arci hyderabad facilities
TRANSCRIPT
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The Centre for Laser Processing of Materials (CLPM) works towards development and
promotion of application of laser-based solutions in the Indian industry through:
Application oriented R&D towards demonstrating feasibility of laser processingroute for specific industrial applications;
Research towards better scientific understanding of various processes; Job works of specialized nature; and Consultancy...
Research Areas
Laser Welding Laser Surface Treatment
o Laser hardeningo Laser cladding/alloying
Laser Drilling Laser Cutting
Facilities
6 kW Diode Laser 3.5 kW CO2 Slab laser 400 W Avg Pulsed Nd:YAG Laser 9 kW CO2 Transverse Flow Laser
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As far as the field of surface modification technologies are concerned, India has matured
significantly in recent years. The conspicuous upward trend in the adoption of surface
modification technologies by the Indian industry has also been catalysed by several initiatives
taken by the Government of Indias Department of Science & Technology (DST). ARCI
scientists have played a prominent role in piloting these initiatives and the organization has
consistently tried to identify coating technologies of national relevance and consciouslypursue those that are unavailable elsewhere in the country.
Over the years, ARCI has successfully projected itself as a leader in the field of surfacemodification. ARCI's Centre for Engineered Coatings has been engaged in developing a wide
spectrum of appropriate surfacing technologies to assist the Indian industry in meeting the
challenge of enhancing the durability and performance of components operating in adverse
environments. The efforts of the Centre for Engineered Coatings have focused on eventuallytransferring relevant technologies to private entrepreneurs in a cost-effective manner.
Several coating technologies are being simultaneously pursued by the Centre for Engineered
Coatings in an effort to offer a range of quality and cost to the potential user industries. Some
of these have matured and already successfully transferred to the industry while yet other
exciting technologies are presently on the anvil.
Major Coating Technologies Established at CEC
Detonation Spray Coating
Cold Spray Coating
Micro Arc Oxidation
Electro Spark Coating
Electron Beam Physical Vapour
Deposition
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Diamond Like Carbon Coating Solution Precursor Plasma Spray
Coatings
Pulsed Electro-Deposition coatings
Research Areas
Detonation Spray Coating Technology
D. Srinivasa Rao, G. Siva Kumar, D. Sen
DSC is a unique variant in the family of versatile thermal spraying which contributes
reputation among the exhaust surface modification technologies. The development of
Detonation spray coating technology at ARCI is aimed to transfer the total technology, along
with equipment and know-how of the coating process to the Indian entrepreneurs and also to
the other countries.
Process: A method of coating, where an explosive high temperature flux of gas mixtures is
used as a source for heating, accelerating and spraying the particles
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Salient Features
Excellent Adhesion Low Oxide Content
< 1% Porosity Good Tribological Properties
High Microhardness High Coating Thickness
Low Thermal Degradation Good Powder Efficiency
Advantages
Low Substrate Temperature Less Electrical Consumption
Low Cost of Operation Less Down Time
Less Gas Consumption Less Work Scrap
Less Water Consumption
Process Capabilities
Thickness Buildup: 5-25 m/shot Particle Velocity: 500 to 1000 m/s
Coating ThicknessParticle Temperature: up to
4000oC
Carbides/Cermets: 20-500 m Deposition Efficiency: 30 to 60%
Ceramics: 50-1,000 m Porosity: 0.1 to 1.0%
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Metals & Alloys: up to few mm Bond strength: >75 MPa
Coating Coverage: 0.5 to 1.0
m2/hr
Coating hardness: WC-Co-1,300
HvCr3 C2-NiCr-1,000 Hv
Type of Powders Sprayed
Metals, Oxides & Cermets, Carbides and Alloys
Substrate Materials
Metals, Alloys, Superalloys, Dielectric substrates, Plastics, Glass and
Ceramics (Any substrate having hardness < 65 HRC can be coated by DSC)
Examples of Powders Sprayed
Al2O3, Al2O3-TiO2, Cr3C2-NiCr, WC-Co, WC-Co-Cr, WC-17Co-8FEP, WC-10.5Co, WC-
10.5Ni, Ni-20Cr, CoCrAlY & NiCrAlY, SS316-Martensitic, Austenitic, Cr2O3, Aluminumbronze, NiCr-5Al, Stellite-6, Cr2O3-20 Al2O3, Ti(C,N)-38%(Ni, Co), Ti(C,N)- 38%(Ni, Co,
Mo), Fly ash, AlN (from SHS), Fe-Al (with Al2O3, Cr2O3), Cr3C2-NiCr- TiB2, Fe-SiC,
Al65Fe20Cu15, Fe, Ni, Cu and many pure metals.
DSC vs APS
Higher bond strength (> 10000
psi)
Controlled residual compressive
stress
Denser microstructure (< 1%
porosity)
Very thick coatings can be
produced without delamination
Reduced thermal degradationVery high melting point materials
like Zirconia can not be sprayed
Smoother as-coated surface finish (1-4m Ra)
DSC vs HVOF
Coating properties nearly similar HVOF has higher productivity
HVOF CANNOT SPRAY OXIDESDSC operating costs are much
lower
DSC fully indigenous spares/servicing issues much simpler
Latest News - Centre for Laser Processing of Materials
Optimization of laser welding process on Ti-6Al-4V sheets to obtain defect free joints withrequired mechanical strength
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Establishment of a new laser processing system based on a 6-kW Fiber-Coupled Diode Laserintegrated with a 6-axis robot and turn-tilt table
Laser hardening of crankshafts for reciprocating compressor Laser welding of tailor-welded blanks (TWB) in three steel combinations for formability
testing
Facilities
1) Coating techniques
Detonation Spray Coating Micro Arc Oxidation
Cold Spray Coating Diamond Like Carbon Coating
Electro Spark CoatingElectron Beam Physical Vapour
Deposition
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Solution Precursor Plasma Spray
CoatingPulsed Electrodeposition
2) Heat treatment
Thermal Cycling Furnace
3) Characterization Facilities
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PerthometerRotating Beam Fatigue Testing
Machine
Erosion Wear Tribometer Dry Sand Abrasion Wear Tribometer
Sliding Wear Tribometer
People
Name - D. Srinivasa Rao
Designation - Scientist-E & Team Leader
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Qualification - MS (Mechanical Engineering)
Areas of expertise - Surface Engineering, Industrial Applications of Coatings,
Implementation of coating technologies for production
eMail [email protected]
Name - N. Ravi
Designation - Scientist-D
Qualification - MTech (Industrial Metallurgy)
Areas of expertise - Diamond like Carbon Coatings and Material Characterization
eMail [email protected]
Name - L. Rama Krishna
Designation - Scientist-D
Qualification - MTech (Materials &Metallurgical Engineering)
Areas of expertise - Micro Arc Oxidization Coatings and Tribological Performance
Evaluation
eMail [email protected]
Name - G. Sivakumar
http://www.arci.res.in/query.aspx?employeeCode=69http://www.arci.res.in/query.aspx?employeeCode=69http://www.arci.res.in/query.aspx?employeeCode=69http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=127http://www.arci.res.in/query.aspx?employeeCode=51http://www.arci.res.in/query.aspx?employeeCode=69 -
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Designation - Technical Of cer-C
Qualification - Diploma in Mechanical Engineering
Areas of expertise - Detonation Spray Coating and Electron Beam Physical Vapour
Deposition
eMail [email protected]
Advisors/Consultants
D Srinivasa Rao
Scientist-E & Team Leader
MS (Mechanical Engineering)
Areas of Expertise: Surface Engineering, Industrial
Applications of Coatings, Implementation of coating
technologies for production
eMail:[email protected]
N Ravi
Scientist-D
MTech (Industrial Metallurgy)
Areas of Expertise: Diamond like Carbon Coatings and
Material Characterization
eMail:[email protected]
L Rama Krishna
Scientist-D
MTech (material & Metallurgical Engineering)
Areas of Expertise: Micro Arc Oxidization Coatings and
Tribological Performance Evaluation
eMail:[email protected]@arci.res.in
G Sivakumar
Scientist-C
BTech (Mechanical Engineering)
Areas of Expertise: Detonation Spray and Solution Plasma
Spray Coatings
eMail:[email protected]
Dr R Kavitha
Scientist-C
PhD (Solution Precursor Coatings)
Areas of Expertise: Solution Precursor Based Coatings
eMail:[email protected]@arci.res.in
http://www.arci.res.in/query.aspx?employeeCode=9http://www.arci.res.in/query.aspx?employeeCode=9http://www.arci.res.in/query.aspx?employeeCode=9mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.arci.res.in/query.aspx?employeeCode=9 -
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Nitin P Wasekar
Scientist-B
ME (Metallurgical Engineering)
Areas of Expertise: Pulsed Electrode Deposition and Micro Arc
Oxidization Coatings
eMail:[email protected]
P Sudharashan Phani
Scientist-B
BTech (Mechanical Engineering)
Areas of Expertise: Cold Spray Coatings and Modeling Studies
eMail:[email protected]@arci.res.in
Naveen Manhar Chavan
Scientist-B
BTech (Metallurgy)
Areas of Expertise: Pulsed Electrodeposition
email:[email protected]
D Sen
Technical Officer-C
Diploma in Mechanical Engineering
Areas of Expertise: Detonation Spray Coating and Electron
Beam Physical Vapour Deposition
eMail:[email protected]
Solution precursor plasma sprayFrom Wikipedia, the free encyclopedia
Jump to:navigation,search
Solution Precursor Plasma Spray (SPPS) is athermal sprayprocess where a feedstock
solution is heated and then deposited onto a substrate. Basic properties of the process arefundamentally similar to other plasma spraying processes. However, instead of injecting a
powder into the plasma plume, a liquid precursor is used. The benefits of utilizing the SPPS
process include: the ability to create unique nanometer sized microstructures without the
injection feed problems normally associated with powder systems and flexible, rapid
exploration of novel precursor compositions.[1][2]
Contents
1 Background
2 The process 3 Thermal Barrier Coatings
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Backgroundhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Backgroundhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#The_processhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#The_processhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Thermal_Barrier_Coatingshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Thermal_Barrier_Coatingshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Thermal_Barrier_Coatingshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#The_processhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Backgroundhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-0http://en.wikipedia.org/wiki/Thermal_sprayhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#p-searchhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#mw-headmailto:[email protected]:[email protected]:[email protected]:[email protected] -
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Background
The use of a solution precursor was first reported as a coating technology by Karthikeyan, et
al.
[3][4][5]
In that work, Karthikeyan showed that the use of a solution precursor was in factfeasible, however, well adhered coatings could not be generated. Further work was reported
in 2001 which refined the process to producethermal barrier coatings,[6]
YAGfilms,[7]
and
silicon ceramic coatings.[8]
Since then, extensive research on the technology has been
explored in large part by theUniversity of ConnecticutandInframat Corporation.
The process
The precursor solution is formulated by dissolving salts (commonly zirconium and yttrium
when used to formulate thermal barrier coatings) in a solvent. Once dissolved, the solution is
then injected via a pressurized feed system. As with other thermal spray processes, feedstock
material is melted and then deposited onto a substrate. Typically, the SPPS process sees
material injected into aplasmaplume orHigh Velocity Oxygen Fuel(HVOF) combustion
flame. Once the solution is injected, the droplets go through several chemical and physical
changes[9]
and can arrive at the substrate in a several different states, from fully melted to
unpyrolized. The deposition state can be manipulated through spray parameters and can be
used to significantly control coating properties, such as density and strength.[2][10]
Thermal Barrier Coatings
Most current research on SPPS has examined is application to create thermal barrier coatings
(TBCs). These complexceramic/metallicmaterial systems are used to protect components inhot sections of gas turbine and diesel engines.
[11]The SPPS process lends itself particularly
well to the creation of these TBCs. Studies report the generation of coatings demonstrating
superior durability and mechanical properties.[12][13][14]
Superior durability is imparted by the
creation of controlled through thickness vertical cracks. These cracks only slightly increase
coating conductivity while allowing forstrainrelief ofstressgenerated by theCTEmismatch
between the coating and the substrate during cyclic heating. The generation of these through
thickness cracks was systematically explored and found to be caused by the depositing a
controlled portion of unpyrolized material in the coating.[15]
Superior mechanical properties
such as bond strength and in-plane toughness result from the nanometer sized microstructure
that are created by the SPPS process.
Other studies have shown that engineered coatings can reducethermal conductivityto some
of the lowest reported values for TBCs.[16][17]
These low thermal conductivities were achieved
through the generation of an alternating high-porosity, low-porosity microstructure or the
synthesis of a low conductivity precursor composition withrare earthdopants.
Research Areas
Back
LASER SURFACE HARDENING
4 Costs 5 References
http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-4http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-4http://en.wikipedia.org/wiki/Thermal_barrier_coatinghttp://en.wikipedia.org/wiki/Thermal_barrier_coatinghttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-5http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-5http://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://www.uconn.edu/http://www.uconn.edu/http://www.uconn.edu/http://en.wikipedia.org/wiki/Inframat_Corporationhttp://en.wikipedia.org/wiki/Inframat_Corporationhttp://en.wikipedia.org/wiki/Inframat_Corporationhttp://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-13http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-13http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Rare_earth_elementhttp://en.wikipedia.org/wiki/Rare_earth_elementhttp://en.wikipedia.org/wiki/Dopantshttp://en.wikipedia.org/wiki/Dopantshttp://en.wikipedia.org/wiki/Dopantshttp://www.arci.res.in/clp/research-areas.htmlhttp://www.arci.res.in/clp/research-areas.htmlhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Costshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Costshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Referenceshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Referenceshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Referenceshttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#Costshttp://www.arci.res.in/clp/research-areas.htmlhttp://en.wikipedia.org/wiki/Dopantshttp://en.wikipedia.org/wiki/Rare_earth_elementhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-15http://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-14http://en.wikipedia.org/wiki/Coefficient_of_thermal_expansionhttp://en.wikipedia.org/wiki/Stress_%28physics%29http://en.wikipedia.org/wiki/Strain_%28materials_science%29http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-13http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-11http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-10http://en.wikipedia.org/wiki/Metallichttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-ReferenceA-1http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-8http://en.wikipedia.org/wiki/High_velocity_oxygen_fuelhttp://en.wikipedia.org/wiki/Plasma_%28physics%29http://en.wikipedia.org/wiki/Inframat_Corporationhttp://www.uconn.edu/http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-7http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-6http://en.wikipedia.org/wiki/YAGhttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-5http://en.wikipedia.org/wiki/Thermal_barrier_coatinghttp://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-4http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2http://en.wikipedia.org/wiki/Solution_precursor_plasma_spray#cite_note-2 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Laser surface hardening is a selective surface hardening process wherein the desired
metallurgical and mechanical properties are achieved by a defocused laser beam irradiated
over the required area with average power density of 103
- 104
W/cm2
produced to desired
case depth. Hardening is effected by transformation, remelting or shock hardening.
Key Features & Advantages
Moderate to rapid cooling rates resulting in fine homogenous structures Selectively localized area processing Controlled case depth Minimal distortion Chemical cleanliness Minimal post treatment High process flexibility Excellent reproducibility Ease of processing with CNC programming Faster production rates No quenchant requirement
Typical Applications
Steam turbine blades Crank shafts Cam shafts Forming dies Cutting tool edges
Ongoing Application R & D Projects
Crankshaft for a reciprocating compressor Piston spacers & rings for IC engines Two-wheeler cam shafts Crossings for rail roads
LASER CLADDING/ALLOYING
Laser surface cladding is a process of deposition of cladding material (alloying species) over
a substrate to form a sound interfacial bond without diluting the clad with substrate. Laser
surface alloying is a process similar to surface melting except that another material (alloyingspecies) is injected into the melt pool. Typically an inexpensive base material is
alloyed/cladded with an expensive alloying material, resulting in desired improvements in
tribological properties of the alloyed region. Laser cladding has also progressed into direct
laser casting (Direct Metal Deposition) for low volume 3D components.
Key Features & Advantages
Moderate to rapid solidification rates resulting in fine homogenous structures Desired coating depth with dilution Minimal distortion with low HAZ Controlled thermal profiles and shape
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Good surface finish Selective alloying/cladding Minimal wastage of costly alloying material Precise control of alloy geometry Extremely versatile Excellent metallurgical bonding Reduced porosity Excellent coating homogeneity High deposition efficiency Faster processing rates
Typical Applications
Gas turbine blades Pump sleeves Engine valves Rotor shafts
Ground rolls Temper mills Automobile pitons Ball and gate valves Friction discs Crane shafts Brake drums Casting molds Excavator blades
Ongoing Application Development Projects
Valve seat cladding with stellite 6 Boiler burner tip baffle plates for erosion resistance Erosion resistant coating on turbine blades
LASER WELDING
Laser welding is a non-contact fusion welding process which involves melting and joining of
two similar or dissimilar materials by the application of heat generated by a fine focused spot
of laser beam.
Laser welding usually employs a power density of 105-107 W/cm2 and hence, categorized as
a power beam welding process. The welding can be done in conduction mode for thin
sections and keyhole mode for thick sections. Generally, the welds are made autogenously
but external addition of filler material to modify the microstructure is also feasible.
Key Features & Advantages of Laser Welding
High power densityo High depth of penetration (aspect ratios upto 20:1)o High welding speeds and low heat input
Can weld wide variety of materials with varying thickness
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Possibility to precisely focus the beam spot at desired locationo Appropriate heat balance can be obtained while welding dissimilar materials
or thicknesses
Pulsed mode operationo Low heat input precision welding
No vacuum requirement, unlike electron beam welding Can weld magnetic materials, unlike electron beam welding Non contact process and hence clean weld unlike Shielded Metal Arc Welding orTungsten Inert Gas welding Some laser wavelengths can be sent through optical fiber and to weld inaccessible
locations
Some Typical Applications
Tailor-Welded Blanks (TWB) for Automotive bodies Gear assemblies in automotive transmission Stringer welding to skin of fuselage
Sandwich panels for ship building Stainless steel equipment Hermetically sealed valves for solenoid applications
Ongoing R & D Projects
Tailor-weld blanks Welding of Ti-6Al-4V Thin section sensors to thick section structures made hardenable steels Dissimilar material joint Ti-SS Galvanised sheet steel Titanium parts for aerospace applications Micro welding of sensors to structures.
LASER DRILLING
Laser drilling involves material removal by vaporization and/or expulsion of molten material
due to irradiation of high laser intensities. There are two types of laser drilling processes:
percussion drilling (hole of diameter 1 mm).
Percussion drilling process involves a stationary beam and one or more pulses to penetrate
the thickness of material. Trepanning involves contour cutting of the hole by moving the
beam / workpiece to create the final dimensions of the hole.
Key Featyres & Advantages
Ability to produce small diameter holes with high aspect ratiosHoles can be drilledat shallow angles to the surface
Optical fiber delivery possible Ability to process a wide range of materials High production rates Drilling of micron level holes to rock drilling Non-contact drilling (no tool wear or breakage, no material distortion) Highly accurate and consistent results
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Precise control of heat input Flexibility to address different applications (for prototypes and low-volume, small-lot
manufacturing)
Typical Applications
Cooling holes in gas turbine blades Aerofoil Laminar Flow Fuel Injection Nozzles Fuel Filters Inkjet Printer Nozzles PCB Via Interconnects Catheters MEMS
Laser Cutting
Laser welding is a non-contact fusion welding process which involves melting and joining oftwo similar or dissimilar materials by the application of heat generated by a fine focused spot
of laser beam.
Laser welding usually employs a power density of 105-107 W/cm2 and hence, categorized as
a power beam welding process. The welding can be done in conduction mode for thin
sections and keyhole mode for thick sections. Generally, the welds are made autogenously
but external addition of filler material to modify the microstructure is also feasible.
Key Features & Advantages
High power densityo High depth of penetration (aspect ratios upto 20:1)o High welding speeds and low heat input
Can weld wide variety of materials with varying thickness Possibility to precisely focus the beam spot at desired location
o Appropriate heat balance can be obtained while welding dissimilar materialsor thicknesses
Pulsed mode operationo Low heat input precision welding
No vacuum requirement, unlike electron beam welding Can weld magnetic materials, unlike electron beam welding Non contact process and hence clean weld unlike Shielded Metal Arc Welding or
Tungsten Inert Gas welding
Some laser wavelengths can be sent through optical fiber and to weld inaccessiblelocations
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Some typical Applications
Tailor-Welded Blanks (TWB) for Automotive bodies Gear assemblies in automotive transmission Stringer welding to skin of fuselage Sandwich panels for ship building Stainless steel equipment Hermetically sealed valves for solenoid applications
Ongoing R & D Projects
Tailor-weld blanks Welding of Ti-6Al-4V Thin section sensors to thick section structures made hardenable steels Dissimilar material joint Ti-SS Galvanised sheet steel Titanium parts for aerospace applications Micro welding of sensors to structures