LIFE ENHANCEMENT OF MS COOL SHUTE BY CRYOGENIC TREATMENT & HARD FACING

CONTENTS
INTRODUCTION ABOUT HARD FACING Relation with Welding. Types of Hard Facing Advantage of Hard Facing Disadvantage of Hard Facing Application of Hard Facing Method of Hard Facing What is Cryogenic treatment. Types of Cryogenic treatment. Advantage of Cryogenic treatment. Disadvantage of Cryogenic treatment. Applications of Cryogenic treatment. Relation with welding and Cryogenic Literature Survey. Objectives. Methodology. Work Done. Work to be done. References.

INTRODUCTION ABOUT HARD FACING Hard facing is a metalworking process where harder or tougher materials is applied to a base metal. It is welded to the base material, and generally takes the form of specialized electrodes for arc welding or filler rod for oxyacetylene and TIG welding. Powder metal alloys are used in (PTA) also called Powder plasma welding system and Thermal spray processes , Plasma spray, Fuse and spray etc.

RELATION WITH WELDING

Hard facing of metal can be deposited by various welding methods: Shielded Metal Arc Welding (SMAW) Gas Metal Arc Welding (GMAW), including both gasshielded and open arc welding Ox fuel Welding (OFW) Submerged Arc Welding (SAW) Electro lag Welding (ESW) Plasma Arc Welding (PAW), also called Powder Plasma welding system Thermal spraying Cold polymer compounds Laser Cladding

REASONS OF HARD FACING

i. Companies use hard surfacing products to: ii. Reduce costs - Hard surfacing a worn metal part to like iii. new condition is usually 25 - 75% of the cost of a replacement part. iv. Prolong equipment life - Surfacing extends life 30 - 300 times, depending upon application, as compared to that of a non- surfaced part. v. Reduce downtime - Because parts last longer, fewer shutdowns are required to replace them. vi. Reduce inventory of spare parts - There is no need to keep numerous spare parts when worn parts can be rebuilt.

CHOOSING FACTORS OF HARD FACING PROCESS

Nature of Work to be Hard faced:- Hard facing can be applied by a number of welding processes. In most cases, the equipment is identical or similar to that used for structural welding. Selection of the most suitable welding process for a given job will depend on a number of factors including Function of the component: What type of hard facing alloy is required; some processes are limited to certain alloy types. Base metal composition: Different processes may have different heat inputs which render them unsuitable for certain base metal types, e.g. manganese steels require low heat input and so gas hard facing would not be suitable. Size and shape: Surfacing large areas with gas or manual arc may often prove uneconomical. Parts of irregular shape may not be suitable for automatic applications. Accessibility: It may not always be possible to manipulate heavy automatic equipment into areas where work must be done. Also, out-of- position welding will limit the choice of processes. State of repair: Large badly worn components requiring heavy rebuilding would be best suited to processes with high deposition rates. Number: If a large number of the same or similar items are to be hard faced, an automatic process would be most suited.

TYPES OF HARD FACING

Manual Metal arc Welding Shielded Metal Arc Welding Shielded Metal Arc Welding Submerged Arc Welding

ADVANTAGE OF HARD FACING

Advantage of Hard facing

Hard facing is a low cost method of depositing wear resistant surfaces on metal components to extend service life. Although used primarily to restore worn parts to usable condition. Hard facing is also applied to new components before being placed into service. Hard facing is addition to extending the life of new and worn components. Fewer replacement parts needed. Operating efficiency is increased by reducing downtime. Less expensive base metal can be used. Overall costs are reduced.

DISADVANTAGES Dilution - two or three layers are needed to obtain maximum wear properties Low efficiency wear properties Material thickness sub arc hard surfacing limited to larger parts that lend themselves to automatic application Extremely high dilution multiple layers are needed for maximum wear properties High heat input - can distort parts Versatility - limited to shop applications due to automatic equipment required Flux required - additional expense and special welding equipment required.

APPLICATIONS OF HARD FACING

Steel and iron industry Brick fabrication Sand and gravel crushing, conveying Chemical Coal-fired power plants Mixers for concrete and asphalt Glass industry Agriculture Timber industry Recycling

INTRODUCTION OF CRYOGENIC TREATMENT

Cryogenics is defined as that branch of physics which deals with the production of very low temperatures and their effect on matter a formulation which addresses both aspects of attaining low temperatures which do not naturally occur on Earth, and of using them for the study of nature or the human industry. In a more operational way it is also defined as the science and technology of temperatures below 120 K.

DEFINITION OF CRYOGENIC : -

Temperatures are defined as those below 120 K (153C). The safety criteria established in this document apply to the cryogens in use in the Physics Division, namely liquid helium and nitrogen. Flammable fluids, such as hydrogen, and reactive liquids, such as oxygen and fluorine, are excluded. The use of flammable cryogens will require special approval procedures not outlined in this document Cryogenic Separation is a distillation process that occurs at temperatures close to -170 degrees Celsius. A cryogenic air separation plant is expensive and large; the distillation column is several stories high and must be well-insulated. Consequently, it only becomes economically feasible to separate air this way when a large amount is needed. Cryogenic separation is also capable of producing much purer nitrogen than either of the other two processes because the number of trays in the distillation column can be increased.

TYPES OF CRYOGENIC TREATMENT

Shallow cryogenic treatment Deep cryogenic treatment

SHALLOW CRYOGENIC TREATMENT

Shallow cryogenic treatment is done using 4-10-4 cycle The temperature of cryogenic chamber is ramp down from atmospheric to -110 degree in 4 hrs. The soaking period is 10 hrs. The temperature of cryogenic chamber is ramp up from -110 degree to atmospheric temperature in another 4 hrs.

DEEP CRYOGENIC TREATMENT

Deep cryogenic treatment is done using 9-18-14 cycle. The temperature of cryogenic chamber is ramp down from atmospheric to -184 degree in 9 hrs. The soaking period is 18 hrs. The temperature of cryogenic chamber is ramp up from -184 degree to atmospheric temperature in another 9 hrs.

APPLICATION OF CRYOGENIC

INDUSTRIAL APPLICATIONS Cryogenic treatment works on Reamers (carbide or HSS), Tool Bits, Tool Punches (carbide or HSS), Milling Cutters, Cutting Tools and Dies. In all cases, this treatment will result a stronger and more wear resistant metal. AUTOMOTIVE APPLICATIONS MEDICAL APPLICATIONS Cryogenics has also been used by the medical industry. Surgical tools used by doctors, surgeons, dentists, and other specialists can all benefit from the increased wear resistance of the treatment. Surgical tools, like many other industrial tools, are expensive to replace, so cryogenic treatment can really pay off. In addition, many surgical implants are also treated. This helps prevent the part from wearing, it increases the tensile and bending strength of the part, as well as reducing the likelihood of mircofracturing. Cryogenics really is a healthy choice for the medical field. OTHER APPLICATIONS Cryogenics is used to treat many types of sports equipment, the most common being golf clubs. Because cryogenics increases the molecular density of treated materials, it improves the distribution of energy (in this case kinetic energy) through the object. The treatment also increases the rigidity of the metal, which in this case might affect the shaft of the golf club. Combined, the increases in kinetic energy distribution and rigidity of the shaft make for a longer and straighter drive. Basically, the club has significantly less give, so the performance increases. This type of treatment can be used on many other types of sports equipment where the same energy and rigidity characteristics would benefit the user. Cryogenics is also used to treat many types of musical instruments. Because treated materials are denser, the surface area of an object is affected. Inside the instrument, the surface is smoother than an untreated instrument. This change in surface characteristics changes the quality of sound that the instrument can produce. In most cases, a crisper, clearer sound is achieved, especially amongst the brass section of instruments. The same type of effect can also be useful in stringed instruments by treating the strings themselves. There really is no end to the numerous ways cryogenics can assist, both at work and at play.

LITERATURE SURVEY
Authors name,

S. N.
Title of Paper

Journal name & Date of

Abstract/work

Result

done /Summary

1 Improvement in High Stress Abrasive Wear Property of Steel by Hard facing

publication S. Kumar, D.P. Mondal, H.K. Khaira, and A.K. Jha (Submitted 5 August 1999; in revised form 30 August 1999) Keywords hard facing surfaces, mild steel, surface teratology, teratology, wear In engineering industries, abrasive wear is probably the most significant cause of mechanical damage of equipment components coming in contact with abrasive/erosive bodies. Results and Discussion Material and Microstructure The abrasive wear characteristics of the material are strongly governed by its microstructure. It is evident from this figure that the microstructure consists of a pearlitic phase in the matrix of ferrite. The ferrito-pearlitic microstructure with elongated ferrite grains of mild steel plate indicates that the steels are in hot worked condition.

S. N.

Title of Paper

Authors name, Journal name & Date of publication

1. Dr.D.P. Girish1, Principal, Kodaikanal Institute of Technology, Machur, Kodaikanal624104, Tamil Nadu. email:omganesha16 @yahoo.co.in 2.Dr.N.Govindraju, Principal, GSSIT, Bangalore. Karnataka. Date of Publication 2007

Abstract/work done /Summary

Result

Microstructure and erosive properties of cobal arc /mild Steel surface hard coating

The Cabal arc hard faced Fe-based surface composite coating were fabricated by arc welding technique. Cobol arc electrodes were used for hard facing on the mild steel substrate. The microstructure, phase structure and erosive properties were investigated by means of scanning electron microscopy and slurry erosion test machine. The results showed that Cobal arc significant improvement in erosive resistance between Cobol arc and conventional weld deposits. The Cobol orchard faced material showed better hardness and erosion properties comparable

Results and Discussion The microstructure of Cobal arc clad layer consists of uniformly distributed and some needle-like carbide phases and eutectoid matrix with very fine carbide precipitates . But in other hand the microstructure of the Cobal arc clad layer shows a typical dendrites microstructure. Near the surface of the clad layer, equiaxed dendrite is generally observed, while in the center of the clad layer, the

S. N.

Title of Paper

Authors Abstract/work Result name, done Journal name /Summary & Date of publication
K. Vadivel & R. Rudramoorthy Received: 25 December 2007 / Accepted: 3 June 2008 / Published online: 3 July 2008 # SpringerVela London Limited 2008 Cryogenic treatment has been acknowledged in several researches as a means of extending the tool life of many cutting tools. Studies on cryogenically treated (CT) cutting tools show micro structural changes in the material that can influence the life of the tools significantly. Tungsten carbide cutting tools are now commonly used in the industry. Comparison of surface roughness of work specimen Comparison of power consumption Comparison of flank wear

3.

Performance analysis of cryogenically treated coated carbide inserts

S. N.

Title of Paper

Authors name, Journal name & Date of publication

Alava L.A. Cryobest International, S.L. Vitoria, Spain 2009

Abstract/work done /Summary

Result

4.

Multistage cryogenic treatment of materials: process fundamentals and examples of application

The multistage cryogenic process is an evolution from the conventional cryogenic treatments of materials. It needs shorter process time achieving the same or even better results. This paper introduces some basic fundamentals of these treatments, their effects and applications, the equipment, etc. Some examples with different materials and from different industrial sectors are also presented as well as some brief comments about R&D and future trends of the technology.

The treatment of materials at cryogenic temperatures is a promising and cost effective technology that, although is not new, is still hardly known and used. Only a small part of its potential has been developed. The metallurgical fundamentals are not fully understood and the cryogenic treatments have been, and still are, developed in an empirical way. During the last years the research activity in this field has significantly increased and nowadays it is also more global than in the past.

S. N. `

Title of Paper

Authors name, Journal name & Date of publication

P. I. Patil Department of Mechanical Engineering, Sandip foundations Sandip Institute of Technology & Research Center, Nasik(, India EMail : pipatil1955@gmail.com R. G. Tated Principal, Marathwada Institute of Technology, Aurangabad, IndiaEMail:rgatated@y ahoo.com Date of Publication : 2010

Abstract/work done /Summary

Result

Comparison of Effects of Cryogenic Treatment on Different Types of Steels : A Review

Cryogenic treatment (CT) is the supplementary process to conventional heat treatment process in steels, by deep freezing materials at cryogenic temperatures to enhance the mechanical and physical properties of materials being treated. Cryogenic treatment (CT) of materials has shown significant improvement in their properties .Various advantages like increase in hardness, increase in wear resistance, reduced residual stresses, fatigue Resistance, increased dimensional stability, increased thermal conductivity, toughness, by transformation of retained austenite to marten site, the metallurgical

The Conclusions of this review study are as follows: 1 The complete process of Cry-Heat-Treatment must be as follows : austenitizing, quenching, DCT and tempering; preferably immediate one-by-one sequentially in a cycle. 2 Prior to DCT austenitizing temperatures plays vital role for improving the properties of the steel like wear resistance, hardness, toughness etc. Each material to be assessed separately for selecting the optimum austenitizing temperature and should be co-relate to the required desired properties after DCT. 3 More useful work has

METHODOLOGY
MMAW process (Hard Facing process) Mannual metal arc welding.
Principles of MMAW An electric arc is maintained between the end of a coated metal electrode and work piece. The flux covering melts during welding and forms gas and slag to shield the arc and molten weld pool The flux also provides a method of adding scavengers, deoxidizers and alloying elements to the weld metal

WORK DONE
Introduction of Hard Facing. Type of Hard Facing. Advantage & Disadvantage of Hard Facing. Study for the MS material. Introduction of Cryogenic treatment. Type of Cryogenic treatment. Application of Hard Facing. Application of Cryogenic treatment. Advantage & Disadvantage of Cryogenic treatment. Relation with Hard Facing & Cryogenic treatment. Literature Review. Objectives. Methodology.

OBJECTIVES
1. To increase the life of M.S. coal Shute under impact abrasive wearing by Hard facing 2. To study the influence of cryogenic treatment on hard-faced M.S. coal Shute.

WORK TO BE DONE
Material Procurement. Process to be finalized. Physical Verification. Observations. Experimentations Work. Calculation. Testing : - Micro Hardness Test, Wear Test, Dilution Test, XRD test, Micro Structure, Spectrographic test. Result.

REFERENCES
Dr. R. G. Stated, Dr. S. R. Kajale, Dr. Kumar Iyer, Improvement in tool life of cutting tool by application of deep cryogenic treatment, 7th International tooling conference held at Polytechnic di Torino, Italy on 2-5 May 2006, pp. 135-141 National Institute of Standards and Technology, Boulder, Colorado Published in: The MacMillan Encyclopaedia Of Chemistry, New York, 2002 Barron, R.F.; Mulharn, C.R. Cryogenic Treatment of AISI T8 and C1045 Steels. Cryogenic Engineering Conference, Madison, WI, August 21.24, 1979; Plenum Press: New York, 1980. Jha, A.R. Cryogenic Technology and Applications; ButterworthHeinemann: Oxford, UK, 2006; 1.21.

THANKS