Barreling Stone 11

2.9 Ferrous Steam Treated Components 12

2.10 Steam Reaction 13

2.11 Steam Treatment Setup 14

2.12 Inspected component 15

4.1 Fish Bone Diagram 23

5.1 Decks 32

5.2 Existing design of layer 33

5.3 Separating layer 34

5.4 Loading Setup 35

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6.1 Bar graph Of Corroded Component 44

6.2 Bar graph of Cleaning Time 45

7.1 Entire Working Setup Of Steam Treatment Process 46

7.2 Barreling 46

7.3 Drying Machine 47

7.4 Drying Output 47

7.5 Final Arrangement Of Component 48

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LIST OF ABBREVIATIONS P Pressure in bar

T Temperature in C

Ts saturation temperature in C

hsup enthalpy of superheated steam in kj/kg

hf enthalpy of water in kj/kg

hfg enthalpy of evaporation in kj/kg

hg enthalpy of dry steam in kj/kg

x dryness fraction

Cps Specific heat of superheated steam in kj/kg.k.

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LIST OF TABLE

Table No Description Page No

5.1 Comparison table 35