Ongoing Projects

S.No. Number Start Date End Date Project Leader Category Type Core Area Sub Area
1NML/IPSG/2018/2019/79377 ()2018-09-302019-10-31Minal ShahScholastic ResearchFull tenure(1 year)Materials EngineeringAlloy Development

Title: Study on Evolution of low temperature nanobainitic steel-Module 3

Abstract: With the increasing demand on energy saving, it is of necessity to develop high performance low cost steels having extraordinary high strength along with good toughness. The possibility of obtaining steels with nano size laths (20-50nm) of bainite by isothermal transformation treatment at low temperature is set forth. In this respect detail work has to be done to accelerate the kinetic of bainitic transformation by processing parameters and economical alloying elements. Role of Cu on mechanical properties of nanobainite steel has to be studied. Continuous cooled bainite has to studied to accelerate the kinetics. Modeling and Simulation of Isothermal and Continuous cooled bainite through Matlab has to be done.

2NML/IPSG/2018/2019/97183 ()2018-10-012019-10-31SNEHASHISH TRIPATHYScholastic ResearchFull tenure(1 year)Materials EngineeringAlloy Development

Title: Study of wear and RCF mechanism in high carbon nano-pearlitic rail steel.

Abstract: The service life of rail steels is dictated by the wear and rolling contact fatigue resistance, which further depend upon the hardness and the toughness of the steel. Both of these properties being inversely dependent upon the interlamellar spacing of pearlite, the refining of pearlitic microstructure becomes an important aspect in the rail steel processing. The previous two modules thus aimed at attempting for nano –pearlitic microstructure in the hypereutectoid regime and evaluation of its mechanical and tribological properties. The promising results in terms of high hardness and excellent work hardening obtained in the previous modules lead to the further evaluation of the developed alloy for Rolling Contact Fatigue resistance. The synergistic effect of high hardness and good work hardening in the developed pearlitic grade is expected to enhance the RCF resistance of the developed grade. Therefore, in continuation with the previous module the present module would focus upon the Rolling Contact Fatigue evaluation of the designed alloy. This would also involve detailed microstructural characterization to detect the deformation behaviour and failure mechanisms in the material.

3NML/IPSG/2019/2020/13886 ()2019-04-012020-03-31KRISHNA KUMARScholastic ResearchFull tenure(1 year)Extractive MetallurgyPyrometallurgy

Title: Heat Transfer Modelling of condensation behaviour of metal vapours during distillation for quantitative analysis of condenser design (module III)

Abstract: During extraction and refining of metals using distillation techniques, the condensation behavior of metal vapors in the condenser is critical to achieving operational efficiency. In earlier works carried out in module I and II, a mathematical heat transfer model had been developed to predict the growth rate of a single liquid metal drop during dropwise condensation (DWC) of Mg metal vapours in Electrothermal process. The growth rate of Mg droplet during DWC had been numerically investigated using theoretical heat transfer models, developed for both homogeneous and heterogeneous DWC. Also, film condensation heat transfer modelling studies has been commenced with single phase laminar boundary layer concept and similarity solution method has been applied to solve the conservation equations in the condensing magnesium film. The proposed module III will be carried out to study the two phase metal vapour condensation phenomena and the associated heat transfer. The single phase film condensation heat transfer model will be extended to address the two-phase boundary layer flow problem in laminar film condensation of metal vapours, incorporating the effect of the shear forces at the liquid-vapour interface present due to induced motions of the metal (Mg, Zn) vapor. This complex two-phase flow problem and the associated heat transfer will be modelled using a coupled multi-physics approach. Non-condensable gases markedly reduce the condensation heat transfer rates. The effect of non-condensable gas on laminar film condensation of a liquid metal on an isothermal vertical surface with forced vapor flow will also be modeled keeping in view of its practical/industrial implications. Also, the experiments will be carried out to understand the separation behaviour based on condensation phenomena and associated heat transfer mechanisms. The proposed module will be consisting of a two phase condensation heat transfer modeling, the distillation equipment commissioning and installation followed by experiments under various operating conditions. This study will be useful in developing an understanding of the separation of metals based on their boiling and condensation behaviour, which may be useful to carry out distillation refining of metals.

4NML/IPSG/2019/2020/22477 ()2019-04-012020-03-31Ranjeet Kumar SinghScholastic ResearchFull tenure(1 year)Mineral ProcessingBeneficiation

Title: Study of Particulate Flow in Centrifugal Force Field with Continuous Fluid Current (Module-III)

Abstract: Aim of the present study is to estimate the settling kinetics of suspensions of particles inside the centrifugal concentrator. In Module-II, a mathematical model was developed for estimation of settling velocity of particle for free settling condition. In the present study (Module-III), developed model is extended for hindered settling conditions. Sensitivity analysis of interaction forces will also be carried out. Developed model will be validated with experimental results, which was performed in Module-I. An attempt will also be made to fabricate the Falcon bowl,if favorable results will obtained.

5NML/IPSG/2019/2020/42298 ()2019-04-012020-03-31NIMAI HALDARTechnology DevelopmentFull tenure(1 year)OthersCSIR-800

Title: Energy efficient coal and oil based brass melting furnace for the artisans of West Bengal

Abstract: In the previous projects OLP-0331, OLP-0299 & OLP-0249 CSIR-NML has developed 10 kg & 50 kg coke-based brass melting furnace and transferred 2 number of technology to (i) Yugantar Bharati, Ranchi, Jharkhand and (ii) West Bengal Khadi & Village Industries Board, MSME & T Dept. Govt. of W.B. Subsequently, CSIR-NML also conducted several training cum demonstration program to the artisans and District Information centre officials. They have shown their interest for the know-how to the rest part of west Bengal. But they require coal based (locally available coal) and oil based brass melting furnace of capacity 500 kg and detailed project report for its implementation. They also require technological intervention of manufacturing of plate (Brass & BronzeThala) through rolling-forging routes and modification pre-heating furnace for rolling operation. In this project, it is proposed to develop coal based (100 kg capacity) and oil based (500 kg capacity) brass melting furnace for the artisans of West Bengal. It is also proposed to develop optimized process parameters for rolling of ingot to obtain circular plate.

6NML/IPSG/2019/2020/44107 ()2019-04-012020-03-31KOMAL SINGHScholastic ResearchFull tenure(1 year)Surface EngineeringSurface Modification

Title: Development of high efficiency Tin Selenide based Thermoelectric and optically tunable coatings for alternative energy harvesting from different industrial applications (Module I).

Abstract: Thermoelectric and optically tunable coatings are very much required for alternative energy harvesting from different industrial applications. They are considered to be great resource for the alternative energy to tap many waste heat energies in different industrial processing right from metallurgical industry to electronic industry. Among different thermoelectric materials selenides have shown reasonably higher figure of merit (ZT). A higher figure of merit can be obtained in single crystal however they are very brittle and hence limits the device applications. The polycrystalline bulk sample show much lesser efficiency. Hence thin film is another alternative as the possibility of growth of epitaxial films are there which can lead to higher figure of merit. Tin selenide (SnSe) in bulk form have shown potential for a good thermoelectric and optical properties. The proposed research aims for the development of thermoelectric SnSe coating with high figure of merit and optically band gap tunable coatings. The investigation of the different mechanisms and structure property correlation of thermoelectric, thermal, electrical, structural and microstructure.

7NML/IPSG/2019/2020/71587 ()2019-04-162020-04-15Swapna DeyScholastic ResearchFull tenure(1 year)Surface EngineeringCorrosion

Title: Hydrogen assisted degradation and fracture in pipeline steel (Module 2)

Abstract: Pipeline steels are widely used for transportation and distribution of oil and natural gas for long distances, and the hydrogen assisted degradation is one of the issues that can affect the structural integrity of these pipelines during long term operation. Pipeline steels can pick-up hydrogen during transport of sour crude oil and other petroleum products. The presence of H2S, CO2 and brine in crude oil not only enhance the corrosion rate but also lead to environmental fracture assisted by enhanced uptake of hydrogen (H) atoms in steels. Moreover, external environmental conditions cause free corroding processes, where hydrogen can be generated on the metal surface as a result of the cathodic counterpart of the anodic dissolution reaction. Furthermore, under service conditions when cathodic protection system is in place, hydrogen charging of pipeline steels is also possible. As result, there is concern of structural integrity of aging buried pipelines having cathodic protection. The proposed work will assess the effect of hydrogen absorption and permeation in pipeline steel by cathodic hydrogen charging in NACE solution and in near neutral pH (NS4) solution, which simulate real operating environment. Therefore, the aim of the study is to obtain realistic data for development of hydrogen embrittlement criteria of steels employed in oil/gas industries. Corrosion is one of the most predominant causes of pipeline failures in oil and gas production, which are related to the physical and chemical factors as well as environmental conditions. Therefore, the study of corrosion by electrochemical methods is also necessary. This work will investigate the corrosion behaviour of pipeline steel by different electrochemical methods (potentiodynamic polarization, electrochemical impedance spectroscopy (EIS)). The proposed research work will extend to study the effects of hydrogen on fracture toughness of the material with the aim to provide an explanation for the hydrogen effect on fracture resistance.

8NML/IPSG/2019/2020/84292 ()2019-04-012020-03-31Mamta SharmaThematic ResearchFull tenure(1 year)Mineral ProcessingPetrography & Process Mineralogy

Title: Study on effect of coal maceral on plastic behavior of different coking coal

Abstract: Quality of coke is vital for blast furnace operation. Based on physical, chemical rheological and petrographic properties of different coals, a proper selection of coal for coke making can be carried out. Petrographic studies of coal are playing an important role in characterizing the coking coal. Coal contains organic reactives and organic inerts and mineral matter. Reactive component undergoes plastic phase during heating above 350ºC, while the reactive component becomes plastic and attains its fluidity, its engulfs both the inerts and the mineral matter which are acts as bonding phase. For coke making, coals should produce adequate quantity of plastic phase, which is dependent on the reactive present in coal and its rank. High inert coals produce inadequate bonding and extra low inert coals suffer from vigorous devolatilisation resulting in excessive fissuring, both adversely affecting coke quality. The size of inerts should preferably be smaller than that of reactives so that the bonding is better. Our objective is to reveal the relationship between petrographical and coking properties of coal. Petrography, plasticity, dilation and swelling index were done for obtaining the relationship. It is evident that petrographic components have a major role in plasticity of coal and coking property as well.

9NML/IPSG/2019/2020/90386 ()2019-04-012020-03-31Mr. Gaurav Kumar BansalScholastic ResearchFull tenure(1 year)Materials EngineeringAlloy Development

Title: Development of Low Carbon Bainitic Steels (Module-II)

Abstract: The lower bainitic transformation in high and medium carbon steel has shown to achieve excellent strength-ductility combinations due to presence of nanobainite (20-40 nm). However, transformation kinetics has been found to be slow due to low temperatures involved. Subsequently, researches on low carbon steel (0.25-0.35 wt.%) with enhanced substitutional elements have resulted in coalescence of bainitic plates (120-150 nm) that lead to reduction in toughness of steel. Also, the reasons behind such coalescence are not fully understood. The possible options to further refine the bainite are modification in chemical composition of steel, altering the heat treatment schedule and controlling the prior austenite grain size through deformation of austenite. Also, the possibilities to achieve nano-bainite in steel containing carbon < 0.2 wt.% has not been given due consideration. However, the low carbon content allows broader application avenues. Therefore, the present work aims at designing a suitable alloy with carbon content < 0.2 wt.% and to study the bainite transformation through various processing routes so as to achieve highly refined bainite.

10NML/IPSG/2019/2020/94496 ()2019-04-152020-04-14Avanish Kumar ChandanScholastic ResearchFull tenure(1 year)Materials EngineeringAlloy Development

Title: Microstructural evolution and deformation behavior of high entropy alloys at ambient and sub-ambient temperatures

Abstract: Abstract: Owing to the vast latitude offered by the High Entropy Alloys (HEAs) in terms of versatility in alloy design and microstructure, the research in HEAs is trending worldwide. Since their advent more than a decade ago, HEAs have been attracting tremendous research attention due to attractive properties over conventional engineering materials, such as ultra-high fracture toughness exceeding that of most metals and alloys, excellent strength comparable to that of structural ceramics and metallic glasses, superconductivity, adequate corrosion resistance etc. The equi-atomic, fully FCC structure, FeMnCrCoNi alloy is one of the most successful HEA with exceptional mechanical properties at cryo temperatures. However, the room temperature properties of the same is not attractive. The reason for lucrative mechanical properties of this alloy is the occurrence of nano-twins at cryo temperature but not at room temperature during deformation. Deformation behaviour of FCC system is principally governed by stacking fault energy (SFE). SFE on the other hand is dependent on composition of the system and service temperature. The present study aims to design new lean alloys based on the SFE of the resulting alloy. The effect of composition vis a vis SFE on the deformation behaviour of the alloy will be studied. Role of various SFE dependent deformation characteristics on the final mechanical properties at ambient and sub-ambient temperatures will be investigated.

11NML/IPSG/2019/2020/95507 ()2019-04-012020-03-31Md Murtuja HusainThematic ResearchFull tenure(1 year)Surface EngineeringSurface Modification

Title: Enhancement of wear, abrasion and corrosion resistance through friction stir processed ceramic particle reinforce magnesium AZ 31 alloy

Abstract: Friction-stir processing (FSP) is based on the basic principles of Friction Stir Welding (FSW), which is an emerging surface-engineering technology that can locally eliminate casting defects and refine microstructures. Thus the process improves strength, ductility, resistance to wear, corrosion resistance, fatigue limit and formability. FSP can be specifically applied to develop fine-grained microstructures throughout the thickness of metal surface, to impart super plasticity and ensure homogeneous distribution of reinforced particles. Metal matrix composites are modern engineering materials where overall microstructure of the material is modified by reinforcing secondary material in the form of powder particles into the base materials and the characteristics of core effect without any changes in compositions. Magnesium is the lightest of all light metal alloys and therefore is an excellent choice for aerospace and automobile industries applications when strength to weight ratio is important. FSP process offers many advantages over the other processing techniques like refinement of coarse grains in the matrix to fine grains, precipitate dissolution, porosity and defect elimination, breaking up of secondary phases and dendrites. An advanced solid state processing technique (FSP) is employed to counter the conventional technique problems as in which the processed zone does not melt and recast. Therefore friction stir processing of magnesium with reinforcement of particle is chosen in the present investigations.

12NML/IPSG/2019/2020/9909 ()2019-04-012020-03-31Sunati MohantyScholastic ResearchFull tenure(1 year)Mineral ProcessingBeneficiation

Title: Study of dewatering behaviour of fine particles in hydrocyclone (Module-II)

Abstract: In mineral processing industries, most of the separation processes involve substantial quantities of water and the final concentrate/tailing has to be separated from pulp in which water-solid ratio is high. So dewatering of fine particles, separation of solid from liquid is an important aspect in mineral processing. But dewaering of fine particle under gravitational force is very sluggish. Keeping the advantage of centrifugal sedimentation, hydrocyclone is found to be the efficient solid-liquid separator. In this regard, hydrocyclone is found to be useful as a thickener. To understand the effect of inputs on dewatering response, a data driven neural network modeling of hydrocyclone is proposed.

13NML/IPSG/2019/2020/99781 ()2019-04-012020-03-31Ganesh ChalavadiThematic ResearchFull tenure(1 year)Mineral ProcessingBeneficiation

Title: Beneficiation of tribocharged particles on multiproperty seperator

Abstract: The existing multi property separator fabricated recently consists of inclined deck on which the feed particles flows.The fine particles gets tribo charged due to their attrition with screen and other particles.Due to high velocity air maintained on Multi property separator they leave the system. The present project aims at treating that tribo charged particles with a tribo charged separator. This will include extra recovery of valuable concentrate in feed.