Professional Documents
Culture Documents
PROCESSING
CHEMICAL VAPOR
DEPOSITION (CVD)
Reaction mechanisms
PHYSICAL VAPOR DEPOSITION (PVD)
PRESENTED BY
SUBJECT HANDLING STAFF
N.BALAJI
17ME319
Dr.K.MAHADEVAN
M.TECH PDM
HEAD OF THE DEPARTMENT
PEC
SUPERPLASTIC FORMING
DEFINITION:
A process for shaping super-plastic materials, a unique class of
crystalline materials that exhibit exceptionally high ductility
with neck-free elongation.
In specific, SPF is a hot forming process in which sheets of
superplastic grade aluminum are heated and forced onto or into
single surface tools by air pressure.
Superplastic materials may be stretched in tension to
elongations typically in excess of 200% and more commonly
in the range of 400–2000%.
There are rare reports of higher tensile elongations reaching
as much as 8000%. The high ductility is obtained only for
superplastic materials and requires both the temperature and
rate of deformation (strain rate) to be within a limited range.
Superplastic forming (SPF) process:
The superplastic forming process having the sheet metal to
be formed and it placed on SPF die (or) mold, the die is
representative of final part to be formed.
Simple or complex shapes can be formed
SPF/HGPF allows
complex shape
design with High-
strength alloys
APPLICATIONS
AEROSPACE - LIGHTWEIGHT LAMINAR
STRUCTURES
Application in sports
Application in arts
Application in furniture
PRODUCTION PROCESS: DIFFUSION
BONDING
VESSEL MANUFACTURING
ADVANTAGES
Complex shapes are easily made
Flexibility in design.
2.Lower die
3.Sheet metal
4.Rabber pad
Loading – jigging
Degreasing
Hot caustic
Pickling
Hydrochloric acid
Pre-fluxing
Quenching
Molten zinc
Dichromate
DEGREASING
Infrastructure development
Telecommunication towers
Severe abrasion/Gouging/High
impact:
Combination of low, moderate and
high abrasion combined with
impact. Large chips and scratches.
Adhesion:
When two metal bodies rub each other
and material is transferred from one
substrate to the other, this is known
as “adhesion wear”.
Occurs under conditions of high
temperature, high pressure and
friction.
Erosion:
This occurs when solid particles or
drops of liquid strike a surface at high
speed.
Rate depends on the angle of attack
and at which it is projected.
Fretting:
Caused when there is recurrent
rolling or sliding action between two
components. Under such conditions a
sudden loss of material, in the form of
pitting or chipping will be observed.
Ex: gear teeth, rails, roller presses.
Thermal fatigue:
This type of fatigue refers to wear
generated by thermal cycle loads on the
base metal.
When metal is repeated heated or
cooled, expansion and contraction
occurs.
Ex : Forge tools.
Cavitation:
Occurs in turbulent liquids in contact
with a solid surface.
Cavities are formed in the liquid and
implode, creating wear.
Cavitation erosion.
Combined wear ?
SURFACE COATING
An economic method for the production of materials ,
tools and machine parts that required the desired
surface properties such as corrosion, erosion and wear
resistance.
Some methods:
Hard facing
Thermal spraying
Vapor deposition
Ion implantation
Hot dipping
WHY SURFACE COATINGS?
Principle of “Better-faster-
cheaper”
Corrosion resistance
Thermal insulation
Electrical insulation
Preventive hardfacing
Hardfacing
Remedial hardfacing
Characterized by
→ Soundness
→ Toughness
→ Environmental stresses like corrosion and high
temperatures
CHOOSING THE HARDFACING PROCESS
Process types
Gas tungsten Arc welding process
Shielded metal arc welding
Flux cored arc welding
Submerged arc welding
Gas Tungsten Arc welding process:
𝐵
% Dilution = ∗ 100
𝐴+𝐵
Medical implants
Hip implant
Vacuum plasma process
Gas turbines
Stationary and flight gas
turbines.
Thermal sprayed coating.
High temp corrosion resistance,
thermally insulating coatings,
repair of super alloy
components.
CHALLENGE
Thermico required a new extraction system to handle the dust
and fumes from the plasma and HVOF spray systems that
were being installed in their new premises.
APPROACHED COMPANY:
Camfil Air Pollution Control (APC)
SOLUTION:
Camfil APC addressed the issue by supplying one of their
ATEX compliant Farr Gold Series® GS40 dust collectors,
complete with a supply air system.
PRODUCT INFORMATION
Product: Farr Gold Series® dust
collector
Size: GS40 ATEX Compliant
Air Volume: 30.000 m3/hr
Application: Thermal spray
processes, HVOF, plasma
Customer: Thermico GmbH &
Co.KG, Dortmund, Germany
Installation date: January 2011
Results
Successful handling of thermal spray dust and fumes
was done.
Additionally an energy saving setup that incorporated
a heat exchange system was installed.
Thermico was delighted with the solution which
provides their workforce with a safe working
environment meeting all legislative requirements,
whilst saving on energy costs and ensuring
sustainability.
An interesting fact
HISTORY
Principle:
The electron’s Kinetic energy is
transformed into heat energy when it strikes
the surface of the work piece.
SCHEMATIC 104
DIAGRAM:
105
Deflection coil
Vacuum pump
CLASSIFICATION OF EBW
MACHINES:
By
accelerating By machine
By pressure
voltage concept
Conveyor
High voltage High vacuum
machine
machine machine
(10-3to 10- Clock system
(Up to150 kV)
6Torr) All-purpose
Low voltage
Fine vacuum EBW
machine (Up machine
to 60kV) machine
(25 to 10-3Torr)
Local vacuum
Atmospheric
machine (NV- machine
EB welding) Mobile vacuum
1 atm = 760 torr machine 106
Micro and fine
welding machine
107
WORKING:
Current is applied to the cathode filament gets heated
up to 2000 Celsius.
Where
v- beam accelerating voltage ,v
I- beam current ,A
P-beam power ,W
v- travel speed ,mm/s
n- fusion efficiency
111
COMPARING EBW WITH SIMILAR 112
WELDING PROCESSES:
PARAMET TIG PLASMA LASER EB
ER
Power input 2kW 4kW 4kW 5kW
to
W-P
Total power 3kW 6kW 50kW 6kW
used
Traverse 2mm/s 5.7mm/s 16mm/s 40mm/s
speed
Positional Good Good Yes Require Requires
welding penetration penetration optics to mechanism to
move the move the
beam beam
Distortion Nominal Nominal Small Minimum
shrinkage significant in significant in Minimum Minimum
113
ADVANTAGES:
Thin and thick plate welding (0,1 mm bis 300
mm)
extremely narrow seams (t:b = 50:1)
DISADVANTAGES:
. electrical conductivity of materials is required
high precision of seam preparation
APPLICATIONS:
Precision Aerospace Gears Weld
magnesium alloys
titanium
tungsten
gold
DIFFUSION BONDING:
Definition:
A solid-state welding process, wherein
coalescence of the faying surfaces is
produced by the application of pressure and
temperature to carefully cleaned and mated
metal surfaces so that they actually grow
together by atomic diffusion.
SCHEMATIC REPRESENTATION OF 119
DIFFUSION BONDING:
The first stage is to achieve intimate metal to metal
contact between the two pieces to be diffusion welded.
120
PROCESSES:
123
Temperature
Pressure
Time
Temperature:
Time:
DISADVANTAGES:
production process.
APPLICATION: 131
SOLID
FUSION
STATE
WELDING
WELDING
Examples Example
SMAW s
SAW FRW
EBW USW
EXW
SPECIAL METAL JOINING PROCESS
Also called MISCELLANEOUS WELDING PROCESS
These processes are used for improved weld quality and
human comfort
Both friction welding and ultrasonic welding
Stresses
involved
• Static Normal
Stress
•Tangential
Shear stress
KEY POINTS TO BE NOTED
Electrode is called ‘Sonotrode’
No fusion or melting
F -Force
V - Speed of movement of tool
APPLICATIONS
Polymers used in
car components Medical Apllications
OTHER APPLICATIONS OF USW
Air craft construction
Building of transistors
Presented by
K.Karthikeyan
PEC
ELECTRO HYDRAULIC FORMING
A sudden electrical discharge in the form
of sparks is produced between the
electrodes and this discharge produces a
shock wave in the water medium.
This shock wave deforms the work plate
and collapses it into the die.
The characteristics of this process are
similar to those explosive forming. Here
the chemical explosive is replaced by a
capacitor bank, which stores electrical
energy.
CIRCUIT DIAGRAM
CONTINUATION