Limited Hostel facilities are available on request
[1] NML
Title
Application of X-ray Fluorescence
Spectrometry for Chemical Analysis
About The Programmew
X-ray Fluorescence Spectrometry
(XRF) has been developed as a powerful non-destructive technique of qualitative as well as
quantitative chemical analysis of materials. As a nondestructive technique, it has the
merit of analyzing noncorrosive metals or alloys, refractory materials and geological
materials irrespective of their solubility in conventional wet chemical methods. Ease of
sample preparation in a very short time has increased its popularity in the industrial
production units. Chemical analysis by XRF technique requires superior level of skill in
the optimization of instrument, choice of source, choice of detector, choice of crystals,
standard preparation, sample preparation, calibration, corrective measures on signal, etc.
The proposed training will give a better insight into the principles of XRF analysis, the
problems in analysis and the remedial measures.
Topics of Lecture No. of hours
- The fundamental principles in X-Ray Fluorescence
Spectrometry XRF3
- Sample preparation of XRF analysis2
- Analytical problems of XRF technique and remedial
measures3
- Recent trends in XRF and its application in
instrumental analysis2.5
- XRF techniques for the analysis of metallurgical
samples2
- XRF techniques for the analysis of geological
samples2
- Discussion2.5
Hands of Training
- Instrumental aspects of XRF Fluorescence
Spectrometer 2
- Sample preparation for XRF analysis2.5
- Analytical program for XRF instrument3
- Calibration in XRF analysis3
- Analysis by XRF2
- Discussion2.5
[2] NML
Title
Complexometric Analysis
About the Programme
Chemical analysis for knowing the
quantitative composition of a substance is considered important and essential for
evaluation and characterization of raw materials and finished products. However, the
classical wet chemical methods involving lengthy and time consuming steps of successive
separations of groups by precipitation and re-precipitation cannot solve the purpose of
quality control since the effectiveness of quality control is largely determined by the
speed with which the determination of critical parameters, compositions and properties
involving evaluation of raw materials and finished products are made. Attempts have
therefore been constantly made for development of rapid and accurate methods of chemical
analysis. The complexometric methods of analysis are very simple, rapid and accurate and
have many potential applications in the analysis of ores, minerals, metals, alloys,
ferro-alloys, refractory materials and ceramic products. Metallurgical, ferro-alloy,
refractory and ceramic industries will be benefited by this training.
Topics of Lecture No. of hours
- Chemical analysis of ferro-alloys1
- Chemical analysis of ores and minerals1
- Chemical analysis of alumino-silicate refractory
materials 1
Hands on Training
- Chemical analysis of ferro-alloys6
- Chemical analysis of ores and minerals13
- Chemical analysis of alumino-silicate refractory
materials 13
[3] NML
Title
Optical Emission Spectrometric
Methods of Analysis
About the Programme
Optical Emission Spectrometers
(OES) are routinely used instrument in a quality control laboratory. This is a very
powerful analytical technique that enjoys a broad dynamic analytical range making possible
the analyses from trace to major level in a single calibration curve. Both spark as well
as Inductively Coupled Plasma (ICP) excitation sources may be used. ICP technique may be
carried out in both simultaneous and sequential modes, which make the analyses quick and
spectral overlap free. The excitation temperature being very high, the chances of chemical
interference is almost eliminated. The capital investment for this techniques is somewhat
high. However, in a quality control laboratory, where the number of samples are large and
where analyses are required fast, ICP OES is the ideal equipment. The same equipment may
also be used for analyzing solid samples using spark as the excitation source.
The objective of this training
programme will be to make the users thoroughly conversant with the theoretical and
practical understandings of the ICP and spark techniques. The objective of this training
programme will also be to train the users so that they are able to handle OES
independently at their own workplace. Training on OES will be useful in the Quality
Control (QC) laboratories of ferrous and nonferrous industries.
This training programme will be
suitable for QC personnel in ferrous and nonferrous industries, research organizations and
academic institutions.
Topics of Lecture No. of hours
- Fundamentals of optical emission Spectrometry (OES)1
- Basic instrumentation 1
- Theoretical aspects of the technique 1
- Sample preparation 1
- Minerals, metals, soil, plants and vegetables
- Method developments 1
- Calibration, recalibiration, interference,
correction
- Analysis of low alloy and plain carbon steels1
- Analysis of ores and minerals 1
- Analysis of soils, plants and vegetables1
- Statistical analysis 1
- Conclusion 1
Hands on Training
- Basic instrumentation 2
- Sample preparation 8
- Minerals, metals, soil, plants and vegetables
- Method developments 4
- Calibration, recalibiration, interference,
correction
- Analysis of low alloy and plain carbon steels4
- Analysis of ores and minerals 4
- Analysis of soils, plants and vegetables3
[4] NML
Title
Atomic Absorption Spectroscopic
(AAS) Methods of Chemical Analysis
About the Programme
Atomic Absorption Spectroscopic
(AAS) methods of chemical analysis for cations have become a very powerful tool in the
hands of analytical chemists. AAS can be used to determine a host of metallic cations from
trace to percentage level. The method offers very little chemical and spectral
interference and information is available for chemical interference and their correction.
Cookbook methods are available from the supplier or one may be developed by qualified
chemists to suit the exact requirement of the user agency. AAS method is quick, does not
require expensive reagents. Also, the cost of the equipment being relatively low, it may
be maintained by a small scale industry or a low budget analytical laboratory.
The basic objective of this
particular programme is to appraise the participants about the fundamentals of the
instrument, the possible interferences and their corrections. The programme will also
outline the precautions to be taken for the smooth and trouble free operation of the
equipment.
This training will be suitable for
all quality control laboratories in small-scale industries, research organizations and
academic institutions, those require chemical analyses for metals and materials.
Topics of Lecture No. of hours
- Fundamentals of Atomic Absorption Spectrometry
(AAS)1
- Basic instrumentation1
- Theoretical aspects of the technique1
- Sample preparation1
- Minerals, metals, soil, plants and vegetables
- Method developments: Calibration, recalibration,
interference, correction1
- Analysis of low alloy and plain carbon steels1
- Analysis of ores and minerals 1
- Analysis of soils, plants and vegetables1
- Statistical analysis1
- Conclusion1
Hands on Training
- Basic instrumentation2
- Sample Preparation8
- Minerals, metals, soil, plants and vegetables
- Method developments : Calibration, recalibration,
interference, correction4
- Analysis of low alloy and plain carbon steels4
- Analysis of ores and minerals 4
- Analysis of soils, plants and vegetables3
[5] NML
Title
Quality Assurance Through
Calibration : A Corporate View
About the Programme
In a domain where the buzzword
quality-assurance rules the market, driven by another buzzword customer-delight, can one
afford to be less quality conscious than their competitors? Even if there is a high regard
for quality and quality products are indeed being manufactured, how confident are the
customers about the quality of the products they buy? In an era, where there is persistent
efforts and demand to realize and ensure highest possible accuracy, how accurate are the
measurements, and do they conform to National/ International standards? Is calibration an
answer to quality assurance?
The top-brass managers and
executives are often riddled with these questions and not too sure about the answers. This
program addresses all such issues which crop up when the companyÕs Management
Representative (MR) and his senior colleagues in the quality control, operations,
metrology departments meet together to discuss the quality aspects of their products.
The aim of this programme is to
make the top-level management better equipped to take policy decisions in their endeavour
to provide quality assured products. This program also aims to develop methods and
practices to produce quality goods, which ultimately help in winning the confidence of the
customers.
Topics of Lecture No. of hours
- Measurement science and technology1
- Understanding the characteristics of instruments1
- Why calibration1
- How are calibration systems designed1
- Uncertainty in measurement and calibration1
- Maintenance and reliability of masters1
- Confidence and quality assurance through
calibration1
- Conforming to quality elements of ISO1
- Guidelines for effective management of calibration
activity1
Hands on Training
- Calibration of temperature and pressure sensors and
indicators2
- Calibration of electrical sensors transducers and
instrument2
Demonstration
- Determination of measurement uncertainty1
- Management of calibration activity1
[6] NML
Title
Calibration, Confidence and Quality
Assurance
About the Programme
With new concepts emerging due to
global competition, the way the products are designed and fabricated has undergone a sea
change. A company need not manufacture all components that go into the making their
product. Procuring some of the components from other companies, who specialize in
manufacturing them, is an attractive and cost-effective solution. So, accuracy and
precision in measurements are no longer confined to the shop floor. They must now conform
to International standards to win the confidence of customers. How confident are you that
your methods and practices lead you to produce high quality stuff? In an era, where there
is a constant, persistent effort and demand, to realize and ensure highest possible
accuracy, how accurate are your measurements, and do they conform to
National/International standards (ISO). An answer to some of these questions lies in
getting your instruments calibrated. Calibration lead to quality assurance too.
This program addresses these issues
and aims to provide a deep insight into what is calibration and how it builds up
confidence in the measurements. The program is very useful for all managers/engineers in
quality control, operations, metrology departments and also for those in mid-level
management who strive for quality assurance.
Topics of Lecture No. of hours
Measurement science and technology
1
Understanding the characteristics
of instruments 1
Why calibration 1
Calibration of temperature sensors
and indicators 1
Calibration of pressure instruments
1
Calibration of electrical sensors,
transducers and indicators 1
Specimen inspection and calibration
of dimension and load 1
Uncertainty in measurement and
calibration 1
Confidence and quality assurance
through calibration 1
Hands on Training No. of hours
Calibration of temperature sensors
and indicators 3
Calibration of pressure instruments
3
Calibration of electrical sensors
transducers and indicators 3
Calibration of mechanical
instruments 3
Demonstration
Determination of measurement
uncertainty 2
[7] NML
Title
Advances in Instrumentation
About the Programme
Rapid advances in technology have
changed the way instruments are designed. To control a process parameter one need not
necessarily rely on models based on absolute values. The data may be fuzzy, the systems
may be chaotic and the models may be imprecise. Conventional instrumentation concepts fail
miserably when used under these sets of constraints.
In the era of intelligent
computing, modern instrumentation systems have overcome these limitations and are now
capable of learning and adapting to such constraints. Can one afford to keep oneself away
from these advances in instrumentation? Here is a program that aims to present an
opportunity for mangers/executives and researchers to learn more about the recent advances
in instrumentation.
Topics of Lecture No. of hours
- Measurement science1
- Sensors & transducers1
- Process instrumentation and control1
- Analytical instrumentation1
- Real-time and embedded systems1
- Expert system applications1
- Artificial intelligence and neural networks1
- Fuzzy-based systems1
- Computer vision and automation1
- Reliability and quality assurance1
[8] NML
Title
Remaining Life Assessment of
Engineering Components
About the Programme
Engineering components experience a
variety of environmental conditions and stresses while in service. This introduces, with
service exposure, a process of degeneration of the components that renders them unsafe
after a period of time. The designer, by anticipating some of the service conditions, may
be able to prescribe the component for a stipulated period of life. In real-life, however,
a number of imponderables offset the calculations and shorten the life of components. It
has often been found that the calculations coupled with the factor of safety, provide a
very conservative estimate of component life. Whether it is retiring a component too early
or too late, there is an economic penalty that may be quite high. Periodic evaluation of
remaining lives of ageing components is possibly the best way to avoid premature failure
and yet use the component till the very end of its useful life. In this programme, the
fundamentals of remaining life assessment will be presented. The course content is ideal
for practising engineers and professionals working in power plant, refineries,
petrochemical industries and those engaged in maintenance of engineering components.
Topics of Lecture No. of hours
- Remaining life assessment: An overview, Importance
of RLA-highlighted with1
- Stress analysis & failure criteria why and how
do materials fail? 2
- Evolutions of structural damages what are the
changes in mechanical properties, 2
component shape and microstructures
due to service exposure?
How these changes effect
performance?
- NDT for flow detection & material
characterization. How to identify &2
- Behaviour of cracked bodiesHow the presence of crack
leads to 2
stress concentrations? Factors
affecting crack growth.
- Design codes & practices Recommended procedures
for 4
Case studies
(a) Life assessment under fatigue
(b) Life assessment under creep
(c) Life assessment under
environmental damage
(d) Life assessment of boilers,
turbine blades etc.
Hands on Training
- Stress analysis using finite element method1
- Software for remaining life assessment(CLIP, RELIEF
etc.)1
- Fracture mechanics based life assessment1
- Special NDT techniques for RLA1
[9] NML
Title
Computational Methods in Metallurgy
and Materials Science
About the Programme
Metallurgy and materials science
has come a long way from the empirical approach based on heuristics and rules of thumb and
is fast maturing into an exact quantitative science. Development of mathematical methods
and computational techniques and affordability of desktop computers have led to tremendous
progress of computational materials science in the last couple of decades. Modern
computational techniques allow practising engineers to analyze a metallurgical process and
study materials behaviour using simple tools of computer aided design and simulation. In
this programme, the fundamentals of the computational methods will be covered for solving
problems of metallurgy and materials science for practising engineers and scientists in
steel plants, power plants, chemical process plants, research and testing laboratories and
so on. Much emphasis is laid on augmenting the mathematical concepts with case studies
relevant to industrial design and analysis. Hands on demonstration-cum-training will be
provided on few softwares developed at NML.
Topics of Lecture No. of hours
- Introduction of computational materials science1
- Fundamentals of matrix methods for algebraic
equations2
- Applications of matrix method for material and
energy balance & process 2
- Fundamentals of Ordinary Differential Equations
(ODE)3
- Application of ODE solvers to creep strainmodelling,
diffusion, phase
- Fundamentals of Partial Differential Equations
(PDE)3
- Application of PDE solvers to fluid flow, heat and
mass transfer, 2
- Artificial intelligence techniques2
Some Case Studies
- Heat and mass transfer in iron-making, steelmaking
operations1
- Material and energy balance for steelmaking
operations1
- Oxidation/carburization in boilers/ heatertubes of
power plants 1
- Creep strain modelling for life prediction of
engineering components1
- Stress analysis of engineering components for
fracture and fatigue1
Hands on Training
- Life assessment packages, finite element packages,
computational fluid3
[10] NML
Title
Practical Course on Corrosion
Science and Engineering
About the Programme
Corrosion of metals has imposed a
serious threat on industry, the society and the nation in terms of both money and
manpower. General statistics reveals that overall cost due to corrosion of metals amounts
to at least 2-4% of GNP. This loss not only included the cost of replacement of metals,
but also the damage to products by contamination, shut down of production, loss of
efficiency and in psychological factors associated with failure or explosion of
equipments. This loss can be reduced effectively to the tune of 20-25% by the application
of appropriate and upgraded knowledge of corrosion and corrosion control science. Present
course is an attempt in this direction which includes the basics and applied aspects of
diffraction forms of corrosion and introduces to the recent developments in corrosion
science and engineering. Further, it includes corrosion inhibitors in general, metallic
and organic coatings for corrosion protection. Emphasis on the metallurgical aspects of
corrosion, coating and electroplating is given. This course covers the latest
electrochemical methods for corrosion monitoring and evaluation.
Topics of Lecture No. of hours
- Principles of electrochemical corrosion and basic
metallurgical 2
- consideration in corrosion control
- Corrosion detection and corrosion control
monitoring1
- General techniques for corrosion measurement2
- Corrosion control during transit and storage2
- Various types of corrosion inhibitors2
- Introduction to protective coatings2
- Corrosion testing and evaluation1
- Newer trends in coating practices2
- Fundamentals of cathodic protection2
Hands on Training
- Acid pickling and evaluation of corrosion
inhibitors1
- Potentiodynamic polarization and determination of
corrosion rate2
- Salt spray test, sulphur dioxide and hydrogen
sulphide gas1
- Moisture condensation test1
- Electrolytic cleaning, standard methods for sample
preparation2
- Coating thickness, zinc plating and electroless
nickel plating2
Demonstration
- Potentiodynamic polarization and determination of
corrosion rate
- Electrochemical impedance analysis.
[11] NML
Title
Testing of Refractory Raw Materials
and Products
About the Programme
Refractories play a vital role in
all the industrial furnaces involving high service temperatures. About 70% of refractories
produced are used in Iron and Steel industry. The quality of refractories mainly depends
on the purity of raw materials and improved processing/making technology. Today, synthetic
refractory raw materials are also being used for making superior quality refractory
products. In this programme, various types of tests for characterization of refractory raw
materials and products will be discussed and demonstrated. The programme is aimed for
engineers, scientists, supervisors engaged in laboratories, institutes and industries.
Topics of Lecture No. of hours
- Refractory raw materials (Natural & Synthetic)2
- Characterization of refractory raw materials2
- Types of refractory products 2
- Evaluation of refractory products(Physical, thermal,
mechanical properties)2
- Furnaces and temperature control devices2
Hands on Training
- Thermal shock resistance4
- Permanent Linear Change on Reheating (PLCR)4
- Hot modulus of rupture4
Demonstration
- DTA/TGA4
- High temperature creep4
[12] NML
Title
Testing of Iron Making Raw
Materials
About the Programme
Raw materials play an important
role in blast furnace (BF) ironmaking. The characteristics of raw materials have greatly
changed in past two or three decades. Normally iron ore, limestone and coke are used as
raw materials. Now-a-days, however, pre-fluxed sinters and pellets, liquid and gaseous
fuels have increasingly replaced the conventional ironmaking raw materials. The role of
the preparation, properties, performance characteristics of raw materials on hot metal
quality would be discussed in the programme.
The programme has been designed for
engineers, scientists and supervisors engaged in blast furnace operation, raw material
preparation and characterization etc.
Topics of Lecture No. of hours
- BF operation, raw materials and properties2
- Characteristics of iron ore2
- Testing of ores, sinters and pellets2
- Factors affecting performance of raw materials2
- Fuels and fluxes2
Hands on Training
- Chemical analysis of ore4
- Thermal and reduction -degradation index4
- Reducibility4
- Softening of iron ore/sinters4
- Testing of BF fuels and fluxes4
[13] NML
Title
Unit Operations in Mineral
Processing: Theory and Practice
About the Programme
Mineral processing plays a vital
role in exploitation of natural ore resources. It is a basic step in the field of
metallurgy and is being practised by small and large mineral based industries. It involves
a number of unit operations ranging from communition to dewatering. A basic understanding
of various unit operations is considered to be useful for the efficient operation of
mineral processing plant. This course is intended to impart the knowledge on the basic
principles of various unit operations of mineral processing. This will also cover
development in this area through lectures followed by hands on training/demonstration in
selected equipment. This programme also envisages visit to other related R&D
facilities existing in the laboratory. This course will be suitable for plant
operators/foremen/technicians and other people connected with mineral processing
activities.
Topics of Lecture No. of hours
- Introduction to mineralogy1.5
- Comminution1.5
- Classification of minerals1.5
- Gravity separation techniques1.5
- Gravity separation of fine materials1.5
- Flotation fundamentals1.5
- Flotation-case studies2
- Magnetic & electrostatic separation techniques2
- Dewatering practice2
Hands on Training
- Jaw crusher, roll crusher, ball/rod mill3
- Hydrocyclone3
- Jigs, Wilfley table3
- Flotation & magnetic separation3
- Multigravity separator3
[14] NML
Title
Agglomeration of ore fines and
concentrates: Theory and practices
About the Programme
In many of the mineral processing
plants, the final product comes in the form of fine particulates. Agglomeration of these
fine materials by sintering, pelletization, briquetting etc., is done for ease in
handling, transportation and subsequent use. Continued R&D in this area has led to
developments of new technologies and processes. Professionals employed in maintenance,
operation and control of agglomeration plants hardly get a scope to broaden their
knowledge on the recent development. Keeping this in view, this course has been designed
to brush-up their knowledge on the principles and to share the developments, through
lectures followed by demonstration of the process in actual equipment in use. This will
help the professionals to discharge their duty in a better way with understanding of the
subject. This course will be suitable for plant operator / foreman / technicians and other
people directly dealing with sintering, pelletizations and briquetting.
Topics of Lecture No. of hours
- Pelletization fundamentals, Pelletization practices3
- Sintering fundamentals: Optimization of process
parameters3
- Briquetting - theoretical developments Briquetting
practices3
- Properties of agglomerates3
- Visit to physicochemical laboratory, visit
toanalytical chemistry, 3
Hands of Training
- Raw material preparation, pelletization3
- Raw material preparation, sintering3
- Physical properties of sinter3
- Briquetting3
[15] NML
Title
Recent Advances in Mineral
Processing
About the Programme
Mineral processing is a basic step
in the field of metallurgy of ore and this is being practised from small to large scale
industries. In the field of mineral processing, technologies are undergoing changes due to
gradual depletion of good quality of ores leaving the industries to use lean and complex
ore. With this scenario in the background, the professionals need to keep themselves
abreast with the new technologies and processes. This course is intended to impart the
knowledge on developments in the area of mineral processing which will help them in
running the plants in a better way. The lectures will be delivered by eminent scientists /
academicians and it will be suitable for plant middle level executives manning the mineral
processing plants.
Topics of Lecture No. of hours
- Role of mineralogy in mineral processing3
- Advances in fine gravity separation3
- Flotation of complex ores3
- Magnetic & Electrostatic separation of minerals
and raw materials3
- Coal preparation: Visit to Laboratory facilities3
Hands of Training
- Ore microscopy - case studies3
- Fine gravity separators - MGS, Duplex con.3
- Flotation - case study3
- High intensity magnetic separation3
[16] NML
Title
Characterization of Ores and
Particulates - Theory and Practice
About the Programme
Mineralogy plays an important role
from study of genesis of ore to mineral processing and extraction. Identification of
minerals and their intergrowth pattern (texture) are important factors to indicate the
probability of liberation of minerals. With gradual depletion of good quality ores leading
to dependence on low grade and complex ores together with stringent specification imposed
day by day on the concentrates, the knowledge of mineralogy has become more relevant today
for the mineral engineers to decide upon the process for separation. To keep abreast with
the latest knowledge on the means of identification and estimation of phases, a geologist
or a petrologist should always brush up and add to his/her expertise. With this view, this
one week course has been designed for field geologist or petrologists working in
industries or R&D institutions so that they can be aware of the latest technologies in
the profession.
Topics of Lecture No. of hours
- Characterization of minerals-Megascopic technique3
- Characterization of minerals-Instrumental methods of
phase analysis3
- Characterization of particulates-Subsieve analysis.
Characterization of
- Phase analysis by advanced techniques-SEM, TEM3
- Case studies / Modal analysis & Visit to
Laboratory facilities3
[17] NML
Title
Training in Metallography and
Microscopy
About the Programme
Microstructure of a material is the
"window" through which one can understand the past, present and the future
behaviour of a material. It is a must for any quality assurance programme, that includes
the whole gamut of activities such as design, procurement of material, fabrication,
operation, maintenance and in-service inspection.
Though many of the industrials
requirements of microscopy can be met by optical microscopy (OM), scanning electron
microscopy (SEM) has now become more common than what it was a few years back. OM and SEM
have their own advantages. SEM can give much higher magnification than OM. It can also
have the advantage of the use of Energy Dispersive Analysis of X-rays (EDAX) by which
microanalysis of individual particles can be done. Thirdly, SEM has the advantage of a
large depth of focus. However, while this is a great advantage in fractography
(examination of fracture surfaces), sometimes it gives a problem while examining a
microstructure at the interfaces. Therefore, if the needed maximum magnification is about
500-1000, OM is often better than SEM.
In view of the inherent importance,
both OM and SEM would be covered for characterization of materials.
Topics of Lecture No. of hours
- Microstructural analysis-why is it needed? Some of
the material properties 2
- Metallographic specimen preparation mechanical
grinding, mechanical 2
polishing, electrochemical
polishing, chemical etching, electrochemical etching
- Construction of microscope, concept of numerical
aperture, resolution, contrast1
- Science and technology of development of and
printing of film1
- Digital photography, microscopy and other imaging1
- Quantitative image analysis1
- Inclusions-their origin, role in the behaviour of
materials, and rating1
- Scanning Electron Microscope - its constructionand
possibilities. 1
- Energy Dispersive Analysis of X-ray(EDAX)1
- Fractography1
Hands on training
- Metallographic sample preparation (optional)
including chemical and 4
- electrochemical etching
- Coating for SEM sample2
- Microstructural analysis on carbon steel,
differently heat treated alloy3
steels, nickel base alloys,
aluminium alloys and cast iron
- Inclusion rating by normal optical microscope and
microscope with the 2
- Examination by SEM (and EDAX) on selected steels and
alloys3
- Fractography by SEM3
[18] NML
Title
Metallurgical Failure Analysis
About the Programme
The training module aims to
integrate mechanical design, manufacturing processes, mechanical behaviour and
microstructural analysis. In the interactive and modular course, the participants learn to
determine the root causes of metallurgical failures. The participants are explained how to
perform nondestructive, mechanical, metallurgical, and chemical tests by both portable and
laboratory metallographic techniques. Optical and scanning electron micrographs and
fractographs will be studied. The multi disciplinary nature of failure analysis benefits
participants by integrating many subjects and requiring the use of modern equipments.
Topics of Lecture No. of hours
- Failure analysis-general discussion1
- Techniques-optical microscopy [laboratory and
in-situ], electron 4
microscopy including fractography,
nondestructive testing, corrosion
testing and mech anical testing
- Residual stress - its effect on failures and
measurement1
- FEM analysis1
- Fracture mechanics concepts1
- Ductile fracture1.5
- Brittle fracture1.5
- Fatigue crack initiation, growth and fracture2
- Wear1
- Corrosion1
- Elevated temperature failures1
Hands on Training
- Optical microscopy of steel, brass,aluminium, nickel
base alloys2
- Fractography using scanning electron microscopy, and
3
- Nondestructive Test (ultrasonic for flaw detection,
X-ray diffraction 3
- Mechanical test (Tensile, Fatigue,Hardness, Impact)4
[19] NML
Title
Creep Evaluation of Engineering
Materials
About the programme
Creep is a special kind of plastic
deformation in which strain increases slowly and continuously at a constant load (below
yield point) and elevated temperature. It is the most important damage, which limits the
lives of high temperature components operating in thermal power plants, petrochemical and
fertilizer plants. Some popular grades of creep resistant steels used in these plants are
1.25Cr-0.5Mo, 2.25Cr-1Mo, 1Cr-1Mo, 9Cr-1Mo, 12Cr-Mo-V etc. These steels in operation under
creep conditions are characterized by their long-term creep rupture strength in contrast
to short-term tensile strength at the operating temperature. Hence, determination of creep
rupture properties of engineering materials are of great industrial relevance from the
view point of ensuring smooth operation of the plant and extended life of the components.
Keeping this in view, this training module is designed to suit the needs of the people
engaged in research and development, creep life assessment and database development of
engineering materials, quality control and assurance, component design and maintenance
activities. This program includes lecture, hands-on training on creep and stress rupture
test and data analysis to develop database on creep of engineering materials. Lecture from
experts would cover various practical aspects to answer some important questions.
Topics of Lecture No. of hours
- Introduction to creep and stress rupture tests1
- Creep testing machines - specifications1
- Creep testing machines - calibration1
- Materials for high temperature services1
- Effectiveness of time - temperature parameters1
- Creep rupture tests for life assessment1
- Creep rupture data analysis1
- Factors influencing creep rupture strength1
- Creep life assessment of main steam pipes1
- Influence of wall thinning on creep life1
- Creep life assessment of boiler tubes2
- Creep life assessment of reformer tubes2
Hands-on Training
- Application of computer software CLIP for creep life
prediction2
- Creep of thick pressurized tubes3
Demonstration
Laboratory demonstration on creep
and stress rupture testing methodology using (i) Single specimen creep testing machines
with three-zone controlled high temperature furnaces, thermocouples, LVDTs, (ii) Data
logging system for monitoring and controlling temperature and creep strain data and
standard test specimens based on national and international standards.
No. of hours : 2
[20] NML
Title
Fracture Toughness Evaluation of
Metallic Materials
About the programme
Engineering fracture mechanics
enables one to evaluate the behaviour of structures / components containing flaws.
Fracture mechanics is a tool to assess the stress distribution in the vicinity of the
cracks, since the conventional tensile properties, buckling stress etc., fail to
characterize the stress situation around flaw like defects. The stress amplitude at the
crack tip is denoted as K, Stress Intensity Factor (SIF), and can be experimentally
evaluated. For the materials, which fail predominantly in elastic loading regime, the
critical SIF is a material property and is denoted as Kic. The advent of high toughness
material which could contain some plasticity before failing in an unstable manner, an
energy based parameter, J integral, has been proposed. Similar to Kic, Jic is also a
material property that can be determined in a laboratory by testing standard specimens.
The significance of these
properties can be gauged from the fact that organizations, world over, responsible for
maintaining the standards e.g., ASTM, BS, JIS, have incorporated methodologies for
evaluation of fracture toughness in their respective standards. Of late, specifications
for alloys employed in aircraft; space and nuclear industries are including the fracture
toughness along with strength properties. Availability of reliable fracture toughness data
will provide a basis for determining critical flaw size/design stress for
safe-life/fail-safe designs.
This training module envisages
imparting the techniques and procedures to be followed for determining the fracture
toughness values of metallic materials based on International standards viz. ASTM, BS.
Hands-on laboratory training is the focus of this module. This program is designed to suit
the needs of the people engaged in research and development related to remaining life
assessment / structural integrity evaluation, quality assurance, design / maintenance
activities and also provides a platform to share the experiences of the users who are
already familiar with FM test techniques.
Topics of Lecture No. of hours
- Introduction1
- Applications1
- Test procedures1
- Data analysis1
Hands-on Training
- Specimen inspection1
- Fatigue pre-cracking3
- Test for Kic2
- Test for Jic5
- CTOD evaluation1
Demonstration
The training would include some of
the basics like specimen inspection, operation of the loading machine and setting-up a
test. Fatigue pre-cracking of the test specimens, which is mandatory for FT evaluation,
would also be demonstrated. The testing procedures will be followed by data analysis; both
by graphical methods as well as digital data processing techniques and culminate in
validation of the test results.
[21] NML
Title
Low Cycle Fatigue and Creep -
Fatigue Interaction in Engineering Materials
About the programme
Low Cycle Fatigue (LCF) is an
important consideration in the design and operation of components of aircraft, automotive
and thermal power generating systems operating at high temperatures. These components
experience cyclic loading and thermal stress arising from heating and cooling during
start-up and shutdowns or during thermal transients, which give rise to low cycle fatigue
damage. Low cycle fatigue under start-up and shutdowns occurs under essentially strain
controlled conditions as the surface region is constrained by the bulk of the component.
Steady load period during operation at high temperatures introduces creep damage in the
component materials. Hence, power plant components have to be designed for fatigue, creep
and its interaction effects.
This training program is designed
to suit the needs of the people engaged in design, quality control and materials
development activities.
Topics of Lecture No. of hours
- Testing methodology1
- Machine specification and operation 1
- Factors influencing LCF behaviour1
- Data compilation and analysis2
- LCF life prediction methodologies2
Hands-on Training
- Machine setup 0.5
- Extensometer and thermocouples0.5
- Parameters setup0.5
- Data logging software0.5
- Demonstration testing8.0
Demonstration
- LCF Testing of a Specimen
[22] NML
Title
Tensile Test to Determine 0.2%
Proof Stress, UTS, % Elongation and % Reduction in Area
About the programme
Tensile test is most widely
employed to characterize the tensile properties of materials over a range of temperature
and strain rate. From any complete test, one can obtain important information pertinent to
the material's elastic properties, the character and extent of plastic deformation, yield
and tensile strengths, and toughness. In engineering applications, these tests involve
determination of the yield strength (sy), the maximum load bearing capacity of a material
(su), and the ductility of the material such as percentage elongation (%EL) and reduction
in area (%RA). These information are useful in research and development for comparison of
materials, alloy development, failure investigation etc., and in industry for quality
control, and design. The properties determined through tensile tests following
National/International standards depend on factors such as temperature, strain rate,
environment and specimen orientation with respect to the component rolling/forging
direction. This training program is designed to suit the needs of people engaged in
research, testing, quality control and design activities.
Topics of Lecture No. of hours
- Testing methodology1
- Machine specification & setup1
- Factors influencing tensile properties1
- Data compilation & analysis1
Hands-on Training
- Machine setup0.5
- Test specimens & extensometry0.5
- Parameters setup0.5
- Data logging software0.5
Demonstration
One specimen will be tested for
demonstration purpose at room temperature.
[23] NML
Title
Foundry, Forge and Heat Treatment
About the Programme
The art of metal founding is the
oldest metal forming process, which requires achievement of melt specification and
appropriate moulding. To ensure casting soundness, moulding materials and methodology have
considerable role to play.
The programme, thus, envisages to
deliberate on sand characterization and control, testing of sands and analysis of defects
arising from improper moulding practice. Hands on training are also designed to match with
the theme of deliberations. The concept of forging practice as other method of metal
forming process and heat treatment schedule for the product are also to be discussed in
respect of quality attainment. The course shall be designed for practising foundrymen to
update skill, improving productivity and imparting knowledge in their respective field of
operations.
Topics of Lecture No. of hours
- Sand characterization and control1.5
- Moulding materials and methods1.5
- Casting defects and remedies1.5
- Forging practices1.5
- Heat treatment principles and procedures1.5
Hands on Training
- Testing and characterization of sand2.5
- Moulding practice5
- Forging practice2.5
- Heat treatment practice2.5
[24] NML
Title
Mechanical Working (Extrusion,
Rolling and Wire Drawing)
About the Programme
The roll of mechanical working in
shaping of metals is well known. The understanding of principles and operational
parameters for extrusion, rolling, and drawing thus are of utter importance to personnel
engaged in the field. The programme shall include technical lectures on Ômechanical
workingÕ with the objective of updating skill of operation. Hands on practice also aimed
to build up confidence of the participants exposed to the mechanical working environment.
Topics of Lecture No. of hours
- Extrusion practice1.5
- Rolling practice1.5
- Wire drawing practice1.5
Hands on Training
- Extrusion practice2.5
- Rolling practice2.5
- Wire drawing practice2.5
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