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    Materials: To Form Final Product 1. Ferrous Materials 2. Non Ferrous Materials

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    Balakumar
    The document discusses different materials used in manufacturing final products, including ferrous and non-ferrous materials. It also discusses various steel grades based on their chemical composition and specifications, as well as welding processes, types of welds, and methods for non-destructive testing of welds.

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    Materials: To Form Final Product 1. Ferrous Materials 2. Non Ferrous Materials

    Uploaded by

    Balakumar
    1K views30 pages
    The document discusses different materials used in manufacturing final products, including ferrous and non-ferrous materials. It also discusses various steel grades based on their chemical composition and specifications, as well as welding processes, types of welds, and methods for non-destructive testing of welds.

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    Materials

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    The document discusses different materials used in manufacturing final products, including ferrous and non-ferrous materials. It also discusses various steel grades based on their chemical composition and specifications, as well as welding processes, types of welds, and methods for non-destructive testing of welds.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    1K views30 pages

    Materials: To Form Final Product 1. Ferrous Materials 2. Non Ferrous Materials

    Uploaded by

    Balakumar
    The document discusses different materials used in manufacturing final products, including ferrous and non-ferrous materials. It also discusses various steel grades based on their chemical composition and specifications, as well as welding processes, types of welds, and methods for non-destructive testing of welds.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
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    MATERIALS

    TO FORM FINAL PRODUCT


    CLASSIFICATION:
    1. FERROUS MATERIALS
    2. NON FERROUS MATERIALS
    Crystal Structures
    • In a solid metal, the atoms tend to align themselves into
    orderly lines, rows, and layers to form three dimensional
    crystalline structures.
    • "Unit cell".
    • Body-centered cubic (BCC),
    • Face-centered cubic (FCC),
    • Body centered tetragonal (BCT), and
    • Hexagonal close-packed, (HCP).
    Basic Metal
    Structures

    I. Simple Cubic II. Body Centered Cubic III. Face Centered Cubic
    (BCC) (FCC)

    Fe, Cr Al, Cu, Ni


    STEEL MATERIALS
    IRON & CARBON
    MOST COMMONLY USED
    INCREASE HARDNESS , WEAR RESISTANCE ETC.
    LOW , MEDIUM, HIGH CARBON
    ALLOYING ELEMENTS
    ELEMENTS WHICH IS ADDED TO ENHACE THE
    PROPERTIES OF THE MATERIAL
    MOST COMMON ALLOYING ELEMENTS
    1. CARBON
    2. MANGANESE
    3. CHROMIUM
    4. SILICON
    5. NICKEL
    6. MOLYBDENUM
    7. VANADIUM
    8. TUNGSTEN
    9. COPPER
    Manufacturing Codes
    • I S -Indian Standard
    • IBR – Indian Boiler regulations
    • BS – British Standard
    • DIN – German Standard
    • JIS - Japan Standard
    • GHOST – Russian Standard
    • ASME – American Society for Mechanical Engineers
    • ASTM – American Society for Testing Materials
    • AWS – American Welding Society
    Chemical Material Specification – Product
    P.No Composition Plate Pipe Tube
    SA178 Gr.D
    Carbon steel SA 515 Gr.60/70
    P1 SA 106 Gr.B SA210 Gr.A1
    (C,Mn,Si,S,P) SA 516 Gr.60/70
    SA210 Gr.C
    SA204 Gr.A
    P3 0.5%Mo SA335 P1 SA209 T1
    SA204 Gr.B
    1.25%cr,
    P4 SA387 Gr 11/12 SA 335 P12 SA213 T11
    0.5%MO
    2.25%Cr,
    P5A SA387 Gr22 SA335 P22 SA213 T22
    1%Mo
    5%Cr,
    P5B SA 387 Gr5.Cl.1 SA335 P5 SA213 T5
    0.5%Mo
    9%Cr,
    P5B SA387 Gr.91.Cl2 SA335 P91 SA213 T91
    1%Mo,V
    Chemical Material Specification – Product
    P.No Composition Plate Pipe Tube
    SA240Type304 SA312TP304 SA213TP304
    P8 18%Cr,8%Ni SA240Type304L SA312Tp304L SA213Tp304L
    SA240Type304H SA312Tp304H SA213Tp304H

    SA240Type310s SA312Tp310S SA213Tp310S


    25%Cr,20%Ni
    SA240Type310H SA312Tp304H SA213Tp310H

    SA240Type316 SA312Tp316 SA213TP304


    16%Cr,12%Ni,2
    P8 SA240Type316L SA312Tp316L SA213Tp304L
    Mo
    SA240Type316H SA312Tp316H SA213Tp304H

    SA240Type321 SA312Tp321 SA312Tp321


    18%Cr,8%Ni
    SA240Type321H SA312Tp321H SA312Tp321H

    SA240Type347
    18%Cr,10%Ni, SA312Tp321 SA213Tp321
    SA240Type347H
    P6/P Cb SA312Tp321H SA213Tp321H
    7
    SA240Type321
    13 % Cr - -
    SA240Type321H
    SELECTION OF STEEL GRADES
    – Strength/ weight ratio.
    – Cost per mass or per area.
    – Melting point.
    – Corrosion and oxidation resistance.
    – Stress Corrosion.
    – Corrosion Fatigue.
    – Compatibility.
    – Electrical and magnetic properties.
    – Fabrication properties..
    – Complexity, section and thickness, weldability.
    Miller Electric Mfg. Co.

    10
    WELDING CLASSIFICATION
    1. FUSION WELDING
    The surfaces of two components to be joined
    are cleaned, placed close together and heated
    while being protected from oxidation.

    2. SOLID PHASE PROCESS


    Friction welding is the main process in this
    class and is widely used to join asymmetric
    components in two different types of steels.
    Types of welding

    welding

    Solid state welding


    Fusion welding
    1. Resistance welding
    2. Friction welding Chemical energy
    3. Diffusion welding
    4. Flash welding 1. Oxyacetylene welding
    5. Ultrasonic welding 2. Oxyfuel gas welding
    6. Explosion welding

    Consumable Non consumable


    electrode electrode Other processes

    1. Gas metal arc welding 1. Gas tungsten arc


    2. Shielded metal arc welding welding 1. Laser beam
    3. Submerged arc welding 2. Atomic hydrogen welding
    4. Flux cored arc welding welding 2. Thermit welding
    5. Electrogas welding 3. Plasma arc 3. Electron beam
    6. Electroslag welding welding welding
    SHIELD METAL ARC WELDING
    GAS METAL ARC WELDING
    GAS TUNSTEN ARC WELDING
    Types of Welded Joints
    • Butt joint
    • Corner joint
    • Edge joint
    • Lap joint
    • T joint
    TYPES OF WELDS
    1. GROOVE WELD 8. SLOT WELD
    2. FILLET WELD 9. SURFACING WELD
    3. FLANGE WELD 10. BACK WELD
    4. EDGE WELD 11. BACKING WELD
    5. SPOT WELD
    6. SEAM WELD
    7. PLUG WELD
    PARTS OF A GROOVE WELD
    PARTS OF A FILLET WELD
    ELEMENTS OF WELDING SYMBOLS
    1. REFERENCE LINE
    2. ARROW
    3. BASIC WELD SYMBOLS
    4. DIMENSIONS AND OTHER DATA
    5. SUPPLEMENTARY SYMBOLS
    6. FINISH SYMBOLS
    7. TAIL
    8. SPECIFIC PROCESS
    WELDING SYMBOLS
    WELD SYMBOLS
    WELD DISCONTIUITIES
    1. POROSITY
    2. CRACKS
    3. INCOMPLETE PENETRATION
    4. LACK OF FUSION
    5. UNDERCUTS
    6. INCLUSIONS
    7. SPATTER
    TESTING

    DESTRUCTIVE TESTING

    NON DESTRUCTIVE TESTING


    NON DESTRUCTIVE TESTING
    REASONS FOR USING NDT
    1.ENSURES PRODUCT RELIABILITY
    2.CUSTOMER SATISFACTION
    3.CONTROLLING MANUFACTURING PROCESS &
    COST
    4.MAINTAIN UNIFORM QUALITY LEVEL
    5.AIDS IN PRODUCT DESIGN
    6.SAFETY & PREVENTS ACCIDENTS
    NDT APPLICATION
    POWER GENERATION
    PIPELINE
    AUTOMOBILES
    AEROSPACE
    DEFENCE
    REFINERY
    SHIPPING ETC.
    NDT METHODS
    1. VISUAL TESTING
    2. LIQUID PENETRANT
    3. MAGNETIC PARTICLE
    4. RADIOGRAPHY TESTING
    5. ULTRASONIC TESTING
    6. EDDY CURRENT TECHNIQUES
    7. ACOUSTIC EMISSION TECHNIQUES
    VISUAL INSPECTION

    APPEARANCE OF THE FINISHED PRODUCT

    DETECT SURFACE DISCONTINUITIES

    PROCEDURES TO BE FOLLOWED
    PENETRANT TESTING
    PRINCIPLE
    CAPILLARITY & REVERSE CAPILLARITY

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