metallic foams: current status and future prospects

9VOL. 9 NO. 4 AUGUST 2006 IIM METAL NEWS

*The authors are presently engaged in Metal Extraction & Forming Division,National Metallurgical Laboratory, Jamshedpur-831007, India. e-mail:[email protected]

IntroductionThe temptation behind the development of metal foams isdue to their unique combination of physical and mechanicalproperties such as high stiffness, low specific weight, highgas permeability, low thermal conductivity, unusual acousticproperties, high impact absorption capacity and goodelectrical insulating properties. The potential applicationsof metal foams has been envisaged to be in the area ofautomotive industries, light weight construction materials,silencers, flame arrester, heaters and heat exchangers,catalysts and electrochemical applications, military armourvehicles and aircraft industries [1-5].

A foam is defined as a uniform dispersion of a gaseousphase in a liquid, separated by a thin film of liquid making acell or pore. This morphology when preserved in solid stateis known as solid foam or cellular solid. When we talk aboutmetal foam, it is understood to have uniformly distributedgas pores in solid metal with volume fraction in the range of40-98%. If we consider the structural aspect of metal foams,there are three most common cell structures, namely, opencell structure, closed cell structure [1] and a combination ofthe two [6]. Recently, a novel structure has been developed,which is known as lotus-type growth structure [7,8]. The opencell structures incorporate interconnected pores, whereas,in closed cell structures, pores are surrounded by a metallicthin wall. The lotus-type morphology consists of longcylindrical pores aligned in one direction. The representativefoam structures of the above morphologies are shown infigure 1 .

Metallic Foams: Current Status and Future ProspectsV. C. Srivastava* and K. L. Sahoo*

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Review Articles

Depending upon the requirements, several metals and alloyfoams have been developed in the last three decades, e.g.,Al, Al-Si, Al-Mg [1], Cu [7-10], Pb [11], Fe, Steels [12-15], Ni3Al[16], Zn [17], Mg and Ti [18], Al-Cu, MMCs, metallic glassesetc. [1]. Though a large number of new materials have beenprocessed, only Al-foam has seen tremendous developmentand also industrial production. However, seeing the unusualmultifunctional properties of metallic foams, research in thisarea has got a thrust in the recent years in all directionsencompassing material and process development,understanding the mechanism of foam formation, findingavenues for widespread applicability and developingpredictive models for foaming process. It is now widelyaccepted that metal foams have potential of becoming aprime structural material for the next generation ofautomotive and aerospace products, lightweight constructionmaterials and military armour vehicles. Keeping this in view,we have attempted to assess the current status of metalfoam research expectations and the challenges to beovercome prior to its wide industrial acceptability.

Processing of Metal FoamsThe basic aim of foam processing is to incorporate largesize and uniformly distributed gas pores in the metallicmaterials. This can be accomplished by several routes, whichare summarised in figure 2 . This indicates the possibility of

Fig 1: Representative structures of (a) closed cell (b) opencell and (c) lotus-type morphologies (after ref. [1]).

Fig 2 : A processing tree for metallic foams

producing metallic foams in two material states: liquid metaland powdered metal. We have summarized it on the basisof gas source used for foams production. The foamingprocess utilizing dissolved gases is due to the precipitationof these gases during solidification of the melt. This processgenerally gives rise to rod-like (known as “lotus structure”)gas pores during directional solidification. The external gassource signifies that the melt is foamed with the help ofinjection of gases such as air, nitrogen or argon directly intothe melt. However, utmost precaution in the gas flow rate,bubble formation frequency and solidification rate isnecessary to effect uniform distribution of pores. The gas

IIM METAL NEWS VOL. 9 NO. 4 AUGUST 200610

source from a blowing/foaming agent implies theirincorporation in a high viscosity melt to effect foaming ormixing a blowing agent with metal powder followed bycompaction, sintering and foaming. In these processes hightemperature exposure of foaming agent leads to gasformation, which in turn results in expansion of liquid/semi-liquid metal. There are some other processing routes suchas gas entrapment, hollow sphere sintering, slurry or slipcasting, sintering and dissolution technique and by usingpowder around filler materials. All these techniques givevariable performance of the foamed materials in terms ofpore size and size distribution, density and mechanicalproperties.

However, processing of foams poses several difficulties. Thegrowth of cells leads to thinning of liquid metal cell walls,breaking of cells walls and subsequently coalescence ofcells and finally collapse of foam structure. In other words,the complete foaming process is concerned with (1) foaminception or genesis where blowing agent decomposes(2) the evolution and growth of spherical pores (3) furtherfoaming leads to thinning of cell wall and thus change ofpore shape from spherical to polygonal and (4) porecoalescence due to surface tension and gravitational pull.This means the eventful life of foams comprises birth, lifeand death. Our aim is to avoid the death or collapse of foamduring the processing. The main convict for the death of foamis the instability of cell walls under the pressure differencesdue to surface tension of liquid or gravity. The death orcollapse of foam occurs at the peak of third and start of thefourth step [19-20]. This part of the foaming process hasinvolved tremendous challenges before researchers world-wide. The problem of foam stability is generally addressedby utilizing a few methods such as mixing of ceramic particlesin the melt so as to increase the viscosity and cell wallstrength [21], pre-treatment of foaming agent that delays theits decomposition [22], experimenting in microgravityenvironment so that the effect of drainage due to gravity isavoided [19], controlling the process parameter like heatingrate and foaming temperature and prior deformation ofprecursor materials [23].

Industrial ApplicationThe projections of the future fuel crisis, the urgency ofachieving high fuel efficiency along with higher passengersafety in automobile industries and the needs of creatinglight weight construction materials have attractedtremendous consideration for ultralight weight metallicfoams. The implementation of metallic foams in theseindustrial sectors depend to a large extent upon theirmanufacturing cost, the environmental durability and fireretardancy [24]. In general, metallic foams possess a rangeof thermomechanical properties that suggest theirapplications in the areas demanding impact/blastamelioration, heat dissipation, acoustic isolation and heatexchange [25-26]. The projected applications of metallicfoams have already been recognised and a detaileddescription of the requirements of various industrial sectorscan be seen elsewhere [1-5,27]. Recently, National PhysicalLaboratory (UK) made a survey both in industries as well asacademic and research institutions to have an idea of theirpotential expectations from metallic foams. The surveyindicated that the major applications of the metallic foams,

around 32%, in the near future would be directed towardsautomotive and aerospace industries (figure 3 ). In addition

Materia ls m anu facturing

10%

Powerengineering

5%

Processindustries

3%

Research/education

16%

Transport26%

Fig 3 : Break up of projected industrial sector requirementsfor metallic foam applications

to this, 26% requirements will constitute materialsmanufacturing, engineering manufacturing and componentmanufacturing. The response from academic and researchinstitutions was 16% in research and development point ofview. As the transport industry has to play a major role in theimplementation of metallic foams, it is essential to know thereasons why it is beneficial to apply foams. Figure 4 shows

Fig 4: The application categories of metallic foams in theautomotive industry [4]

application categories for metallic foams in the automotiveindustries [4]. The figure is self-explanatory and depicts threemajor properties associated with their respective utility. Thebending stiffness of metal foams are directly proportional tothe thickness and inversely proportional to density of foampanels. A high porosity in foams makes them potential

Damping,insulation

Lightweightconstruction

High strengthHorizontalσ-ε curve

Damping capacityLow conductiv ity

Acoustic propertiesHigh stiffness

Bifunctionalapplications

Energyabsorption

Low densityHigh stiffness

Idealmultifunctional

applications


candidates to absorb large amount of mechanical energy;therefore, they can also be used as impact energy abosorber.The properties of damping vibrations and sound absorptioncould be well exploited. However, a metal foam can be analternative option compared to other engineering solutionsif two or more of these properties are exploited together.Multifunctionality of metal foams can be realised if alightweight structure is capable of reducing noise andabsorbing impact energy in an automobile crash. We haveconsidered to make an attempt to see where we need to usethese foams in a car. For this purpose we should have anidea of the frequent accidental possibility in different parts ofa car. We also know that foams in transport industries arebasically needed for weight saving, impact absorbing andthermal insulation. Figure 5 shows a sample car (designed

The aim of the development was to separate the two stepsof foaming and shaping of components so as to reduce thecost by continuous production route. The process involvesmaking small volume foamable precursor (similar topowdered metal processing) and foaming them in acontinuous manner on a conveyor belt furnace. The stack ofspherical foamed elements is further sintered to get acomponent shape. The process gives added advantage ofopen porosity thus decreasing the relative density ofaluminium foam to 0.36 g.cc-1 compared to other processes.The advantage of the process lies in the fact that theproduction process has two main steps that are fullyindependent of each other. They can be carried out at differenttimes, in different locations and by different companies. Dueto the bulk character of APM foam elements, all sub-steps infoam element and part production can be fully automatedwith commercially available equipment.

So far as real application is concerned, bare foam is not atall advisable for a given engineering problem, as the basicrequirement for high stiffness requires sandwich panels withdense face sheets. The German Karmann has developed Alfoam sandwich (AFS) panels [1], which are light weight andstiff (figure 6c) . The sandwich panels can now also be formedin any shape by using APM foam elements discussed above[6]. A picture of the sandwich structure with a cellular corelayer is shown in figure 6d . An example of other application

Fig 5 : Karmann car with parts made of aluminium foam(courtesy: IFAM, Bremen, Germany) along with the collisiontypes and subsequent in-vehicle injury cost

by Karmann, Germany) with components made of Al foam. Itis indicated in the figure that 67% of in-vehicle injury costincurs when the collision takes place at the front end of thecar and about 22% in-vehicle injury cost constitute duringcollision from the side. This indicates that the front endcollision of a car is most detrimental during an accident andtherefore utilisation of foamed materials in these partsbecomes necessary for the passenger safety. As a result,the imperative should be to use metallic foams in the frontend for crash safety and rear end should be replaced withfoam to reduce the weight. In addition to the automobileindustries metal foams have other potential applicationareas, which include compressor casings, structuralhardware, motorcycle exhausts and frames, support forradar antenna, submarine structures, substitute foraluminium honeycomb structures, instrument housings,sound absorbing linings, acoustic transducers, loudspeakerenclosures, gearbox housings, structural parts forspacecraft, thermal management, cores for casting andvibration damping.

As the cost of metal foams is still prohibitive and restricts itswide industrial acceptability recently, IFAM (Bremen,Germany) has developed APM (Advanced Pore Morphology)process [6] where small volume spherical foam elements,in the size range of 9 to 10 mm are produced (figure 6 a & b) .

Fig 6 : (a) APM foam elements developed at IFAM, Bremen,Germany (b) sintered structure from foam elements (c)aluminium foam sandwich (AFS) panels [1] and (d) sandwichstructure made from alternate layers of APM elements [6]

is crash absorbers in automobiles. As the safety guidelinesand passenger protection has received increased attention,automobile manufacturers are using novel idea of crash boxto meet new standards [27]. The crash box enhances safetyand minimises repair cost in the event of a collision. Theseare placed between the impact beam and the front rail of thecar (figure 7a) . Recently, a spin off company of Karmann hasdeveloped a novel lifting arm, supporting a repair arm in a


small lorry, made of Al foam sandwich structure. This helpsin increasing the lifting height of the systems keeping thetotal weight of the lorry below a given limit. Out of differentfoaming routes, powder metallurgy technique, however, hasbeen recognised a better way to produced required shape ofcomponent. A foamed part made by this route is shown infigure 7b .

Figure 7: (a) Prototypes of crash absorbers based on Alextrusions with a filling of foam (b) shaped aluminium foampart [24].

The requirements of the above components and theenvisaged application of metallic foams made of differentmetals and alloys have led to the commercial production ofwork specific metallic foams. The products include foamfilled tubes and sections as shown in figure 7 , foamreinforced polymer structures developed by threecollaborating German companies Huebner, SchunkSintermetaltechnique and Siemens for use in tram crashabsorbers. There are several commercial establishmentsthat are engaged in the production of metals foams. A list ofa few of them is given in Table 1 along with their trade nameand products.

Future Prospects and ChallengesThe strength and weight saving by using Al foams arecurrently believed to be insufficient for critical areas ofapplications. Therefore, recently, tremendous efforts aredirected towards steel foam developments which, inprinciple, can have several potential advantages over

aluminium foams such as increased strength and specificstiffness, lower raw material cost, higher melting temperatureand compatibility with steel structures [12-15]. Initialdevelopments in the processing of steel foams have alreadybeen done by conventional powder metallurgical routes, andalso by space holding techniques. However, for thecommercial production of steel foams, we have to go a longway as the high operating temperature and the low viscosityof liquid steels are the major challenges to overcome. Theauthors of this paper are also actively engaged in thedevelopment of steel foams along with the processoptimisation for Al foams.

Similar to the development of steel foams, efforts have beenmade to develop bulk amorphous metal foams (AMF). Theamorphous foams are seen to have promising prospects inapplications such as sporting goods and cellular telephonehousings due to their high strength, high eleastic strain, andhigh wear and corrosion resistance. A high corrosionresistance of AMFs compared to other metallic foams isadvantageous in applications such as filters, electrodes andcatalyst supports [28-30]. So far as applicability in transportindustry is concerned, AMFs may not prove to be a betteroption than metallic foam, despite its very high strength.Stronger foams may be able to mitigate heavy impacts butsimultaneously transmit unacceptably large forces todelicate objects or human beings. Therefore, AMFs may begood for structural applications but not for the transportindustry. The processibility and strength of metallic foamsare determined by the processing temperature and strengthof the parent material e.g. Al-based foams can be easilyfabricated by various processes but have mechanicalproperties limited by those of their base alloys, while foamsmade from stronger crystalline alloys generally requirehigher-temperature and/or more difficult processingmethods. Whereas, amorphous metal foams are easy tofabricate due to their low melting temperature andsuperplastic like flow at higher temperatures [31]. Despite alow processing temperature, the application of such AMFs

Table 1: List of a few commercial establishments and theirrespective foam products

Supplier Processing route Material Cell size Cell(Trade Name) (mm) typeShinko Wire Foaming agents to Al, Fe, steel, Ni 0 .5 -5 Closed(Japan) “Alporas” meltIFAM (Germany) Foaming agents in Al, Zn, Fe , Pb 1-5 Closed“Foaminal” PM precursor and

Sintering of hollowspheres

Cymat/Alcan Gas infiltration Al –based, MMCs 3 -25 Closed (Canada)Hydro Aluminium Gas infiltration Al –based MMCs 5 -20 Closed(Norway)Neuman (Austria) Foaming agents in Al, Zn, Fe , Pb 1-5 Closed“Alu Foam” PM precursorMepura (Slovakia) Foaming agents in Al, Zn, Fe , Pb 1-5 Closed“Alulight” PM precursorCambridge Foaming agents to Al 0 .5 -5 ClosedUniversity (UK) melt “Alporas”Inco (UK) Deposition Ni 0.25-0.30 Open“Incofoam” techniqueERG (Canada) Investment casting Al, M g , Ni-C r, 5 – 40 Open “Duocel” Cu, Stainless,

Ceramics


above the glass transition temperatures, where toughnessis drastically reduced, the use of AMFs is limited to27-480 0C for an extended period. However, processing ofbulk AMFs is still a challenge due to compositional accurayand cooling rate requirements. A slight deviation incomposition, due to external additives for foaming, may leadto deviation from deep eutectic composition resulting instable crystalline phases. Even if the purity is overcome, thecompatibility of external gas blowing phases or spaceholders and the processing equipment must be ensured torealise amorphous foams. Progress in the identification andunderstanding of new glass-forming systems with still higherrobustness against contaminants and slow cooling, whichis currently the subject of intensive research, should lead toequivalent progress in AMFs [28].

Despite the current developments and future possibilities inprocessing and applications of metallic foams, there areseveral limitations, which has to be considered andaddressed so as to open new avenues for the metallicfoams. The first and the foremost hindrance in the wideapplicability of metallic foams is the cost of production. Thesecond concern is the variability in the materials and thelarge scatter in measured properties [32]. And also, reliabletest methods have to be invented to fully exploit the potentialof these cellular materials. World-wide efforts are being madeto model mechanical behaviour of metallic foams, andresearchers are, to some extent, successful in predictingthe same. However, theoretical and numerical modelsrelated to the processing of metal foams are not available,which could be useful in predicting the effect of processparameters. The developmental process could be madefaster by making process models, otherwise ‘trial and error”would be the only way. The lack of process models is due tothe fact that the mechanism of foaming process is still notfully understood. All these aspects of metallic foamdevelopment has restricted the industries only in niche areas,whereas, prior to undertaking wide spread commercialproduction these challenges have to be overcome. Further,large structures of metallic foams can be built only by joiningbare foams or sandwich structures. However, currently,joining metal foams is a big challenge as the foam structureis difficult to keep the foam morphology intact at the joints.

Concluding RemarksRecent technological advances in the field of metallic foamshave led to the development of a wide range of processingtechniques for the open as well as closed cell morphologies.The processing route has to be decided on the basis of thecost of production, materials properties and the intendedapplications of the final product. However, as the cost ofproduction of a good quality metallic foam is still high,continual innovations are underway so as to draw maximumbenefit by opening newer avenues for a wide range ofindustrial applications. Foams of new classes of materialssuch as high temperature melting materials, superalloys,steels, bulk metallic glasses etc. are seeing tremendousapplication opportunities in the near future. However, the lackof full understanding of the mechanisms of foam formationand theoretical/numerical models inhibits the developmentalprocess to a large extent. A versatile predictive model forprocessing as well as property has become a necessity fora faster growth in this direction as well as innovations inprocessing techniques.

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*The author presently engaged in Metallurgical and Materials EngineeringDepartment of the Indian Institute of Technology Madras. He is a life memberof IIM.

History, Range and ScopeNanotechnology is an umbrella that covers many areas ofresearch dealing with objects that have dimensions up to afew hundreds of nanometers. A nanometer (nm) is a billionthof a meter. Thus, as we make a shift towards the nanoscale,we slowly approach closer to the atomic or molecular scales.Atoms are the building blocks of all matter. Materials areassembled in a multitude of ways to get the final product.The properties of those products depend on the atomicarrangement. If we rearrange the atoms in coal, we can makediamond. If we rearrange the atoms in sand (and add a fewother trace elements), we can make computer chips. Clearly,engineering at the nano level can bring about drasticchanges in properties of the products.

While “nano” has become the buzzword in technology onlyrecently, the idea of nanotechnology is not so new. Way backin 1959, Richard Feynman delivered a classic talk duringthe annual meeting of the American Physical Society, wherehe talked about manipulating and controlling things on asmall scale. He further went on to quote “In the year 2000,when they look back at this age, they will wonder why it wasnot until the year 1960 that anybody began seriously to movein this direction”. The year 2000 has come and gone, and itis obvious that the great scientist’s words ring loudly now,more than ever. Due to his vision, Feynman is often regardedas the first nanotechnology guru.

Nanotechnology in its present form has been ushered in byEric Drexler. The revolution originated by Drexler has nowreached gargantuan proportions with far reachingapplications in a number of diverse fields starting fromelectronics to biotechnology. The scope of this newgeneration technology is immense. It finds applications inthe automotive segment. New electrostatic filters; high powerswitches in ignition devices via field emission principles atsharp tips; new catalysts using highly porous and chemicallyselective surfaces all go a long way in the production offaster, pollution free, efficient and reliable automobiles.Manufacturing systems technology has also been a majorbeneficiary on nanotechnology, with efficientnanoelectromechanical devices providing the basis fordevelopment of nano robots and assemblers, which movemolecule sized particles into precise locations. High densityinterconnections by nanoscale surface-activatedinterconnections are made possible by nanowires. Similarly,the development of nanoscale magnetic materials has atremendous bearing on the development of large scalememory storage devices. Without these, the Moore’s lawwould have been rendered null and void.

The advancement of nanotechnology in many fields, thus,required development of high performance materials,Nanoscale materials research was pioneered by Gleiter,who coined the term “nanomaterial”. The decresed lengthscale imparts drastically different physical properties to these

Glimpses of NanotechnologyProf B S Murty *

materials. For example, it has been demonstrated that ametal, in nanostructured form, behaves like a ceramic.Similar phenomena have been observed with regard to avariety of properties like magnetism, conductivity and evencolor. Perhaps one of the most lucrative areas for thenanotechnologist is catalysis. A variety of chemical reactionstake place on the surface of the catalyst, and the larger thesurface area, the more active the catalyst. Nanoscalecatalysts thus open the way for numerous processinnovations to make many chemical processes more efficientand resource-saving - in other words more competitive. Themedicine segment has also been reaping the benefits ofnanotechnology, with nanobots or nano robots becoming areality. The nanobots can be injected into the blood streamand their motion controlled through external electric field.Thus, they have huge potential for efficient drug deliveryapplications.

Synthesis and CharacterizationThe one major question that needs to be asked if one wantsto delve in nanotechnology is how to manipulate things atsmall scales. Such a task requires advanced techniques fornanostructured materials synthesis, product assemblingcharacterization and control. The synthesis of materials and/or devices with new properties by means of the controlledmanipulation of their microstructure on the atomic level hasbecome an emerging interdisciplinary field based on solidstate physics, chemistry, biology and materials science.

Nano materials and/or devices should have at least one oftheir dimensions in the nanoscale. Thus, there arenanometer-sized particles, nanowires or thin films ofnanoscale thickness. CVD, PVD, inert gas condensation,various aerosol techniques, precipitation from the vapor, fromsupersaturated liquids or solids (both crystalline andamorphous) appear to be the techniques most frequentlyused to generate this type of microstructure. PVD, CVD, ionimplantation and laser beam treatments are the most widelyapplied to produce nanocrystalline surfaces with enhancedcorrosion resistance, hardness, were resistance orprotective coatings. The methods to produce nanomaterialsare usually classified into two groups, the bottom up and thetop down approaches. In the first route, one starts withindividual atoms and builds the nano particles by bringingthese atoms together. PVD/CVD, chemical routes and thoseinvolving amorphous precursors fall into this category. In thesecond route, the bulk materials are brought down tonanoscale by severe plastic deformation. High energy ballmilling equichannel angular extrusion, etc. fall into thiscategory.

Assemblage of nanoscale devices using the nanostructuredmaterials would be the next logical step required to exploitnano science and move into the realm of nanotechnology.Such manufacturing process often draws uponnanopositioning, the technology of moving and measuringobjects with nanometric precision. The machines used forsuch applications combine optical design with advancedmotion control technologies. Piezoelectric devices have the


potential to meet the resolution requirements. However, thenon-linear nature of piezoelectrics means that an externalsensor should be present for position control. Thecapacitance micrometer is ideally suited to this task, beingsmall with intrinsic sub-atomic resolution.

Once the nanomaterials have been developed for a givenapplications and the devices assembled, one has tocharacterize them, and test their capabilities. There in liesthe role of microscopy. With increasing focus onnanotechnology and nanomaterials, the demand for betterelectron microscopes is on. This has been the motivatingfactor for development of the new breed of high resolutionelectron microscopes and the scanning probe microscopes.The impact of such microscopes is huge. For instance,electrochemical processes can be studied at the molecularlevels. Studying the process exhaustively is the first steptowards controlling and tailoring the process.

Achievements of Nano TechnologyThere are three trends in manufacturing: greater flexibility,greater precision, and lower cost. Nanotechnology is aboutadvances in all three. Some of the achievements ofnanotechnology have been enumerated below.

1. Manipulation and bond formation by STM (ScanningTunneling Microscopy). This research hasdemonstrated that direct molecular manipulation andbond formation is feasible, but it’s still hard; we needto reach a state where this is routine and possible withlots of molecules.

2. DNA Sequencing with Nanopores . If one can make avery small and very precise hole, you can solve a wholeclass of problems, of which gene sequencing is onlyone example.

3. Modification of Virus shells . When it comes tonanotechnology, viruses are way ahead of us. Recentresearch piggybacks on this fact by modifying virusshells rather than building complex molecules fromscratch. For example, in one experiement, the CowPeaPosaic Virus was modified to incorporate gold into itsshell, perhaps one day enabling a new methodologyfor mineral extraction.

4. DNA Motors. Ned Seeman has demonstrated that youcan shift DNA from single-to double-stranded byintroducing complementary strands, with the resultbeing the development of “sliding struts”-a three-phasemotor. There is also some older work by Montemagnoat UCLA -interfacing biological motors to siliconsystems.

5. Nanotube inverter . An IBM team led by Phaedon Avouriscreated an inverter, a basic computer device, by drapinga bucky tube over a prepared surface to make a type ofnanoscale transistor.

6. NRAM from Carbon Nanotubes . People are workingon building what they call NRAM out of carbonnanotubesn-“NRAM will be considerably faster anddenser, have substantially lower power consumptionthan flash, be as portable as flash memory, and behighly resistant to environmental forces (heat, cold,magnetism).”

7. IBM’s Millipede . Merkle commented that “Whileelectronics is interesting, it isn’t really quite what we’retalking about. We want manufacturing.” IBM Zurich’sMillipede, which uses an array of STM microscopes,gives the first inkling that we are building a core ofmolecular manufacturing capabilities.

8. Nanolayers . New light emitting materials are madepossible by nanostructuring semiconductor materials.The vertical cavity surface emitting laser (VCSEL) inwhose development Sandia National Laboratory playeda major role is a good example of nanomaterial thatuses layered quantum well structure to produce highlyefficient, low power consumption light sources. A keyto achieve high efficiency and optical control is thequantum confinement that results from designing andbuilding materials with chemically distinct layers thatare on the order of 10 nm thickness.

9. Three dimensional nanomaterials . Molecular self-assembly, hitherto used exclusively in biologicalsystems, is extremely well suited to the production of3-d nanomaterials including porous and solidcomposite structures. Self-assembly methods havealso been used to make nanoscale hybrid organic /inorganic materials. A recent example is the self-assembly of mesoscopically ordered chromaticpolydiacetylene/silica nanocomposites. This materialhas excellent electronic and optical properties whichrenders it useful for LEDs to biomolecular sensors.The origin of these properties lie in the fact that subtleshifts in the organic bond structure causes optical colorchanges.

10. Drug delivery systems . Drug delivery systems havebecome the craze today. For efficient drug delivery, it isimperative to develop reliable magnetic nanoparticles,which can be coated with appropriate medication,injected into the blood stream and then guidedmagnetically to the organ where drug delivery isrequired.

11. Manufacturing . The development ofnanoelectromechanical systems is another huge leapin cutting-edge technologies for the future. Suchdevices are essential for development of nano robotsand assemblers, which move molecule sized particlesinto precise locations, thereby revolutionizing themanufacturing industry.

12. Cooling systems . Advances and nanoscience in formof nanofluids have heavy implications in applicationsrequiring high heat transfer media. With theirtremendous stability and high thermal conductivity,nanofluids truly represent the wave of the future in heattransfer technology.

13. Health sector . Nanotechnology is also making wavesin the health sector as well. Development of nanoscalefilters for steril izing drinking water is an issueparticularly relevant to the third world countries, whichonly have access to dubious sources of drinking water.

The Future ProspectsWith all these wonderful achievements already surfacing fromdifferent directions, it is perhaps pertinent to ask “where is


nanotechnology heading”? The view that nanotechnology willlead to tiny robotic submarines navigating our bloodstreamis ubiquitous. Yet today’s products of nanotechnology aremuch more mundane - stain - resistant trousers, better suncreams and tennis rackets reinforced with carbon nanotubes.There is an almost surreal gap between what the technologyis believed to promise and what it actually delivers.

Back in 1986 Drexler published an influential book calledEngines of Creation: The Coming Era of Nanotechnology, inwhich he imagined sophisticated nano-scale machines thatcould operate with atomic precision. We might call this goal“radical nanotechnology”. Drexler envisaged a particular wayof achieving radical nanotechnology, which involved usinghard materials like diamond to fabricate complex nano-scalestructures by moving reactive molecular fragments intoposition. His approach was essentially mechanical, wherebytiny gears and bearings are integrated to make tiny robotfactories, probes and vehicles. The most compellingargument that radical nanotechnology must be possible isthat cell biology gives us endless examples of sophisticatednano-scale machines. These include molecular motors ofthe kind that make up our muscles, which can convertchemical energy to mechanical energy with astonishinglyhigh efficiencies. There are also ion channels and ion pumpsthat can control the flow of molecules through membranes.Other examples include ribosomes - molecular structuresthat can construct protein molecules with ultimate precisionon DNA.

Drexler argued that if biology works as well as it does,researchers ought to be able to do much better. Biology,after all, uses unpromising soft materials — proteins, lipidsand polysaccharised - and random design methods that arerestricted by the accidents of evolution. Furthermore,molecules are moved around through their continualbombardment by other molecules — what is known asBrownian motion — rather than via pipes and tubes. Weresearchers, however, have the best materials at ourdisposal. Surely we can create what are in effect, syntheticlife forms that can reproduce and adapt to the environmentin the competition for resources.

Even if the most extreme visions of the nanotechnologyevangelists do not come to pass, nanotechnology — in theform of machines structured on the nano-scale that dointeresting and useful things—will certainly play a growingpart in our lives over the next half-century. How revolutionarythe impact of these new technologies will be is difficult tosay. Scientists almost always greatly overestimate how muchcan be done over a 10 year period, but underestimate whatcan be done in 50 years. Sometimes the contrast betweenthe grand visions of nanotechnology — roboticnanosubmarines repairing our bodies — and the reality itdelivers — say an improved al-in-one shampoo andconditioner — has a profoundly bathetic quality. But theexperience we will gain in manipulating matter on the nano-scale in industrial quantities is going to be invaluable.Similarly, there is no point being dismissive about the factthat lots of early applications of nanotechnology will beessentially toys — whether for children or adults - just asdata-storage technology is currently being driven forward bythe needs of digital TV recorders and portable music players.These apparently frivolus applications will provide theincentive and resources to push the technology further.

But which design philosophy of radical nanotechnology willprevail - Drexler’s original “diamondoid” visions orsomething closer to the marvellous contrivances of cellbiology? One way of finding the answer would be to simplydevelop the exising technologies that have driven therelentless miniaturization of microelectronics. This “top-down” approach, which uses techniques likephotolithography and etching, has already been used tomake so-called microelectromechanical systems (MEMS).Such systems are commercially available and havecomponents on length scales of many microns — theacceleration sensors in airbags being a well known example.All we need to do now is shrink these systems even furtherto create true nanoelectromechanical systems or NEMS. Theadvantage of this top-down approach is that a massiveamount of existing technology and understanding is alreadyin place. The investment, both in terms of plant, and researchand development, is currently huge, driven as it is by the vasteconomic power of the electronics and computing industries.But, as we have seen, the disadvantage is that there areboth physical and economic bounds to how small thistechnology can go. Although industry has shownextraordinary ingenuity in overcoming seeminglyinsurmountable barriers already — new ultraviolet lightsources and phase-shifting masks have made feature sizesbelow 100 nm a commercial reality — may be its luck willsoon run out. A more fundamental problem is the importancein the nanoworld of Brownian motion and surface forces.Strong surface forces may make the moving parts of a NEMSdevice stick together and seize up.

So how could we follow biology’s example and work with the“grain” of the nanoworld? The most obvious method is simplyto exploit the existing components that nature gives us. Oneway would be to deliberately remove and isolate from theirnature havitats a number of components, such as molecularmotors, and then incorporate them into artif icialnanostructures. Another approach would be to start with awhole, living organism probably a simple bacterium — andthen genetically engineer a stripped-down version thatcontains only the components that we are interested in.

As we learn more about how bionanotechnology works, itshould be possible to use some of the design methods ofbiology and apply them to synthetic materials. Likebionanotechnology, such “biomimitic nanotechnology” wouldwork with the grain of the special physics of the nanoworld.Of course, the task of copying even life’s simplestmechanisms is formidably hard. Proteins, for example,function so well as enzymes because the particularsequence of amino acids has been selected by evolutionfrom a myriad of possibilities. So when designing syntheticmolecules, we need to take note of how evolution achievedthis. But despite the difficulties, biomimetic nanotechnologywill let us do some useful — if crude-things. For example,ALZA, a subsidiary of Johnson and Johnson, has alreadybeen able to wrap a drug molecule in a nanoscopic container— in this case a spherical shell made from double layers ofphospholipid molecules — and transport it to where it isrequired in the body. The container can then be made toopen and release its bounty.

The entire gamut of biosciences and nanostructured solidscoming together with wonder devices sounds exciting. It doesseem that the future of technology is best viewed at nanoresolutions. The invitation to enter a new dimension ofscience and technology has never looked so alluring before.


Metallic Materials for Marine ApplicationsDr K Srinivasan*

Abstract

Metals have played a key role in the development of humancivilization. Ship building is one of the oldest activities ofhuman kind. Over the years a large number of metals andalloys have been used in the construction of ships and seashore installations. Here an attempt has been made to puttogether the metals and alloys widely used in marineapplications.

Introduction

Components used in ships and harbors are exposed to saltatmosphere since seawater contains about 3.4% salt. It isalso slightly alkaline with pH being 8. It is a good electrolyte.It can cause galvanic corrosion, crevice corrosion and pittingcorrosion. Fig. 1 shows corrosion of ordinary steel in

seawater. Fig. 2 shows resistance of metals and alloys toseawater. Apart from these, salt water can sustain thousandsof types of animal and plant life, including barnacles,mussels, algae and others. These animal and plant formsattach therselves to solid surfaces during their growth cycle.The accumulation of these organisms cause intense andinsidious fouling of structures. Another problem with metallicmaterials especially steel is that it becomes brittle at lowtemperatures below—50C. In cold seawater breakage ofships can occur. This problem also has to be avoided whileusing materials for ship construction. The nature of each ofthe above problem and the metallic materials used to resistthem are discussed in this paper.

Galvanic CorrosionA potential difference usually exists between two dissimilarmetals when they are immersed in a solution such as

Fig 1 : Corrosion of Ordinary Steel in The Sea

seawater or brackish water. If these metals are placed incontact or electrically connected, this potential differenceproduces electron flow between them. Corrosion of the lesscorrosion resistant metal is usually increased and attack onthe more resistant material is decreased as compared withthe behavior of these metals when they are not in contact.The less resistant metal becomes anodic while the moreresistant metal becomes cathodic. Usually the cathodicmetal corrodes very little. This is called Galvanic Corrosion.It is electrochemical in nature. The driving force is the potentialdeveloped between two metals or alloys. Table 1 gives the

Fig 2 : Corrosion of Metals and Alloys by Quiet Sea Water-Less Than 2 ft. Per Second

Table 1: Standard EMF Series of Metals

Metal-metal ion equilibriunt Electrode potential vs. normal(unit activity) hydrogen electrode at 250C, volts

Au-Au+3 +1.498Pt-Pt+2 +1.2

Noble or Pd-Pd+2 +0.987cathodic Ag-Ag+ +0.799

Hg-Hg2+2 +0.788

Cu-Cu+2 +0.337

H2-H+ 0.000

Pb-Pb+2 -0.126Sn-Sn+2 -0.136Ni-Ni+2 -0.250Co-Co+2 -0.277Cd-Cd+2 -0.403Fe-Fe+2 -0.440Cr-Cr+3 -0.744Zn-Zn+2 -0.763

Active or Al-Al+3 -1.662anodic Mg-Mg+2 -2.363

Na-Na+ -2.714K-K+ -2.925

➝

➝

Source : A. J. de Bethune and N. A. S. Loud, “Standard AqueousElectrode Potentials and Temperature Coefficients at 25 0C,”Clifford A. Hampel, Skokie, III., 1964. See also Table 9-1.

*Dr K Srinivasan is presently engaged in Metallurgical and Materials Engineering,National Institute of Technology Karnataka, Surathkal, Srinivasnagar P.O.575 025, Mangalore. He is a life member of IIM. E-mail : [email protected]

M arineatm o sphere

Splash zone

Nil except fo r deep pitting



except for deep p itting

except for p itting Usually <1 mpy

Usually <1 mpy

* Trademark Union CarbideCorporation

Dezincifies

N il 0 .1 0 .5 1 2 5 10

Typical ave rage corrosion rates, mpy

Hostelloy* ‘‘C ’’

Titonium

Type 316

Type 304

Nickel chrom ium alloy

Nickel copper a lloy

N ickel

70 - 30 copper nickel 0.5 F e

90 - 10 copper nickel 1.5 F e

Copper

Admiralty

A lum inum brass

G b ronze

Nickel a luminum bronze

Nickle aluminum manganese

Manganese bronze

Austen it ic nickel cast iron

Carbon steel


Table 2(a) : Galvanic Series of Some Commercial Metals andAlloys in Seawater

potential differences between metals under reversible ornon-corroding condition. In sea water the relative positionsare changed and is given by Table 2(a) and (b). Galvanic

corrosion is more severe in marine atmosphere in seasand near seashore compared to an inland location. Toprevent galvanic corrosion do not put dissimilar metals incontact or give a protective coating (eg. galvanizing iron orsteel) or use sacrificial anode, such as zinc which will corrodein preference to iron which will be intact. Fig. 3 gives thegalvanic compatibility for pump and valve trim in seawater.Valves are manufactured with different materials and withdifferent trims. Trim is the seat of the valve and is made ofmaterials different from the pump and the valve body.Therefore there will be galvanic coupling of the pump andthe valve trim. Fig 4 gives the effect of velocity of sea water oncorrosion of piping.

Fig 4 : Effect of Velocity on Corrosion of Piping by Seawater

Fig 3 : Galvanic Compatibility — Pump and Valve Trim

PlatinumGoldGraphiteTitaniumSilver

Chlorimet 3 (62 Ni, 18 Cr, 18 Mo)Hastelloy C (62 Ni, 17 Cr, 15 Mo)18-8 Mo stainless steel (passive)18-8 stainless steel (passive)Chromium stainless steel 11-30% Cr (passive)Inconel (passive) (80 Ni, 13 Cr, 7 Fe)Nickel (passive)

Silver SolderMonel (70 Ni, 30 Cu)Cupronickels (60-90 Cu, 40-10 Ni)Bronzes (Cu-Zn)CopperBrasses (Cu-Zn)Chlorimet 2 (66 Ni, 32 Mo, 1 Fe)Hastelloy B (60 Ni, 30 Mo, 6 Fe, 1 Mn)Inconel (active)Nickel (active)

TinLeadLead-tin solders

18-8 Mo stainless steel (active)18-8 stainless steel (active)

Ni-Resist (high Ni cast iron)Chromium stainless steel, 13% Cr (active)

Cast ironSteel or iron

2024 aluminum (4.5 Cu, 1.5 Mg, 0.6 Mn)CadmiumCommercially pure aluminum (1100)ZincMaganesium and magnesium alloys

Active oranodic

➝

➝

Noble orcathodic

Table 2(b) : Galvanic Potentials in Flowing Seawater

Metal or alloy Temperature, 0C, Volt* vs. saturated calomel

Zinc 26 -1.03Mild steel 24 0.61Gray cast iron 24 0.61Austenitic cast iron † 14 0.47Copper 24 0.36Admiralty brass 24.6 0.36Gunmetal 24 0.31Aluminum brass 24.6 0.29Admiralty brass 11.9 0.30 ‡Lead-tin solder (50-50) 17 0.2890/10 Cu/Ni (1.4 Fe) 6 0.2490/10 Cu/Ni (1.4 Fe) 17 0.2990/10 Cu/Ni (1.5 Fe) 24 0.2270/30 Cu/Ni (0.51 Fe) 6 0.2270/30 Cu/Ni (0.51 Fe) 17 0.2470/30 Cu/Ni (0.51 Fe) 26.7 0.20Monel § alloy 400 22 0.11Nickel 25 0.10 ‡Titanium 27 -0.10Graphite 24 +0.25Platinum 18 +0.26 ‡

* All values negative vs. saturated calomel reference electrode except those for graphite andplatinum.† Ni-Resist § ductile cast iron type D-2 (3.0 C, 1.5-3 Si, 0.7-1.25 Mn, 18-22 Ni, 1.75-2.75 Cr).‡ Seawater velocity = 7.8 ft/sec.§ INCO trademark

Trim

N il

< 1 m py

< 1 m py

< 2 m py

< 2 m py

< 3 m py > 5 m py

> 5 m py

> 5 m py

> 5 m py

5 m p y 3 0 m py

< 1 m p y

< 1 mpy

< 1 mpy

< 1 mpy

< 1 mpy

M ay p it

May p it

Deep p itting

Deep p itting

Deep p ittingDeep p itting

*Trademark Union Carbide Corporation

Hostelloy* ‘‘C’’

Titanium

70 - 30 copper

90 10 copper n ickel 1.5 Fe

Alum in ium bross

Admiralty

Copper

Carbon steel

Nickel Copper alloy

70 - 30 copper n ickel 5% Fe

Tipe 316

Nickel chrom ium alloy

Type 304

nickel 0.5 Fe

Velocities, fps

0 3 6 8 12 15

Foulingdecreases

Pipedesign

vel.

Condenserdesign vel.

Powerplant

Noval condenser design vel.

> > >

N il


Crevice Corrosion

Intense localized corrosion occurs within crevices and othershielded areas on metal surfaces exposed to seawater. It isusually associated with small volumes of stagnant solutioncaused by holes, gasket surfaces, lap joints surface depositsand crevices under the bolt and rivet heads. Therefore it iscalled crevice corrosion or deposit corrosion or gasketcorrosion. Deposits may be sand, dirt, corrosion productsand other solids. These deposits act as a shield and createa stagnant condition under them. Contact between metaland nonmetal surfaces can cause crevice corrosion Wood,plastics, rubber, glass, concrete asbestos, wax and fabricsare some of the nonmetallic materials, which when in contactwith metals may cause crevice corrosion. 18-8 stainlesssteel in contact with rubber gasket when exposed to seawatercan undergo crevice corrosion. The crevice must be wideenough to permit liquid entry, but sufficiently narrow tomaintain a stagnant zone. Normally to be considered ascrevices, they should be less than a few thousands of aninch but should not in any case be wider than (1/8) inch.Crevice corrosion is more intense in solutions containingchloride ions. A long incubation period is necessary.Sometimes six months to a year is required for the crevicecorrosion to start. Once initiated it proceeds at an everincreasing rate. Metals and alloys, which form an oxidepassive film on their surface and become inert and corrosionresistant are more susceptible to crevice corrosion becausethe oxide film is destroyed by chloride ions or hydrogen ionsin solution. To prevent crevice corrosion one should usewelded joints instead of riveted or bolted joints. Avoid lapjoints. Avoid sharp corners and stagnant areas in vesselsso as to facilitate complete drainage. Inspect equipment andremove deposits periodically. Use Teflon gaskets which arenon absorbent. Use welded tubes. Table 3 shows alloysresistant to crevice corrosion.

Table 3 : Tolerance of Crevices Immersed in Quiet Seawater

Useful resistance

Crevices tend to

Inert Best Neutral Less initiated deep pitting

Hastelloy* “C” 90/10 copper nickel Aus. nickel Incoloy † alloy Type 3161.5 Fe iron 82570/30 copper nickel Cast iron Alloy 20 Nickel-chromium0.5 Fe alloys

Titanium Bronze Carbon steel Nickel-copper Type 304Brass alloy Series 400 S/S

Copper

* Trademark Union Carbide Corporation.† INCO trademark

surface and a liquid is such that repeated loads are appliedto the surface causing very high stresses when thesebubbles form and collapse regularly. These collapsesproduce high stress impacts which gradually removeparticles of the surface eventually forming deep pits,depressions and pock marks. This type of corrosion isminimized by using a more resistant material or by aprotective coating. Stellite, some stainless steels, certaintool steels have good resistance to cavitation damagewhereas cast iron, bronze & steel castings and plates havepoor resistance. Table 4 gives alloys resistant to cavitationin ship propellers, pump impellers and hydrofoils.

Table 4 : Cavitiation Resistance(Ship Propellers, Pump Impellers and Hydrofoils)

Based on field experience Based on laboratory test

Stellite* 1. Stellite*17-7 Cr-Ni stainless steel weld 2. Two layers 17-7 Ci-Ni stainless steel weld18-8 Cr-Ni stainless steel weld 3. 18-8 Cr-Ni stainless steel weldAmpco† No. 10 weld 4. Ampco † No. 10 weld25-20 Cr-Ni weld 5. Cast Ampco † No. 18 bronzeEutectic-Xyron 2-24 weld 6. Nickel-aluminum bronzeAmpco † bronze casting 7. 18-8 Cr-Ni cast stainless18-8 Cr-Ni cast stainless 8. 13% Cr, cast stainlessNickel-aluminum bronze, cast 9. Manganese bronze, cast13% Cr cast 10. BronzeManganese bronze, cast ** 11. Bronze18-8 stainless spray metallizing 12. Cast ironCast steel 13. Sprayed stainless 18-8 Cr-NiBronze 14 RubberRubber 15. AluminumCast iron 16.Aluminum 17.

* Trademark Union Carbide Corporation.† Trademark Ampco Metals, Inc.** 58.5% Cu-39% Zn- 1.4% Fe-1% Sn-0.1% Mn

Cavitation Corrosion

Cavitation corrosion is caused by the collapse by bubblesand cavities within the liquid. Vibrating motion between the

Pitting Corrosion

Pitting is a form of extremely localized attack that results inholes in the metal. These holes may be small or large indiameter, but in most cases they are relatively small. Pitsare sometimes isolated or so close together that they looklike a rough surface. Generally a pit may be described as acavity or hole with the surface diameter about the same asor less than the depth. Pitting is one of the most destructiveand insidious forms of corrosion. It causes equipment to failbecause of perforation with only a small percent weight lossof the entire structure. It is often difficult to detect pits becauseof their small size and because the pits are often coveredwith corrosion products. In addition it is difficult to measure

quantitatively and compare the extent of pitting because of

the varying depths and numbers of pits that may occur under

identical conditions. Pitting is also difficult to predict by

laboratory tests. Sometimes pits require a long time, several

months or years to show up in actual service. Pitting is

particularly vicious because it is a localized and intense formof corrosion and failures often occur with exteme


suddenness. Pitting may be considered as the intermediatestage between general overall corrosion and completecorrosions resistance. A corrosion pit is a unique type ofanodic reaction. It is an autocatalytic process. The corrosionprocesses within a pit produce conditions, which are bothstimulating and necessary for the continuing activity of thepit. Pitting in reality is a special case of crevice corrosion. Allsystems which show pitting are susceptible to crevicecorrosion. For example, stainless steel in seawater. Thereverse is however not true always. Most pitting failures arecaused by seawater and brackish water containing chlorideand its ions. It also occurs in stagnant conditions such asseawater in a tank or seawater trapped in a low part of anyinactive pipe system. Increased velocity often decreasespitting. Stainless steel pump will give good service if it wererun continuously with seawater but would pit if it were shutdown for extended periods. As a class stainless steels aremore susceptible to damage by pitting in seawater. Ordinarysteel condenser tubes are more resistant to pitting thanstainless steel tubes when exposed to seawater or brackishwater. Rapid perforation does not occur in the former. Type316 stainless steel containing 2% Molybdenum are moreresistant to pitting than Type 304 stainless steel, containing18% Cr 8% Ni. The former is suitable for seawater while thelatter is not. To prevent pitting one solution is to use materialthat doesn’t pit. Titanium have very good resistance to pitting.Next comes Hastealloy C, Hasteally F and 316 stainlesssteel in that order. Materials resistant to pitting in quietseawater are given in Fig 5 .

Fig 5 : Pitting in Quiet Seawater

Fouling

Ship bottoms rapidly accumulate barnacles and other

organisms which markedly affect the streamlining andincrease the power requirements. A severely fouled up shipmay require as much as 30% more electric power during its

operation. Similarly the accumulation of macroorganisms inheat exchangers and other such devices severely limits theheat transfer and fluid flow and may result in complete

obstruction. The accumulation of aqueous macroorganismsis a function of environmental conditions. The most severeproblem occurs in relatively shallow water, since in deeper

water there are no surfaces to which the organisms mayadhere. Thus harbour conditions are specially conducive tothe formation of deposits on ship hulls. In general warm

temperatures favour a long breeding season and rapidmultiplication of macroorganisms such as barnacles andmussels. In northern and southern cold seawater fouling

generally occurs in summer months only, where as in tropicalwaters in equatorial regions fouling is practically continnous.Relative motion between an object and water generally tends

to inhibit the attachment of organisms. Thus rapidly movingvessels accumulate only small quantities of organisms andthe major portion of fouling occurs when the vessel is docked.

The same effect is also noted in heat exchangers employingseawater as a coolant. Rapid fluid flow tends to suppressfouling of heat exchangers whereas rapid accumulation

occurs at low fluid rates or during shut down periods. Alsothe nature of the surface strongly influences the attachmentof macroorganisms. Smooth, hard surface offers an excellent

point for adhesion. Whereas rough flaking surfaces tend toinhibit adhesion. For example the fouling of stainless steeland iron occurs initially at about the same rate in seawater.

However after some exposure the surface of iron is coveredby a loosely adhering iron oxide and fouling tends to be lesson iron than stainless steel after long exposure periods.

Fouling by organisms is most effectively inhibited by the useof antifouling paints. These paints contain toxic substancesusually copper compounds. They function by slowly releasing

oppper ions into the aqueous environment, which poisonsthe growth of barnacles and other creatures. A similartechnique is used in closed system where various toxic

agents and algaecides such as chlorine containingcompounds are added to the environment. These methodswork more or less successfully depending on their

application. However, under conditions conductive to thegrowth of aqueous organisms periodic cleaning shouldalmost always be done to ensure unimpeded fluid flow and

to prevent crevice attack Table 5 gives some materialsresistant to fouling. Brackish water is contaminated with

G ro up ingin glo vo n ic

se rie sN il re sistan t In te rm e dia te

I on p ittin g

G ro ph itiz es

R e sis tan t

R e sis tan tD e zin cifie s

o r p ito r p it

N o p ittin g re p orte dN o p ittin g re p orte d

R a te d ec re as esw ith tim e

P itt ing in crea se s w ith F e co nte n t

C o rro de s s ac rific ially

Q uitesu sc ep tib le

Ful

lypa

ssiv

e

Low

erM

iddl

eU

pper

(act

ive)

Z incA lu m inu mC a rb o n s te el (1 )C a st iro n

A u s,N i ca st iro nC o pp e rA lu m inu m bra ssA d m ira ltyG bro nzeM an g an es e bron zeN ic ke l alu m in um b ro n ge9 0 - 1 0 co pp er n icke l 1 .5 F e7 0 - 3 0

co pp e r n ick el 1.5 F e

N ic ke l co pp e r a llo yA llo y 2 0N ic ke lType 3 16N ic ke l ch ro m ium a llo yType 3 04Type 4 00 s/sH o stella y* CTita niu m

(1) S h allo w ro un d - b o tto m pits(2) A s ve locity in cres es ab o ve 3fps , p ittin g de crea ses. W h en co n tinu o usly e xp ose d to 5 fp s a n d hig he r ve loc itie s th e se m etals, e xce pt se rie s 400 s/s , te n d to re m ain p ass ive w itho ut a nyp ittin g ov er th e fu ll su rface in the a bse n ce of crev ices.

* Trad e m a rk U nio n C arb ide C o rpo rit ion


Table 5 : Fouling Resistance - Quiet Seawater Above 3 ft/secContinuous Velocity (about 1.8 knots) Fouling OrganismsHave Increasing Difficulty in Attaching Themselves andClinging to the Surface, Unless Already Attached Securely

Arbitrary rating Scale Materialsof fouling resistance

Best 90-100 Copper 90/10 copper-nickel

Good 70-90 brass & bronzeFair 50 70/30 copper-nickel, aluminum bronzes, zinc

Very slight 10 Nickel-copper alloy

Least 0 Carbon and low-alloy steels, stainless steels,Hastelloy* “C” Titanium

Table 6 : Marine Applications of Metals and Alloys

1. Iron & SteelsPlain Carbon Steel - Mild Steel0.1-2.% C 0.03-1% Mn, 0.05-0.3% Si <0.05%S <0.04% P, Bal Fe.

Ship building

Stainless steel-High Nickel High Chromium0.04% C, 21.2% Cr, 12.5% Ni, 5% Mn, 2.2 Mo,0.2% Nb, 0.2% V, 0.3% N, Bal Fe

Fittings in marine environments

Wrought Iron0.06% C, 0.045% Mn, 0.101% Si, 0.68% P,0.009% S, 1.97% Slag, Bal Fe.

Ship building

Malleable Cast Iron2.0-2. 65% C 0.90-1.40% Si 0.25-0.55% Mn,<0.18% P, 0.05% S, Bal Fe

Anchors, Chains, Captstans, FasteningsTowingbits, Hardware

2. Copper alloysAdmirality Brass of 71% Cu, 28% Zn, 1% Sn.

Condenser tubes

Aluminium Brass 76% Cu, 22% Zn, 2% Al. Condenser tubes

Muntz Metal 60% Cu, 40% Zn Sheets for ship sheathingLeaded Naval Brass or Tobin Bronze 60% Cu,39.25% Zn, 0.75 Sn or 58.25% Cu, .39.25%Zn, 0.75% Sn, 1.75% Pb

Marine hardware, Construction

Admiralty Gunmetal 88% Cu, 5% Sn, 5% zn Pumps, Valves, miscellaneous castings formarine purposes

Leaded Gunmetal or Red Brass 85% Cu, 5%Sn, 5% Zn

Substitute for Admiralty Gunmetal. Also wherepressure tightness is required

Silicon Bronze 95% Cu, 5% Si (max) Marine construction

Aluminium Bronze max 7.5% Al, max 5% Ni,0.5-55% Fe max 2% Si, Bal Cu.

Protective sheathing in marine applications

Narcolloy 92.25% Cu, 7% al, 0.5% Co,0.25% Sn.

Cold forged bolts & thread rolled studding formarine atmospheres

3. Aluminium AlloysAluminium-Silicon-Casting Alloys 88-95% Al,5 to 12% Si

Marine fittings

Aluminium-Magnesium-Wrought Alloys 95.5%al, 4.5% Mg

Welded marine structural applications

90% al, 10% Mg Marine work, Sea planes

3.5% Mg, 0.1% Cu, 0.5% Si, 0.5% Fe, 0.5%.Mn, 0.25% Cr, 0.2% ti, Bal Al

Ship building & other marine structures

4.5% Mg, 0.4% Si, 0.4% Fe, 0.5 to 1% Mn25% Cr, 0.2% Ti, Bal Fe.

Marine parts

Aluminium-Magnesium Cast Alloys 90-97.2%al, 3.8 to 10% Mg, F

Fittings for marine use

4. Magnesium AlloysMagnesium-aluminium-Cast Alloys 86% Mg,9% Al, 5% zn

Parts for marine exposure

5. Nickel Alloys-DNickel 95% (Ni+Co), 2-4.5% Mn, 0.1% C,0.05% Fe, 0.05% Si, 0.02% Cu, 0.005% S

Marine boiler refractory bolts

Monel 66.15% (Ni+Co), 31.30% Fe, 0.90% Mn Marine equipment

K Monel 65.25% (Ni+Co), 29.60% Cu, 2.75%Al, 0.45% Ti

Marine pump shaft

6. Titanium and its AlloysCP. Titanium

Parts resistant to sea water corrosion and marineatomosphere exposure

Titanium AlloyTi-6 Al-4V

Marine heat exchangers, Scrubbers, Sonar andYacht fittings

chlorides usually because of tidal action in rivers and bays

near the seas and oceans. Corrosion problems are less

severe in these waters than in full strength seawater but

guidelines for materials of construction are approximately

same.

Ductile Brittle Transition of Steels

Mild steel with 02% carbon has a DBTT of — 50C. As carbon

content increases this temperature increases. Thereforce

carbon content has to be as low as possible. In cold waters,

either when the ship is on the seas or docked in harbours,

mild steel becomes brittle. During World War II some of the

Liberty ships and T2 tankers broke completely into two while

in other instances the brittle fracture did not completely

disable the ship. Moreover mild steel should contain very

low P and N. Both of them raise DBTT. Alloying with Mn and

Ni are beneficial as they lower DBTT. But alloying makes

welding difficult. Welding of mild steel for ship building has

to be done with special electrodes to avoid defects and

strresses. These give rise to brittleness and lower the

toughness due to notch effect. For ship building mild steel

with a low carbon content is to be used.

Conclusion

There are a variety of materials available for marine

applications—Wood, Metals & Alloys, Polymers, Ceramics

and Composite materials. Here a brief overview of metallic

materials used in marine application has been given to

highlight the various options and bring an awareness among

Marine Engineers about materials. In Table 6 , various metals

and alloys used in marine applications are listed.

References

1. M. G. Fontona & N. D. Greene, Corrosion Engineering

McGraw Hill, 1978.

2. Sydney H. Avner, Introduction to Physical Metallurgy,

McGraw Hill, 1984.

3. D. S. Clark W. R. Varney, Physical Metallurgy for

Engineers, East West Press, 1962.

4. R. A. Higgins, Engineering Metallurgy Applied physical

metallurgy, ELBS, 1974.

5. G. E. Dieter, Mechanical Metallurgy, McGraw Hill, 1988.


New Blast Furnace at JSPL - RaigarhS. Telang, D. K. Saraogi & P. S. Rana

Jindal Steel & Power Limited (JSPL) - Raigarh are in the process of setting-up their mega steel project for raising thesteel production capacity from existing 0.7 million ton per annum to 2.5 million ton per annum. The projects arenearing completion and will be commissioned in next few months.

As part of the expansion project, state of the art blast furnace is being installed. This will be the most modern blastfurnace being set-up in India. The technology supplier for the blast furnace is M/s Danieli Corus Netherlands. Theblast furnace will have useful volume of 1681 Cu M with rated annual capacity of about 1.25 million tons of hot metal.The important features of the blast furnace are as following :

- Specific Productivity - 2.5 T/Cu M/D guaranteed.

- 80% sinter ratio in the burden.

- Screening of sinter, iron ore and coke at the Stock House.

- Continuous charging of raw materials through the belt conveyor.

- Bell-less Rotary Charging Unit (BRCU) and the stock level indicator for proper distribution of raw material withinthe blast furnace.

- Carbon block lining in the hearth.

- Copper plate coolers.

- Common tap holes for hot metal and slag.

- Slag granulation at the Cast House.

- Mushroom domed Hot Blast Stoves, 3 Nos.

- Waste Heat Recovery System for utilization of heat from out-going flue gas from the Stoves.

- High top pressure of 1.2 bar.

- Hot blast temperature of 1250 deg C.

- Pulverised Coal Injection system.

- Oxygen enrichment and humidification of blast.

- Guaranteed Coke rate (Net & Dry) 400 Kg/THM along with 200 Kg/THM of pulverized coal.

- Tarpedo Ladle Cars for handling of hot metal.

- Dry fog dust suppression system covering all the sensitive locations and dedusting system at the cast house.

- Centralized control system for monitoring & regulating various process parameters.

- Compact layout with maximum space utilization and the best engineering practices.

Optimization of energy consumption through adoption of modern features will improve the overall economy of hotmetal production. The blast furnace project is being executed on non-turnkey basis with support from M/s MECONLtd - Ranchi as consultants.

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Company Profile


Failure Analysis of Bolts Used on Dumper Main Pump Assembly—ACase Study

C.Mahendravarman, S.R.Shivakumara & D.B.Prakash*

Abstract

The most common location for fastener failures are in thehead to shank fillet or on threaded fasteners, through thefirst thread roots immediately adjacent to the edge of the nut.The bolt elongates as it is tightened this produces increasedloads on the threads near the bearing face of the nut andadds to normal service stresses.

This failure investigation is on high strength alloy steel boltof M1432 (total length 115 mm and threaded length 40 mm).It report failure of the bolt along the threaded portion due toexcess run out of the thread, use of spring washer and inferiorquality of the material.

IntroductionIn a well-designed mechanically fastened joint, the fastenermay be subjected to either static loading or dynamic fatigueloading.

The primary force in the bolt is tension, which is set up bystretching the bolt during tightening; whereas the mostimportant stress in nut is the shear stress in the threads.Experience suggests that non-axial loading of bolts and studsis one of the most common causes of failure.

Spring washers should not be used under fatigue condition;in fact, any washer is undesirable, as it increases theelasticity of the parts held together by the bolt and so raisesthe range of stress fluctuation to which it is subjected.

Apart form the above another important characteristic, whichhas to be considered, is the metallurgical properties of thebolts. Hence the bolts should be properly heat treated, thesegregation and inclusions rating should be within theacceptable range and free from defects like thread rollinglaps, decarburisation etc.,

Stress DistributionThe stress distribution of a bolt with pump case is shown inFig. 1. The figure shows that first few bolt threads from bearing

*The authors belong to the Materials Science Laboratory, Research &Development, Bharat Earth Movers Ltd., Kolar Gold Fields, Karnataka

Pum p Case

Pum p Body Bolt

the shank end. The failed bolt broken exactly at 6th root fromthe shank end and the other has no damage.

Macro Examination

The fracture surface texture of the failed bolt reveals bright,shiny & crystalline appearance with a number of secondary

Fig 1 : Stress distribution pattern

Failed location

Fig 2 : Bolt in the as received condition

Secondary cracks

Fig 3 : Fracture surface texture of failed bolt

cracks. This evidence shows that the failure of the bolt isbrittle in nature as shown in Fig. 3 (Stereo microphotograph)

Results and Discussion1. Chemical Composition

The table below shows the chemical composition of boththe bolts (Wt % by spectrometry)

AnalyzedElement Specified

Failed Not Failed (SAE4140H)C 0.40 0.40 0.37-0.44S i 0.26 0.29 0.15-0.35Mn 0.76 0.81 0.65-1.10S 0.025 0.027 0.040P 0.015 0.014 0.035Cr 1.00 1.01 0.75-1.20Mo 0.20 0.21 0.15-0.25

face carry the major portion of load. The stress intensificationnear the bearing face of few engaged threads creates seriousproblem.

Visual ObservationThe bolts received for analysis is shown in Fig. 2 . Both boltswere engaged in the main pump case upto 6th thread from

Technical Notes


The chemical composition of both bolts conforms to SAE 4140 H

2. Mechanical Properties

The hardness and tensile properties of the bolts are given inthe table below.

3. Micro Examination

Test Tested ValuesCharacteristics Failed Not Failed Requirement

Hardness (HRC) 39 / 40 41 /42 38 / 44

UTS (N/mm2) 1361.42 1360.90 1220 Min

Elongation (%) 14 15 8 Min

Reduction in Area (%) 40 45 44 Min

Fig 4 : Segregation of sulphide inclusion stringers alongthe band (400X)

(a) Inclusion Rating

Failed: A – 4 / -

D – 2 / 1

Type A inclusions were segregated along the white band asshown in Fig.4 .

Not Failed: A – 3 / -

D – 2 / –

In both the bolts the inclusion ratings were higher than theacceptable range

(b) Miocrostructure

The microstructure of the not failed bolt-reveals fine carbidesdispersed in a matrix of tempered martensite with bainite asshown in Fig. 6

The microstructure of the failed bolt reveals bands oftempered martensite and bainite Severe by segregatedsulphide inclusion stringers along the tempered martensiteband are shown in Fig. 4 & 5. The bainite originated fromcarbon / manganese segregation within the material, whichwould, lead to increased internal stresses.

40 0 X

Segregated sulphide inc lusion stringers

Tem pered m artensite & Bainite

Tem pered m artensite

100X

Fig 5: Microstructure of failed bolt

10 0X 40 0X

The failed bolt microstructure reveals that the sulphideinclusion stringers are segregated along the temperedmartensite bands (white) these tempered martensite bandsare very hard and brittle compared to the adjacent region(the difference in hardness between the bands is @ 60 HV)and this type of microstructure will introduce more stress onthe tempered martensite bands. The stringers of segregatednon-metallic inclusions also act as stress raisers. Hencethis banded type structure and stringers of segregated non-metallic inclusions will produce crack even with small non-axial load.

ConclusionThe failure of the bolt is due to the inferior metallurgical qualityof the material i.e., higher inclusion rating, bands of temperedmartensite (white bands) and regregated inclusions alongthe hard (tempered martensite) bands.

Another important reason for the bolt failure is the excessrun out of the threaded portion from the bearing face. Hencethe end of the bearing face will act as a stress concentrationsite. The bolt elongates as it is tightened, producing increasedloads on the threads near the bearing face of the pump case.This adds up to normal service stresses.

Apart form the above the usage of spring washers also maybe the reason for the failure because it increases the elasticityof the parts held together by the bolt and so raises the rangeof stress fluctuation to which it is subjected.

AcknowledgementThe authors wish to thank the management of Bharat- EarthMovers Ltd., for providing the necessary support for carryingout this study. The authors are also thankful to Mr. K.Venkatramana Rao, General Manager, Research &Development.

Reference1. F.R.Hutchings & Paul M.Unterweiser, Failure Analysis:

The British Engine Technical Reports, American Societyfor Metals, Metals Park, Ohio, 1981.

2. Metals Handbook, Ninth Edition, Failure Analysis andprevention, vol. – 11, American Society for Metals,Metals Park, Ohio, 1986.

Fig 6: Microstructure of not failed bolt


Steel Slag detection by Thermal ImagingSlag carryover from the furnace to the ladle is securely avoidedby the new SDS slag detection system from Land InstrumentsInternational . SDS records each tap and simultaneouslygenerates a log and graph of the steel/slag data. When a presetprecentage of slag or steel is detected within the definedwindow, an alarm is generated to stop the tap, and the video,text and graph files are saved and identified by tap number forlater analysis.

The SDS camera uses a focal plane array micro-borometer witha temperature measurement range of 600 to 2,0000C and athermal image resolution of 320 x 240 pixels. Its operatingwavelength is 3.9 mm, with a field of view of 6 degrees x 4.5degress and a motorized focusing range from 3 m to infinity.

(Ref : M P T International)

Recovery of Ironfrom residues usingthe OxiCupTechnologyDusts and sludge fromsteel plants rich in ironoxides and even fineores can be processedafter agglomerationtogether in the OxiCupshaft furnace, a recentcupola development.Because the OxiCUPprocess can also easilymelt heavy metallicrevert materials likeskulls or metallicfraction fromdesulfurization slag,these materials may beleft out of the BOF andwill no longer impair thetreatment times becauseof their unknownanalysis.


PC-based X-ray inspection systemThe latest-generation for XrayII PC-based X-ray inspectionsystem from Vidisco, is said to provide the most sophisticatedand versatile CCD X-ray system available today.

The battlefield-proven system is based on a sophisticatedVideo Camera Unit (VCU) coupled to a laptop computer (ControlDisplay Unit—CDU) either through a wired or a wireless systemthat allows the operator to fully control the X-ray source from asafe distance. A ruggedised, waterproof carrying case onwheels houses all the components needed to operate thesystem, including the 50 m cable on a reel, and canaccommodate any golden pulsed X-ray source.

The equipment can work autonomously for hours on its internalbatteries and work for an unlimited time on any AC power (110/220 V automatically adjusting), or be powered for almostendless work by a vehicle battery when using a standard DC/ACinverter. Each Vidisco VCU can provide over two weeks ofoperation on a single battery charge.

(Ref : Insight)

Treasure hunt on the seafloorGeological Survey of India published a report that more thantwo dozens black smokers have been found undersea indifferent volcano-tectonnic settings. These smokers shows a richmineralization of gold and silver in addition to copper, lead

and zinc. Amongst the hydrothermal chimneys on the sea floor,some are called white smoker because of comparatively coolerwaters and presence of compounds of calcium, barium andsilica, which are white. From one such smoker in SW Pacific,gold inclusions were initially discovered at surprisingly lowtemperature of less than 3000 C.

A hydrothermal vent is a geyser on the seafloor: super-hotmineral rich water is continuously spewed through these ventswhich are deposited at site. Though the sea bottom is anextremely cold place the superheated steam from the womb ofthe earth makes the areas around the vents comfortable forsome rare creatures like eyeless shrimps (at the vents in theAtlantic ocean). These vents are known to exist in the Pacificand the Atlantic occeans at an average depth of about 2100metres in the areas of sea floor spreading along the underwatermountain chain, the Mid Ocean Ridge System that snakesaround the globe.

The hydrothermal vents are formed undersea because someareas along the Mid Oceanic Ridge plates of the earth’s crustare moving apart. This leads to the formation of cracks. Seawater seeps down from these cracks. The molten magmaunderneath the earth’s crust heats up that water and asuperheated steam enriched with minerals finds escape throughthe cracks and fissures. Though the vent water comes out attemperatures as high as 4000 C, it does not boil because of thepressure of the water coloun above.

More than 200 occurrences of hydrothermal mineralization areknown on the sea floor. The best amongst them is in Red Sea. Itis estimated that the vent contains 50 tonnes of gold, 4000tonnes of silver in addition to 94 million tones of ore with 2percent zinc and 0.5 percent copper. It is now believed thathydrothermal vents have been responsible for some of theworld’s richest ore deposits, like the copper ore of Cyprus.Geologists are already thinking in terms of mining some of themineral rich vents of the ocean bed. Problem is the economicviability of such extraction.

(Ref : Deccan Herald)

Managing high level nuclear wasteSpent fuel

High level nuclear waste consists of spent fuel or highlyradioactive residues left after reprocessing and extractinguranium and plutonium. Most of the radioactivity in spent fuelis due to fission products, which have relatively short half lives.

Their activity will reach background levels in a few thousandyears. Isolation of activity from biosphere for a few thousandyuears is achievable. High level waste is made non-dispersibleby vitrifying (incorporating them into glass, a material which isnon-leachable for thousands of years) it.

The public wrongly believes that vitrification process is storagein glass containers ! India has developed the borosilicatetechnology.

If any waste leaches from glass, it has to penetrate severalprotective barriers such as a stainless steel container, acladding of lead, a casing of titanium (a special corrosion-resistant alloy), several metres of backfill material such as clayor salt or granite before reaching the living environment. Eachof these will last thousands of years.

Titanium in flowing saline water dissolves at a rate of 0.0013mm per year. A six mm layer of titanium used to contain wastemay last at least 4000 years (IAEA, 1981). Roman lead articlessurvived in the Mediterranean for 2000 years with little loss.

Lead casing of 10 cm, which may be used with waste, shouldlast longer.

Archaeologists recovered over 875,000 nails from Inchtuthil inScotland, where Romans hid 12 tonnes of iron nails in AD 86.Nails from the outer few centimetres are heavily corroded; manyof those inside are almost intact after nearly two millennia.

(Ref : The Hindu)

Section view of a OxiCupfurnace showing the zones ofoperation and its components

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New Developments


AT HOME

FERROUS

New Blast Furnace at JSPL-Raigarh

Jindal Steel & Power Limited (JSPL)-Raigarh are in the process of setting-up their mega steel project for raisingthe steel production capacity fromexisting 0.7 million tonne per annum to2.5 million tonne per annum. Theprojects are nearing completion andwill be commissioned in next fewmonths.

As part of the expansion project, stateof the art blast furnace is beinginstalled. This will be the most modernblast furnace being set-up in India.The technology supplier for the blastfurnace is M/s Danieli Corus -Netherlands. The blast furnace willhave useful volume of 1681 Cu M withrated annual capacity of about 1.25million tonnes of hot metal. Theimportant features of the blast furnaceare as following:

● Specific Productivity-2.5 T/Cu M/Dguaranteed.

● 80% sinter ratio in the burden.

● Screening of sinter, iron ore andcoke at the Stock House.

● Continuous charging of rawmaterials through the beltconveyor.

● Bell-less Rotary Charging Unit(BRCU) and the stock levelindicator for proper distribution ofraw material within the blastfurnace.

● Carbon block lining in the hearth. ACopper plate coolers.

● Common tap holes for hot metaland slag.

● Slag granulation at the CastHouse.

● Mushroom domed Hot BlastStoves, 3 Nos.

● Waste Heat Recovery System forutilization of heat from out-goingflue gas from the Stoves.

● High top pressure of 1.2 bar.

● Hot blast temperature of 1250 deg C.

Pulverised Coal Injection system

● Oxygen enrichment andhumidification of blast.

● Guaranteed Coke rate (Net & Dry)400 Kg/THM along with 200 Kg/THM of pulverized coal.

● Tarpedo Ladle Cars for handling ofhot metal.

● Dry fog dust suppression systemcovering all the sensitive locationsand de-dusting system at the casthouse.

● Centralized control system formonitoring & regulating variousprocess parameters.

● Compact layout with maximumspace utilization and the bestengineering practices.

Optimization of energy consumptionthrough adoption of modern featureswill improve the overall economy of hotmetal production. The blast furnaceproject is being executed on non-turnkey basis with support from M/sMECON Ltd - Ranchi and consultants.

(Authors : Sri S Telang, Sri D K Saraogiand Sri P S Rana)

Alloy Steel Plant likely to ClockRecord Turnover

Alloy Steels Plant (ASP) Durgapur,hopes to post a marginal net profit in2005-06, after running up losses fornearly a decade. The plant is alsoexpected to post an all time recordturnover, exceeding Rs 650 crore forthe year, which is 15 per cent higherthan the previous year’s figure. Thespecial steels plant is now in theprocess of implementing a Rs 460crore up-gradation plan that willincrease its capacity to producestainless steel slabs among othermaterials. According to sources, ASPis planning to raise production to 4.31lakh tones of saleable steel by the year2012, when the up-gradation iscompleted.

(Ref : J P C Bulletin)

Bhilai provides rails for proposedfreight corridor

Rail Minister announced plans forRs 22000 crore dedicated multi modelfright corridor. Bhilai Steel Plant will

indigenously design, develop andmanufacture ‘thick web’ asymmetricalrails, to be used at major loadswitching points along the tracklength. This makes BSP the secondplant after Voest Alpine of Austria to beable to make these rails. TheCompany decided to apply for aprocess patent for it. With the freightcorridor project on, BSP is thus eyeinga potential domestic market ofanywhere between 5,000-10,000tonnes per year. In addition, thick webrails have a significant export potential.BSP is looking at the prospect of afairly bit export market opening upbefore it.

(Ref : Economic Times)

All-time best Performance byRourkela Steel Plant

Rourkela Steel Plant (RSP) ended thefiscal 2005-06 with a sterlingperformance registering best-everannual performance since inception ofthe steel plant. While productionsurpassed the earlier best levels,dispatches too reached a new peak.

The steel plant worked on a strategy ofincreasing volumes of production withemphasis on capacity utilization tobring down cost of production. Focuswas also on maximizing revenueearnings by production of value addedproducts from its wide range offinished products besides increasingdispatches and reducing finishedsteel stocks for sustaining profitability.

RSP’s products have become moreacceptable in the market which led torecord dispatch of saleable steel andsignificant growth over the previousfiscal in the production of nicheproducts.

(Ref : Ispat Sahayog)

Main Athletic Stadium, Hyderabad

The Main Athletic Stadium, NationalGames 2002, Hyderabad won the firstprize for INSDAG’s Professional AwardCompetition 2004-05. 1180 metrictones of reinforcement steel andstructural steel totaling to 1780 metrictones has been used in the stadiumconstruction. It was decided right fromthe beginning to give clear non-obstructed view of the sports area to allthe spectators. Roofing systemsupported on single column at back ofthe stadium and cantilevering over the

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News Update


spectators seating was developed.The stability of the system wasachieved by provision of a back-tie.The resulting structure was very lightweight. Expansion joints are located atregular intervals of 5 to 6 bays.

(Ref : Insdag News)

Largest Blast Furnace

JSW Steel Limited, recently signed acontract with Siemens VAI for settingup a 2.8 mtpa Blast Furnace, atVijayanagar works. This would beIndia’s largest blast furnace. While thecurrent expansion plant to increasethe capacity to 3.8 mtpa by March 2006(from the existing capacity of 2.5 mtpa)is on track, with the new blast furnacethe capacity is projected at 7mtpa by2008.

(Ref : J S W)

Jindal Steel in Race for World’sLargest Mine

Jindal Steel & Power is on the lookoutfor one of the largest iron ore depositsin the world, El Mutun, Bolivia. Themine is estimated to have more than40 billion tonne of reserves. Jindalsteel & Power is understood to be oneamong four companies in the race forEl Mutun. Industry sources said theiron ore project is valued at more than$ 1 billion.

(Ref : J P C Bulletin)

High grade Iron Ore exports amountto 12.38 million tonnes in 2005-06

Indian Commerce Minister Mr KamalNath said that high grade iron oreexport during the first ten months of2005-06 stood at 12.38 million tonnes.Mr Nath added that the governmenthad granted permission to 17companies for export of high gradeiron ore having over 64% iron contentduring 2005-06 for total quantity of 7.18million tonnes.

Cold Rolling Mill

A Cold Rolling Mill is being set up atBaidyabati near Dankuni by M/sUtkarsh Galva Limited. This is going tobe the second state of the art coldrolling mill in West Bengal. The projectwas taken up with a completion periodof 8 months. The main mill structure is42 metric tones wide x 162m long withcolumn height of 17.5 m. A 30 metrictonnes EOT Crane will ply at a height of12m. The quantum of steel consumedwas 600 metric tones for this structurehaving TATA SHS/RHS Portals, CHSPurlins & Side Runners with Built-upCrane girders. Columns were spaced

at a distance of 6m each. M/s ConceptProject & Consultancy Services did theConstruction on turnkey basis.

(Ref : Insdag News)

JSW Steel Ltd bags IMEA award

JSW Steel Ltd’s manufacturingexcellence was once againrecognized, when it was awarded theFrost & Sullivan’s India ManufacturingExcellence Awards (IMEA). Based onthe findings of the assessment andrecommendation of the panel, Frost &Sullivan announced JSW SteelLimited’s facility at Vijayanagar worksfor the Platinum Award in the MetalsCategory.

(Ref : J S W)

SAIL set to take over Neelachal Ispatin ‘06

SAIL is all set to take over NeelachalIspat Nigam Ltd. The merger was onthe cards for sometime after theCommittee of Secretariesrecommended take over. Thecompany was producing only pig irontill date. Now it will become the secondsteel plant in Orissa in less than threeyears’ time. The process is expectedto be completed by the end of this year.

(Ref : Econonic Times)

RSP emerges as front-runner inOrganisational Climate Survey

RSP has emerged as the front-runnerin a comprehensive survey carried outamongst all integrated steel plants ofSAIL.

This organizational climate surveywas carried out recently byInternational Management Institute(IMI), New Delhi. Among the objectivesof the survey was to compare therelative strengths and weaknesses ofvarious units of the organization. Thefindings state that “Rourkela SteelPlant stands out from the rest of thePlants as having the highest ratedclimate.” Several important factorswere considered while determiningthe final rating of OrganizationalClimate. These includecommunication system, costconsciousness, customer orientation,decision making, grievance handling,objectivity and rationality, qualityconsciousness, safety orientation,team work, training and developmentand organizational commitment. Thefindings revealed that RSP has themost highly committed workforce.

(Ref : Ispat Sahayog)

Posco to set up unit in Pune

Posco will process and sell 1.3 lakhtonne of electrical steel from its

upcoming Posco-India ProcessingCentre (POS-IPC) in Pune’s TalegaonIndustrial Complex. The $14 millioncentre will come up by November thisyear. Almost 25% of the output will besourced to LG and the rest will be soldin the local and international markets.The centre will include four cutting andshearing machines, including a grain-oriented magnetic steel sheet andstrip facility and will be capable ofproducing up to 130,000 tonne ofelectrical steel sheets.

(Ref : Business Standard)

Durgapur Steel Plant to supplywheels to Railways

Durgapur Steel Plant aims to supply1,20,000 wheels for Indian Railwayscoaches and to step up its steelproduction to 3mt by 2012. Rs 2,800crore has been earmarked as part oftheir corporated plan to augmentcompany’s steel production to 3mtfrom 1.86mt by 2012


Bhilai Steel Plant gets bestperformer award

Bhilai Steel Plant has been adjudgedas the best performing steel plant inthe country for the year 2004-05. Withthis, BSP will become the only steelplant in the country, public or private, tohave won it in seven out of the 13 timessince the award was instituted.


SAIL BSP to build New Ladle Furnace

Danieli Centro Met will supply a 130tladle furnace to Bhilai Steel Plant(BSP) for the steel melt shop II DanieliWean United will supply a new slabcaster for the same melt shop. Thescope of supply will extend from thetechnological equipment to theinstallation and commissioning,including the LF electrode regulationsystem and Level 2 automation byDanieli Automation, the fumetreatment plant, the ferroalloy feedingand additive system, the watertreatment plant, the civil works andstructures.


RebarZ

RebarZ are steel reinforcing barscoated with zinc. Corrosion of steelreinforcements is the key reason fordistress in concrete structures andcalls for heavy repairs andmaintenance. RebarZ have very highcorrosion resistance and increase thelife of RCC structures manifold. Theyhave been used extensively over the


Non-ferrous metals to keep shining inFY 07

As prices of non-ferrous metalscontinue to climb higher, companieslike Sterlite, Hindalco, Nalco andHindustan Zinc can see good growthin the current year. Last year, prices ofmost non-ferrous metals saw

last few decades and have beenproviding sustained protection even inadverse environments.

RebarZ involve metallurgical reactionbetween iron and zinc forming a seriesof alloy layers. Almost all coatedrebars (except RebarZ) exhibit thetendency of losing the coating on steelduring handling, & transportation,reduction in the bond strength, andtendencies of creep corrosion andholidays. RebarZ have excellentabrasion and wear resistance, highchloride and carbonation tolerance,besides providing cathodic protectionto steel.

The first project in India using RebarZwas at the Lotus Temple in New Delhi.Since then several institutions andorganizations like MSRDC, CentralRailways, CPWD, State PWDs, JNPT,Customs, Municipal Corporations,several private buildings andcommercial establishments havebeen using RebarZ in their projects.Many upcoming infrastructure projectsare also using RebarZ across thecountry.

(Ref : Construction World)

SAIL’s Salem Steel Plant to haveRs 1,553 crore expansion plan

SAIL has approved in principle aproposal for expansion of its SalemSteel Plant at an indicative cost ofRs 1,553 crore. It envisagesinstallation of steel making facilities,including a continuous slab caster(steel melting shop), expansion of theplant’s cold rolling capacity. The newsteel making facility to be completed in36 months will have a capacity toproduce 1,80,000 tonne of stainlesssteel slabs per annum. With this, thecapacity of SSP’s cold rolling mill willgo up from 65,000 tonne to 1,46,000tonne per annum. The overall capacityof the plant would go up to 3.70 lakhtonne.

(Ref : The Hindu)

NON-FERROUS

Nalco raises products price byRs 4,000 per tonne

NALCO raised the prices of itsproducts by about Rs 4,000 per tonnein the domestic market to adjust to thedemands of global steel markets,especially the London Metal Exchangewith immediate effect.


Hindalco readies aluminium sectorfunds

Hindalco industries is likely to spendRs 32000 crore on its expansionprogrammes in the aluminiumsegment in the next couple of years. Ifall projects materialize, the company’saluminium smelting capacity willincrease from 4.29 lakh to 1.5 mt. Thecompany announced plans to set up a3.25 lakh tonne aluminium smelter inSidhi district of MP at an estimatedcost of Rs 7,700 crore. It alsoannounced other large projects whichinclude a 3.35 lakh tonne aluminiumsmelter in Jharkhand costing Rs 7,800crore, a 2.6 lakh tones smelter and a 1mt refinery with a 650 MW power plantcosting Rs 11,000 crore in Orissa aspart of the Aditya Aliminium project anda 1.5 mt alumina refinery costingRs 4000 crore under Utkal AluminaProject. Smaller brown field projectsinclude the alumina capacity at Muribeing raised from 1.1 lakh tones perannum to 5 lakh tones per annum. Thecapacity at the Belgaum refinery will beraised from 3.5 lakh tones to 6.5 lakhtones. The high value added specialalumina capcity at Belgaum will behiked to 1.67 lakh tones per annumfrom the current 91,000 tonnes at acapital outlay of Rs 675 crore.

Along with Alumina expansion,Hindalco is also augmenting itssmelter and captive power generationcapacity at Hirakud. The companyplans to set up a 750 MW coal firedpower plant for the new smelter.


Vedanta wants SEZ status for OrissaPlant

Vedanta Resources has applied forspecial economic zone status to begranted to 5 lakh tpa grrenfieldaluminium smelter at Jharsuguda inOrissa with a 1215 MW power plant atan estimated cost of Rs 7,000 crore($ 1.6 billion) If the status is granted,the company will be able to operate thesmelter at a minimal cost and will savea lot of cost on account of taxes.


unprecedented gains on the back ofgrowing demand for outstrippingsupply. Average prices of aluminiumhave seen an increase of 13% in FY 06from FY 05. Copper prices have grownmore than 35% over the same period.Zinc has seen a rise of 43% in averageprices of FY 06. And the prices are stillrising. While aluminium and copperhave already seen 20-25% jump inprices in the current year, zinc pricesare almost 50% higher than the lastyear.


High non-ferrous metal prices reaprich returns for companies

The Indian non-ferrous metals sectoris gearing up for another year of growthand profit, as prices continue to rise ata time when new plants are coming onstream. Companies like Hindalco,Nalco and Hindustan Zinc havebenefited from price jump in FY 05Prices have rallied significantly in thelast few months. Average monthlyprices for aluminium have risen morethan 38% in the last one year. Averagecopper prices have risen 88% in oneyear to $6,400 per tonne in April. Thisis for cash contract.

Long term contract prices have risen104% showing persisting concernsover future supplies. For zinc, thesituation is the other way round. Herecash-contract prices have risen 137%to $3,100 per tonne levels. Long termcontract prices have increased by 70%over the same period of one year. AsME stocks of the metal continue todiminish concerns over short-termsupply are likely to push prices higher.

Concerns over supply of non-ferrousmetals combined with strongdemand-pull from consumerindustries are likely to keep metalprices flying high. In such a scenario,companies in the sector are likely topost robust growth.


Hindustan Copper net doubles to 112crore

Hindustan Copper Ltd recorded a100.55% growth in net profit to Rs112.27 crore for the year 2005-2006,compared to Rs 55.98 crore in theprevious year. The company’s higherprofitability follows a 88.42% rise ingross revenue earning at Rs 1,053,51crore (Rs 559.11 crore)



OTHERS

Excerpts from the speech of Shri B.Muthuraman President, IIM & MD, TataSteel in the Press Conference heldduring the 6oth Annual GeneralMeetine of IIM on 11th August2006 in Kolkata

With rapid unprecedented boom inInfrastructuraI projects across thecountry in roads, ports, airports, railwaysand housing sectors; there is bound tobe spectacular rise in the demand forsteel and aluminium. These dynamicforces will in turn exert amazingmultiplier effect on income, output andemployment generation in theIndian economy - Shri Muthuramancommented.

India must aim to enhance its steelproduction to over 100 mt per annumby 2020 as against 300 mt by Chinatoday itself. Similarly her currentaluminium smelting capacity of 1 mt perannum should rise to a 2 mt per annum.Per capita consumption of steel in Indiashould aim to grow from the presentlevel of 30 kg to 330 kg per head in tunewith the pattern of deveIoped countries.

The vision of 10% growth per annum ofthe Indian economy is very much anattainable proposition and not a far cry,if her economic development isspearheaded by the manufacturingsector including ferrous metals.

Given the growing Indian economy andher buoyant metal sector, there isbound to be demand supply gap in theavailability of qualified metallurgists. Atthis crucial junction IIM should step into fill up this impending void. IIM as thelead Institution will have to draw theroad map for enhancing India’sstanding in the global metal industry inthe next 10 years. To meet thechallenges and seize the opportunitiesthe institutional set up of the IIM shouldbe geared up. India will require 20,000to 30,000 metallurgists in the next 10years. IIM should guide and inspiretalented young people to take upmetallurgy as a profession, whichwould be a stable income earner in theyears ahead. The IIM through its

institutional network of 52 Chaptersspread across the length and breadthof the country is poised to usher in reallymeaningful collaboration by andbetween Indian industry, academy andresearchers on a common platform.Series of conferences, seminars andworkshops are going to be organizedfor mutually beneficial interactions.

L & T to decide on Location forShipyard

Mr M V Kotwal, senior EVP of HeavyEngineering Division of Larsen &Toubro said L & T will invest about $110 million to set up a shipyard thatcan build huge vessels includinglarge crude carriers. He said thecompany was examining potentialsites, both along the East and Westcoasts of the country that would beideal for a shipyard.

Greenfields pull Rs 1.4 lakh croreinto Orissa

Orissa has signed MoUs worth astaggering Rs 1,37,156 crore withas many as 43 steel companies forsetting up Greenfield steel plants fora total capacity of 58.04 mt. And mostof these were signed in the previousfiscal. Investment to the tune of Rs40,000 crore is flowing into thestate’s aluminium sector. Out of 43steel companies, as many as 13mostly small investors havecompleted phase I of their project.And, about 14 have made someprogress in setting up their projects.However, six big ticket projects,including the $ 12 billion Poscoproject are yet to take off. In thealuminium sector, VedantaResources has begun work on its1.4 mt alumina project at Langigarhin Orissa’s Kalahandi district. The$ 800 million project is expected tobe commissioned in March 2007.Hindalco is commissioning a 1 mtaumina project at Kasipur inRayagada district with an investmentof Rs 4,000 crore. Its groupcompany, Aditya Aluminium, haslaunched work on its world class Rs11,000 crore auminium projects inthe Koraput district.

Amidst all hype for new investments,brown fields projects, despite theirtotal size of Rs 10,000 crore, aresomewhat unnoticed. Nalco isinvesting Rs 4,091 crore into itsPhase II expansion programme.Hindalco is investing Rs 1,000 crorefor enchancing the metal capacity ofits Hirakud smelter to 1,46,000tonne from 65,000 tonne and powergeneration capacity from 67.5 mw to317.5 mw in a phased manner. Aspart of its programme to become a 1mt sponge iron producer and 100mw power generator, Tata SpongeIron Ltd will invest Rs 800 crore for isplant at Bilaipada in Keonjhardistrict. It recently expanded itssponge iron capacity to 3.90 lakhtonne. Tata Refractories haslaunched an expansion andmodernization programme of its unitat Belpahar in Jharsuguda districtwith a capital outlay of Rs 282 crore.With the completion of the project,the plant capacity will increase from1,23,000 tonne to 2,45,000 tonne byMarch 2007.

(Ref : Financial Express)

Materials Camp

The second ASM Materials Camp,was conducted at the Indian Instituteof Technology, (IIT), Bombay,Mumbai, India from April 24 to 28,2006. A total of 25 students from nineJr. Colleges actively participated inthe camp. The students performed‘hands on’ experimental work in thelaboratories of Dept. of MetallurgicalEngg. and Materials Science, IITBombay, Mumbai. The experimentswere on: Heat Treatment of carbonsteels and stainless steels;evaluation of hardness andmicrostructure (optical) of heattreated steels; Powder Metallurgyprocessing-compaction andsintering, powder characterizationand surface area measurement byB.E.T. technique; X-ray diffraction;corrosion potential measurement.Electroplating of nickel and copperand estimation of current efficiencyin each case, Cementation process(Immersion Coating),Characterization of polymers-melt


flow index, melting point and density.The students were also exposed tomechanical testing, modes offailures and their identification byelectron microscopy (SEM) andactivities of the Industrial DesignCentre of IIT Bomaby. Industrialvisits were also organized.

The camp evoked a positivefeedback from the students. It wasvoiced by everybody that the camphas ‘opened their eyes’ to MaterialsEngineering and Technology as anattractive option for their careers.

(Ref : Report from ASM International)

Tata Steel, Mittals Eye SA Co.

Tata Steel is learnt to be exploringthe option of bidding for a controllingstake in South African’s HighveldSteel and Vanadium Corporation.The move will pit the country’slargest private sector steel companyagainst the world’s largest companyMittal Steel. It will also boost theIndian company’s efforts to increaseits presence in the lucrative SouthAfrican steel market.

It has been reported earlier that theMittals-who own the largest steelcompany in South Africa-hadexpressed interest in acquiringHighveld which has been put on theblock. Having Highveld under its beltwould enable Mittal in South Africa togain majority control of the SouthAfrican steel market, which has oneof the highest prices for steelproducts anywhere in the world.

(Ref : Steel Scenario)

Minister confirms that CIL is not onPrivatization List

Minister of State for Coal, Dr DasariNarayana Rao informed that there isno more to privatize Coal IndiaLimited, its subsidiary companies orthe coal mines operated by them atpresent.

Comparing CO 2 emissions andEnergy demands for AlternativeIronmaking Routes

Re-melting 100% scrap in an EAFoffers the lowest energyrequirement and lowest CO2

emissions of any steelmaking routereducing these by 65% and 77%respectively when compared with atypical N American blast furnace -oxygen converter charging 89%molten pig iron and 11% cold scrap.For high grade steels where an allscrap charge cannot be used, theenergy requirements of the BF-BOF(89% hot pig, 11% scrap) route are9% lower compared with charging80% cold DRI to the EAF but CO2

emissions are 40% higher if the DRIis made using natural gas. (By GEMetius, J M Mcclelland & Dr SHornby-Anderson).

(Ref : Steel Times International)

Broner Metals Solutionsestablishes partnership with CISDIfor inplementation of planning &scheduling solutions in China

Watford, UK, 1st June 2006. BronerMetals Solutions, leading providersof supply chain planning,scheduling and manufacturingexecution systems, specifically forthe Metals Industry, has announceda new partnership, working withCISDI in China, for theimplementation of Broner’sAdvanced Planning & Scheduling(APS) solutions in the growingChinese market.

About CISDI

CISDI Engineering Co., Limited(CISDI) is an internationalengineering company based inChongquing, China, that is focusedon the steel industry.

About Broner Metals Solutions

Broner Metals Solutionsspecializes 100% in deliveringvalue to the Steel and Aluminiumindustries.

FROM ABROAD

FERROUS

For further information pleasecontact:

Broner Metals SolutionsRichard Wightman+44 1923 652032-direct,+44 1923 [email protected]

(Ref : Press Release, Broner MetalsSolutions)

Daegu Stadium, South Korea

The Daegu Stadium, South Korea,originally appointed Atkins asconceptual designers for a 70,000-seater stadium for the 2002 footballWorld Cup in South Korea. Thesteelwork was fabricated on site infive sections. These were lifted ontotemporary towers before beingwelded together the form the 273 mlong arch. The arches themselvesare supported on concrete towerstied into the bedrock with rockanchors. An elegant lightweight roofwas designed to keep the weightdown and provide a high degree oftransparency.

(Ref : Insdag News)

IRCON to build Rail Link for MittalSteel in Liberia

IRCON International has bagged$ 1.10 million rail link constructionproject for Mittal Steel in Liberia.The project involves rehabilitationof a 250 kilometers long railway linewhich had been abandoned 15years ago and 350 wagons. Thetrack will move about 15 milliontonnes of iron ore per annum by theend of 2007.

Mittal Steel entered into anagreement with the Government ofLiberia last year gave the companyaccess to approximately one billiontones of iron ore reserve. Thecompany is now involved indeveloping the mines and relatedrailway and the infrastructurearound the mining area to startshipments by 2007.

Buildco to set up $61 M Steel Plantin Abu Dhabi

Abu Dhabi National Company forbuilding materials (Buildco) issetting up a DH225M (US$ 61.2M)steel plant with an annualproduction capacity of 300kt-350kt,sources said.

The new facility will produce re-enforcing steel. The company is to


sign the supply contract by the firstquarter of 2006. Already thecompany has acquired 44500m ofland in the up-coming IndustrialCity of Abu Dhabi (ICAD)-2 for theproject to be called Buildco Steel.

(Ref : Steel Times International)

Mr DiMicco becomes NucorChairman

Nucor Corp CEO Mr Dan DiMiccohas assumed the additional role ofcompany Chairman, Mr DiMicco hasbeen president, CEO and amember of the company’s boardsince September 2000. He hasbeen Vice Chairman since June2001.

The board has also appointed PeterBrowning, formerly non executivechairman its lead director. MrBrowning, former dean of theMcColl Graduate School ofBusiness at Queens University ofCharlotte, has been a Nucordirector and non executivechairman since September 2000.

Cap Lambert to begin Pilbara ironore drilling next month

Cape Lambert Iron Ore Ltd hasannounced plans for a reversecirculation drilling program at itsiron ore project in the Pilbara regionto commence next month. Thedrilling program, the first by thecompany at the project, will be for atotal advance of approximately4000 meters. The first drillingphase will provide the companywith further data relating to themineral processing characteristicsof the known deposit.

IISI joins UNEP’s SustainableBuildings and ConstructionInitiative

The International Iron and SteelInstitute have joined the UnitedNations Environment Program onSustainable Building andConstruction Initiative as a FounderMember. Through its involvementwith UNEP, IISI will work in thisimportant sector to further developsolutions that focus on sustainableconstruction solutions. In onespecific area, IISI already has itsown program, “Living Steel”, whichis focused on meeting the growingdemand for housing, withaffordable sustainable solutions.

MUFG increases equity stake inNippon Steel

Japan Metal has reported thatMitsubishi UFJ Financial Group Inchas spent some billion yen toincrease its equity stake in NipponSteel Corp from 1.5% to 2% atrequest of the steelmaker.

Nippon Steel has asked the bankholding company to become astable shareholder to help preventany hostile takeover bids, thesources said. Among other majorJapanese banking groups, MizuhoFinancial Group Inc has a 4.6%stake in the largest Japanesesteelmaker.

Arcelor-Mittal braces forintegration

Mittal Steel’s final bid represents a49% improvement over its originaloffer. The offer gives Arcelorshareholders the option ofexchanging each share of theirs for12.55 euros in cash plus 1,084shares of Mittal Steel. Alternately,Arcelor shareholders have theoption of subscribing to a pure cashoffer of 40.4 euros per share as wellas a pure share swap offer in theratio of 11 Mittal Steel shares forseven Arcelor shares. This issubject to condition that 69% of theoffer be in the form of exchange ofshares and a maximum of 31% inthe form of cash. This means thatthe total cash outgo for Mittal Steelwill be around 7.8-8 billion euros.

● Arcelor to have a new CEO.

● Arcelor shareholders to beoffered cash, Mittal Steel sharesor a combination of cash andshares.

● A mixed offer at Î 12.55 in cashand 1.084 Mittal Steel sharesper Arcelor share.

● A cash offer at a price equal to Î40.4 per Arcelor share.

● Shareholders of Arcelor andMittal Steel will hold 50.5% and49.5% of Arcelor-Mittal,respectively.

● Mittal Family to own 43% of thecombined entities agree to alockup for 5 years and astandstill at 45% of equity.

● The Board of Directors will beseparate from the managementboard and have a majority ofindependent directors.

● The Board of Directors will have18 members, 12 currently inplace at Arcelor, includingArcelor’s 3 employee reps, and6 Mittal Steel nominees,including 3 independentdirectors.

● The combined group will bedomiciled in Luxembourg.

● The Management Board willhave 7 members: 4 currentArcelor members, including theCEO and 3 Mittal Steelnominees.


Arcelor investors reject SeverStaldeal

Arcelor Shareholders rejected amerger deal with Russia’sSeverStal, clearing the way for anagreed $ 32 billion take over byMittal Steel. Shareholdersrepresenting 57.94% of capitalvoted against the plan which wouldhave given SeverStal’s main ownerAlexei Mordashov a key stake in themerged group. At least 50% of thecapital was required to block thedeal. Seeing this vote, the board willnow unwind the agreement with MrMordashov. Originally hailed byArcelor’s board as salvation, thedeal with SeverStal was the primeobstacle to the company’s presentagreement with Mittal Steel to joinforces.


Jindal Steel & Power Ltd (JSPL) toset up Steel Plant in Bolivia

Jindal Steel & Power Limitedhasbeen allowed by the BolivianGovt. to set up a US $2.3 billionintegrated steel plant by sourcinglocally available rich iron ore. TheJSPL has been granted the miningrights for 20 billion tones of iron orereserves from El Mutun iron oremines in Bolivia. The companyplans to invest $2.3 billion over nexteight years in creating anintegrated steel plant, which wouldbe capable of producing 1.7 milliontonne per annum of long productsof steel. The company will set up asix Mtpa capacity DRI/sponge ironplant and a pellet plant with acapacity of 10 Mpta. The companyalso plans to set up supportinginfrastructure for the proposedplant including a 400 MW powerplant

(Ref : Deccan Herala)


NON-FERROUS

METAL SCIENCE

Market for Electronic Waste toExceed $11 Billion by 2009

The global market for electronic wasteis expected to rise at an averageannual rate of 8.8% over the next fiveyears, from $7.2 billion in 2004 to anestimated $ 11 billion in 2009. Thefaster revenue growth will be seen inthe recycled plastics sector, which isexpected to grow at an average of10.2% per year in response toincreased demand for high-valueengineered plastics. Growth in metalsrecovered from end-of-life electronicwaste will continue to outpace thebroader recycled metals market,growing at an annual rate of 8.1%,

Platinum, Palladium use likely to goup

Platinum demand will beat productionin 2006 for an eight consecutive yearsas automakers install more plllutioncontrol devices. The use of platinum inauto-catalysts will exceed 4 millionounces in 2006 compared to 3.8million last year. Platinum demandamong automakers gained 9.5%. Useof palladium also used in auto-catalysts, rose to a four year high lastyear. Automakers are also changingthe mix of metals in auto-catalysts tosubstitute platinum with palladium,whch is cheaper.

(Ref : The Financial Express)

The Carbothermic Route toMagnesium

The carbothermic reduction ofmagnesia to produce magnesiumoffers the potential of a lower energyand higher productivity route for metalproduction compared to existingindustrial routes. The reaction ofmagnesia and carbon produces amagnesium and carbon monoxidevapor. Slow cooling of that vapor willallow the reaction to quickly revert andthe prevention of this reversionreaction is a major technicalchallenge. Two main approaches canbe taken to prevent reversion andallow recovery of the metal product;rapid quenching of the vapor anddissolving the magnesium directly in asuitable metal solvent beforereversion can occur. The commercialviability of either carbothermic route tomagnesium is closely connected to bephysical chemistry of each system.

(Ref : J O M)

Aluminium

In the 19th centrury aluminium wasconsidered rare and novel. An ingot ofthe ‘new precious metal’ was evendisplayed in 1855 at a Paris exhibition,and at that time the metal was moreexpensive than gold.

Aluminium remained rare until 1886,when two teams workingindependently of each otherdiscovered an electrolytic process forrefining aluminium from bauxite. Thepair simultaneously found that if they

while the market for recycled glasscontinues to be stagnant, with lowvalue attached to recycled glass.

Electronic waste is growing at threetimes the rate of other waste in themunicipal solid waste stream,resulting in the need to rapidly curbtoxins in the waste stream. Electronicwaste equals 1% of solid waste onaverage in developed countries and isexpected to grow to 2% by 2010. Indeveloping countries, electronic wasteas a percentage of solid waste canrange from 0.01% to 1%. However, ledby China, developing countries will bethe fastest growing segment of theelectronic waste market with thepotential to triple output over the nextfive years. (www.tms.org/jom.html)

(Ref : J O M)

Insights into siliconsemiconductors

The researchers from the Universityof Wisconsin-Madison examinedthe inimitable 7x7 surface structureof Si (111), the most stable surfaceof silicon. Surfaces and interfacesdominate in today’s silicon devices,since the surface to volume ratiogoes up in small structures. Thesetwo dimensional structures aredifficult to study and the SRC workexplores an aspect that hasremained unexplored onsemiconductors so far. Resultsreveal a very unusual surface bandstructure which can be bestexplained by a mechanism called‘electron-phonon interaction’.Phonons are vibrations of theatoms, which are surrounded byelectrons. By shaking the surfaceatoms the orbiting electrons ‘feel’these vibrations and change theirmovement in a characteristic way.The research work connects twointensively studied fields: electron-phonon interaction that causesconventional superconductivity andsemiconductor surfaces which areof great importance for electronicdevices and semiconductortechnology. The current study is thefirst example of such examinationon a semiconductor surface thoughsimilar research has been done onmetal surfaces. The ultimate goallies in the possibility of tailoringmaterials for a new generation of‘designer superconductors’.

(Ref : The Hindu)

dissolved bauxite in a bath of moltencryolite and passed a powerful electriccurrent through it, molten aluminiumwould be deposited at the bottom ofthe bath. The Hall Héroult Processtakes its name from these co-discoverers - Paul Louis ToussaintHéroult, from France and CharlesMartin hall from the USA. This processenabled the mass-production of themetal, and the first factories went intoproduction two years later.

In industry aluminium is valued for itslight weight, and is used in the aviationindustry where it can cope with thestresses and strains involved withhigh altitude flying. The Wrightbrother’s first aeroplane, whosemaiden voyage was in 1903, had afour-cylinder. 12-horse power auto-engine modified with a 15 kgaluminium makes up 80% of theunladen weight of the 5,300 aircraftflying around the world.

The light weight of aluminiumcontributes to fuel efficiency and overthe life of a vehicle, for every tonne ofaluminium used it will save 20 tonnesof carbon dioxide equivalents whencompared to a tonne of traditionalheavier materials. Aluminium alsoabsorbs kinetic energy, and so for alargely aluminium vehicle in animpact, the structure absorbs much ofthe shock, rather than the vehicleoccupants, and so far this reason it isused extensively in off-road vehiclessuch as the Land Rover.(www.iom3.org)

(Ref : Materials World)


IISI News Items - 2005 ULSAB,ULSAC, ULSAS etc.

ULSAB has provided the ideas andinnovations automakers need to buildlightweight, fuel-efficient automobilesthat are affordable to consumers. Theimportance of the ULSAB projects wasrecently recognized with theprestigious 2005 Stars of EnergyEfficiency award from the US Allianceto Save Energy. The ULSAB projectsstarted with the goal to maintainsteel’s position in the automobile. Butthe projects continue to positivelyimpact the largest industry in theworld, and its customers.

IISI’s Committee for AutomotiveApplications (AutoCo), continues itsaggressive global collaboration thathas proven to be so successful. Anumber of projects encompassingresearch and market development areunderway. The projects focus onmaintaining or advancing steel’sposition in the automotive sector.Future technology and relatedopportunities to position steel in theforefront of achieving automaker goalsare also underway.

With this ongoing work, AutoComember steel companies helpcustomers use steel, the besttechnology available, to make thesafest, efficient and environmentally-friendly vehicles the world has yetknown. Following is a brief synopsis ofAutoCo’s latest work:-

a) Advanced High-Strength Steel(AHSS) Application Guidelines.

b) Alternative Vehicle Architecture:Market Intelligence Survey.

c) CO2 Life-cycle.

d) Competitive Analysis andBenchamarking.

e) High-Strain Rate Test Methods.

(Ref : IISI Annual Review)

A report on the 12th InternationalConference on ‘Rapidly Quenchedand Metastable Materials’

The 12th International Conference on‘Rapidly Quenched and MetastableMaterials’ (RQ 12), held in Jeju Island,Korea (21-26 August, 2005), wasattended by more than 350 scientistsfrom 22 countries. There were

OTHERS8 participants from India.S Ranganathan and K Chattopadhyay(IISc) and B S Murty (IIT Madras)presented invited talks and chaired thetechnical sessions. N KMukhopadhyay (BHU) made an oralpresentation and chaired a session.‘RQ Distinguished Fellowship’ forpioneering and landmark contributionin the field of RQ was awarded to R WCahn (University of Cambridge, UK), TMasumoto (Tohoku University, Japan)and D Tumbull (Harvard University,USA). There were four parallelsessions for the oral presentations.Most of the papers and discussionswere on (i) metallic glasses andbulk metallic glasses (BMGs),(ii) nanomaterials, (iii) quasicrystals(QCs) and complex crystallinematerials, and (iv) rapidly solidifiedmetastable materials.

China & India move up on pollutingnation’s list

“Greenhouse gas emissions fromChina and India are growing veryrapidly at the moment, very muchbecause of inefficient investments inenergy, in power generation.”

According to the World Bank’s LittleGreen Data Book released recentlyChina increased carbon dioxideemissions by 33% between 1992 and2002. India’s emissions rose by 57%during the same period. He said themain reason that the emission fromChina and India are rising so fastcompared to the rest of the world,which is a 15% rise in carbon dioxideemissions between 1992 and 2002,was older & inefficient coal fired powerplants in both countries. While cleanercoal fired plants are possible, Indiaand China cannot afford to make theswitch.

US remains the world’s biggestpoluters accounting for nearly 24% ofall emissions of carbon dioxideglobally, while EU contributing almost10%.

41.79 million tonne Shortfall in Coal tobe Bridged by Imports

Indian government proposed to meetthe shortfall in coal through imports,which stands at 41.79 million tonnes.Minister of State for Coal Dr DasariNarayana Rao said 432.39 milliontonnes of coal would be suppliedthrough domestic sources in 2006-07that fell short by 41.79 million tonnes tomeet demand forcast.

IISI Extranet

IISI’s Extranet provides members withfast, secure, and efficient access to thework of the Institute. Introduced inNovember 2001, the Extranet is nowused by over 2,700 representativesfrom our 180 member companies. InApril 2005, a new Software wasinstalled to ensure that the Extranetcontinues to be an effective tool. Theupgrade has provided members withnew features such as an improvedhomepage and search facilityNavigation is also made easerthrough the implementation of theTopics & Projects area, making itquicker to locate information. Theresponse time of the Extranet has alsobeen dramatically improved.

The Extranet now features directaccess points for statistics,membership data and informationabout IISI. The About IISI section nowincludes a list of IISI staff with directcontact details.


Steeluniversity.org

Late in 2004, IISIs steeluniversity.orgProject was selected as one of thewinners of the 2004 EuropeanAcademic Software Awards (EASA).The EASA award aims to stimulate theunderstanding development and useof knowledge media within highereducation in Europe. The awardconfirms steel university’s place at theforefront of web-based steeleducation.

Modules are typically launched forevaluation via the steel university.orgsite before being finalized. Over thepast year new modules have beenadded including Steels inConstruction, Sustainability andContinuous Casting. An additionalfour modules are scheduled forcompletion in 2005. Information hasalso been added on SteelApplications, Steel Processing andFerrous Metallurgy. Some modulesare interactive real-time simulations.


WEBSITE


DELHI

Diamond Jubilee Celebrations

To mark the completion of 60 years of the formation of IIM,India’s premier body of professional metallurgists, DelhiChapter of IIM is celebrating and hosting a mega DiamondJubilee Event by holding 6th International Trade Fair &Conference - 2006 in Minerals, Metals, Metallurgy andmaterials (MMMM 2006). These celebrations comprise of aconference with the theme as “Unleashing India’s Potential inMetals and Minerals” to be held during September 11-13, 2006.There will be concurrent Exhibition from 11-14 September,2006. These events shall be held at Pragati Maidan, NewDelhi. These celebrations have been co-sponsored by theMinistry of Steel, Min. Coal & Mines, Min. of Heavy Industriesand Public Enterprises, Min. of Small Scale industries, Min. ofCommerce and Industry, Min. of Science & Technology,Council of Scientific & Industrial Research, PlanningCommission, Govt. of India.

DUBURI

The Duburi Chapter of IIM, Jaipur, Orissa, was inaugurated on25th July 2005 and is the youngest of all Chapters. TheChapter has members from all the units of this area.

The Chapter has decided to undertake a number ofprogrammes which are as follows :

● Internal discussion/presentation on improvement ofworking system.

● School/College quiz from Class VII to Class XII studentsof local school and colleges in different group.

● Participation in workshop on “Analytical InstrumentalTechniques - Current Trends & Practices” organized byIIM - Bhubaneswar Chapter.

Further Duburi Chapter also plans to start an examinationcentre in this locality to promote metallurgy amongyoungsters.

HYDERABAD

Technical Lecture

Dr R Kasiviswanatham , Manager, Materials/ReliabilityEngineering, Sandvik Rotary Tools,

CHAPTERS

Inauguration of the technical lecture programme byDr R Kasiviswanatham

Houston, Texas delivered a Technical Lecture “AbrasionResistance Testing of WC-Co Composites” on 25th May2006 at Sundarayya Kala Kendram, Hyderabad. The speakerhighlighted processing, mechanical testing andmicrostructures of WC-Co composites.

RANCHI

Professional Activities

● Delhi Public School, Satellite Colony: 2 teams● DAV, JVM, shyamali: 2 teams● Kendriya Vidyalaya, Hinoo: 2 teams● St. Thomas School, Dhurwa: 2 teams● DAV Public School, Hehal: 2 teams● DAV Kapildev, Kadru: 2 teams● Guru Nanak Higher Secondary School, PP compound: 1 teamTotal : 13 teams from 7 schools

Participating School, Ranchi Winner Runner-up

Guru Nanak HigherSecondary School:(Riya Rani, NaziaHassan & AlishaanHaider)

DAV JVM, Shyamali-2nd Team(Chandan Kumar,Ankit Shrivasava andSavan Kumar)

● Delhi Public School, Satellite Colony, 3 students ● DAV Public School, Hehal: 2 students

Guru Nanak Higher Secondary School,PP Compound: 1 student

Total : 7 students from 3 schools

Participating School, Ranchi Winner Runner-up

Ms Monica fromDPS, Ranchi

Joint award : ● Ms Ankita, DAV

Hehal ● Ms Riya Rani, Guru

Nanak HigherSecondary School

Distinguished Service Award (1 No.)

WinnerAward

● Sri S Chakraborty, RDCISAward of Excellence (3 Nos.) ● Sri B B Mazumdar, MECON

● Sri Sushant Rath, RDCIS● Sri Madan Kumar, CET

Best Paper Publication Award (4 Nos.) (Elevenpapers were received)

● Dr M S Prasad, RDCIS● Dr Surendra Kumar, NIFFT● Dr S N Prasad, RDCIS● Sri N K Das, RDCIS

International Conference on “CokingCoals and Coke Making: Challengesand Opportunities: ICC 2005”

Seminar Date Vanue, City

Dec. 12-15,2005

RDCIS, SAIL,Ranchi

IIM Ranchi Chapterin association

● RDCIS,● CET● MECON

Quiz competition on “Metals and Materials-2005-06” forthe School Children at Ranchi level on January 22, 2006.

Debate competition on “Huge Potential of SteelIndustry in Jharkhand: Myth or Reality” for the SchoolChildren at Ranchi level on April 25, 2006

IIM Ranchi Chapter Awards

TRICHY

Technical Lecture

A Special Lecture was delivered by Dr K Bhanu Sankar Rao ,Head Mechanical Met. Division, Kalpakkam, The theme of thelecture was “Mechanical behaviour of Ferritic Steels”. TheChapter won two coveted awards:

1. Best Chapter in the country among the largest chapters ofour Country (Nine times)

2. Minimum Defaulters Award for the Fifth Consecutive Year

IIM Activities


It is a record in the history of IIM. The plaques were receivedby chapter Vice Chairman, Sri G Uma Shankar , Addl. GeneralManager, WRI for Dr Baldev Raj , President, IIM, during theinaugural function of 59th NMD held at Chennai on 14thNovember 2005.

TRIVANDRUM

19th Prof. Brahm Prakash Memorial Lecture-2006

The 19th Prof Brahm Prakash Memorial Lecture of IIM -Trivandrum Chapter was delivered by Dr S Banerjee , VicePresident, IIM, Chairman, Metal Science Division and Director,BARC, Mumbai on 23rd February 2006 at Trivandrum. In hisaddress entitled “Challenges in the Selection of Materials forNuclear Applications”, Dr Banerjee dealt in details, the

Sri R V Perumal , Director, LPSC (ISRO), Trivandrum and theInaugural session was presided over by Prof T KChandrashekar , Director, RRL-Trivandrum. Dr S Banerjee ,Vice President IIM and Director, BARC offered felicitation.

VARANASI

The Varanasi Chapter, in association with Metallurgy Society(METSO), BHU, organized Metals and Material Quiz (MMQ-2005) on August 28, 2005 for selecting the best school teamof Varanasi to represent the Chapter at the National LevelProfessor Brahm Prakash Memorial Materials Quiz-2005organized by IIM Kalpakkam Chapter. Dr R K Mandal , was thequiz master. The team from Sunbeam School, Bhagwanpurstood first in the quiz competition.

VIJAYANAGAR

Highest ever Converter Life of 13771 Heats in India, adream of JSW become reality

JSW Steel has finally put down their Converter-I for campaignrepair after successfully completing 13771 Heats.

Some of the highlights of JSW Converter-I are as follows:

1. Highest ever converter life in India (13771 Heats)2. Longest ever campaign from 21/11/2004 to 26/06/2006

(19 months)3. Highest ever production of 1.78mt from a converter in a

single campaign4. Minimum residual brick length found 54mm at the lower

part of the barrel towards non-drive side.

This was made possible with continuous monitoring ofrefractories, proper action on the feedback of regular liningmeasurement, slag splashing, proper blow & slag regime,optimized flux and iron ore usage and maintaining uniformlylow tap temperature. JSW is aiming for greater than 10000Heats as an average converter life.

VISAKHAPATNAM

Aug-Nov 2006 A talk on Personality and Leadershipquality development to students ofMetallurgy Engineering, Andhra University,Visakhapatnam.

Technical talk on opportunities inMetallurgy and Material Science to bedelivered by Dr V V Kutumba Rao ,Principal, Gitam College of Engineering,Visakhapatnam. The talk will be organizedat premier institutes having Sciencestream for Class XI & XII.

Organizing inter school debate betweenthe students of Class IX & X on topicsrelated to Steel Industries.

Dr S Banerjee, delivering Brahm Prakash MemorialLec tu re

development of Indian nuclear energy programme and thematerials of construction in various type of nuclear reactors.Dr P P Sinha , Deputy Director, Mechanical Engineering Entity,VSSC, Trivandrum, introduced the speaker and chaired thesession.

The IIM Trivandrum Chapter had organized 2 (two) dayNational Seminar on “Advances in Nano, Metal andCeramic Matrix Composites” during 23-24, February 2006at Trivandrum. The seminar was attended by more than 100delegates from all over the country and was inaugurated by

Sri R V Perumal, Director, LPSC (ISRO), Trivandrum,Inaugurating the Seminar

Dr K Bhanu Sankar Rao, delivering the Lecture


30.17.05 Prof A K Seal Memorial Lecture on “Coke- B E COLLEGE Dr T K Roy , Tata Chair Professor Dept. of Met. &will be the cause?” Mat. Engg. and Director M N Dastur School of

Materials Science and Engineering, BASU,Shibpur, Howrah

24.08.05 “Electron Microscopy” B E COLLEGE Dr T R Ramachandran , Former Director,JNADRC, Nagpur and consultant NFTDC,Hyderabad

10.09.05 “Pursuit of Science-Joy and Pride” COIMBATORE Dr Baldev Raj , President of IIM

07.02.06 “Super Plastic forming & Ultra fine COIMBATORE Dr Abjit Dutta , Scientist-G, DMRI, Hyderabad

Grain Refinement”

03.06.06 “Effect of Cyclic Annealing on Stee/White DURGAPUR Prof D Mondal, NITCast Iron”

06.07.06 “TPM for Metallurgical Industries” ICHAPUR Sri V K Singh , DDG, Ordnance Factory Board

12-14.01.07 A Technical Festival on “Exclusive KANPUR Sri Saket Raj Tripathi Hon. Secretary andEmphasis on Metallurgy, Materials and STUDENT Ms Priya Ghatwai , Jt. Secretaryrelated fields” CHAPTER-VINT

03.08.06 “Metallic Material Testing Systems RANCHI Mr Gerad Lim and Mr Hermann Bloching ,

Standards & Producers” from Zwick Roell, Germany

26.09.05 “Special Steel Products, Processing RANCHI Engineers from RDCIS, TISCO, JadavpurProperties and Users University, ASP, NIFFT

11.11.05 “Coal Analysis Instrumentation” RANCHI Team members from Changsha KaiyuanInstruments Co. Ltd. China

18.11.05 “High Strain Rate Testing” RANCHI Mr R Bardenheier , Instron Ltd., U K

09.01.06 “Delhi Iron Pillar” RANCHI Dr R Balasubramaniam , IIT, Kanpur

11.07.05 “The Quasi Crystal Story” TRIVANDRUM Prof T R Anantharaman , Former V C, BHU,Varanasi

04.10.05 “In-situ Composites and nanocomposites” TRIVANDRUM Prof B S Murthy , Dept. of Met. & Mat.Engineering, IIT Chennai

01.06.05 “Micro Structural Characterization TRICHY Dr Anish Kumar , IGCAR, Kalpakkamusing Ultrasonics”

27.07.05 “Welding of Titanium and its Alloys” TRICHY Sri T K Mitra , BHEL,Trichy

08.08.05 “Degitally Controlled Inverter Welding TRICHY Sri Lauri Leinonen , Kemppi OY, FinlandPower Sources”

25.08.05 “Energy Scenario and Interaction” TRICHY Sri S Mahadevan , ICP, Council of India, Chennai

27.08.05 “Manufacturing of thick walled Pipes” TRICHY Sri J D Chandel , Welspun Gujrat Sthal RohrnLtd. Dahej

04.10.05 “Ischaemic Heart Diseases” TRICHY Dr V N Balakrishnan Sharma , BHEL, Trichy

28.10.05 “The number ‘e’” TRICHY Sri V Thyagarajan , AGM, BHEL, Trichy

17.11.05 “Historical Perspective on Compressor TRICHY Dr Srinivasan Shanker , USAand Turbine Coatings”

30.11.05 “Application of Fracture Mechanics in TRICHY Prof Dr V P Raghupathy , PESIT, BangaloreWelded Structures”

04.01.06 “Experiments with Impression Creep Testing” TRICHY Prof D H Sastry , IISc, Bangalore

17.01.06 “Diffusion Bonding of some (alpha & beta) TRICHY Dr M Sujatha , Scientist, MS Division, NAL,Titanium Alloys to Titanium” Bangalore

10.02.06 “Recent Trends in Heat Treatment” TRICHY Sri Jukka Sirvio , Heat Master O. Y., Finland

15.03.06 “Indian Metallurgical Industry Unleashing TRICHY Sri L Pugazhenthy , VP, IIM, ILZDA, New Delhiis true Potential”

11.07.05 “The Quasi Crystal Story” TRIVANDRUM Prof T R Anantharaman , Former V C, BHU,Varanasi

Date Topic Chapter Speaker



04.10.05 “In-situ Composites and nanocomposites” TRIVANDRUM B S Murthy , Dept. of Met. & Mat.Engineering, IIT Chennai

03.12.05 “Materials for Space Endeavours” TRIVANDRUM Dr K Ninan , Dy. Director, VSSC, Trivandrum

08.12.05 “Localised Corrosion behavior of high TRIVANDRUM Prof V S Raja , Dept. of Met. Engg., IIT, Mumbaistrength 7010 Al alloy”

23.02.06 “Challenges in the Selection of Materials for TRIVANDRUM Dr S Banerjee , Vice President, IIM & ChairmanNuclear Applications” MS Division, BARC, Mumbai

22.08.05 “Science Content in Ancient Indian Scriptures” VARANASI Sri Acharya Agni Vrat Naishthik , Rajasthan

08.09.05 “Planetist’s Future through Leadership, VARANASI Sri Ajit Mahapatra , M D, Kalinga EngineeringLearning & Innovation” Ltd., Bhubaneswar

24.09.05 “Innovative Methods in Processing of VARANASI Prof S N Ojha , Dept. of Met. Engg., IT, BHU,Metallic Materials” Varanasi

09.12.05 “A Journey through India-Mofits from Ancient VARANASI Prof Ludwig W Danzer , Emeritus Professor,and Modern Monuments” University of Dortmund, Dortmund, Germany

24.03.06 “Al Based Metal matrix Composites NML VARANASI Sri Ajoy Kumar Ray , NML, JamshedpurContributions”

24.03.06 “Nanoindenation Technique: An Emerging VARANASI Sri A K Mukhopadhyay , NCC Division, CGCRI,tool for Materials Characterization” Kolkata

24.03.06 “Characterisation of Engineering Materials VARANASI Sri Goutam Das , NML, JamshedpurUsing Ball Indentation Technique”

24.03.06 “Impurities Accelerated Hot Corrosion: Some VARANASI Sri L B Singh , R R L, CSIR, BhopalNew Observation”

24.03.06 “Kolmogorov-Johnson-Mehl-Avrami Isothermal VARANASI Sri I Sinha , and Dr R K Mandal Dept.Kinetics Revisited” of Applied Chemistry, IT-BHU, Dept. of

Met. Engg., IT-BHU

24.03.06 “Importance Metal-matrix Composites VARANASI Dr S Mohan , Dept. of Met. Engg., IT-BHU,in Tribological Varanasi

24.03.06 “Developments in the Spray Processing of VARANASI Dr V C Srivastava , NML, JamshedpurMetal Matrix Composites”

24.03.06 “Observation of Coherent Twins Present on VARANASI Dr Ashit Kumar Pramanick andNickel Surface by Atomic Force Microscopy” Sri Arvind Sinha , N M L, Jamshedpur

24.03.06 “Application of Dynamic Materials Modeling VARANASI Sri N S Mishra , Dept. of Forge Technology,to Industrial Rolling” NIFFT, Ranchi

24.03.06 “Thermodynamic and Kinetic aspects of the VARANASI Sri A K Vaish Sri R C Gupta , BHU, &smelting reduction of Multimetalic Sri S P Mehrotra , NMLIndian Magnetite Ore”

24.03.06 “Spallation Characteristics of Oxide Scales VARANASI Sri B B Jha , Sri B K Mishra , R R L Bhubaneswar,of 2,25 Cr-1 Mo Ferritic Steel by Acoustic Dr S N Ojha , IT-BHU, VaranasiEmission Technique”

24.03.06 “Effect of Magnesium, Silicon and Inoculan on VARANASI Sri S S S Rao , and Sri V N R Vinana Jyothi , the Microstructure of Spheroidal Graphite Iron” Institute of Engineering & Technology,

Hyderabad

25.03.06 “Spinel-Corundum Equilibria and Activities in VARANASI Sri C K Behera , IT-BHU, Varanasithe System MgO-Al2O3-Cr2O3 at 1473K

25.03.06 “Equal Channel Angular Processing of VARANASI Sri R Manna , Dr N K Mukhopadhyay &Commercial Purity Aluminium” Prof G V S Sastry , IT-BHU, Varanasi

25.03.06 “Deformation Behaviour of the Alloy 718” VARANASI Sri K V U Praveen & Sri Vakil Singh,IT-BHU, Varanasi

25.03.06 “Dissolution Kinetics of Mechanically Activated VARANASI Sri C Sasikumar , & Sri S Srikanth , N M LBeach Placer Ilmenite in H2SO4” Madras and Dr N K Mukhopadhyay IT-BHU

Varanasi


25.03.06 “Computational Thermodynamic of Alloys using VARANASI Sri G S Gupta , V I of Tech, Hyderabad andCVM:Estimation of CE-CVM Parameters and Dr B N Sarma , IT-BHU, VaranasiCorrelation Function”

25.03.06 “Impact of Centrifugal Casting on the Distribution VARANASI Sri J K Singh , Prof J P Pathak andof Lead in Hollow Cylindrical Casting of Prof S N Ojha , Dept of Met. Engg., IT-BHU,Leaded Aluminium Silicon Alloys” Varanashi

25.03.06 “Effect of basicity on the Properties of VARANASI Sri D Pawan , Prof R C Gupta andFluxed DRI” Dr S Mohan , Dept. of Met. Engg, IT-BHU,

Varanasi

25.03.06 “Geometrical Parameters and Glass VARANASI Sri S Azad , Dept. of Met. Engg., IT-BHU, VaranasiForming Ability”

25.03.06 “Synthesis and Characterization of Nano VARANASI Sri D Mukherjee , Sri R Manna & Prof I Manna ,g-Barass Alloy” IIT, Kharagpur and Dr N K Mukhopadhyay ,

IT-BHU, Varanasi

25.03.06 “Spray forming and Tribological study of VARANASI Sri M Anil , M K Ghosh , Mech Engg., IT-BHU andAl-Si, Al-Sn-Si Alloys” Prof S N Ojha , Met. Enmgg., IT-BHU, Varanasi

10.06.06 “Physical Modeling” VIJAYNAGAR Dr Dipak Mazumdar , Prof IIT Kanpur


The General Body Meetings of the following Chapters were held and New Committee(s) were elected as given below :

B E College : Date of Annual General Body Meeting : 04.05.2006

Dr S Chatterjee Sri P S Kothari Prof S K Ghosh — Dr K Biswas —Executive Members

Dr P S Banerjee, Dr P P Chattopadhyay, Prof S Sadhukhan, Prof D Das and Dr Ahindra Ghosh

Bhopal : Date of Annual General Body Meeting : 24.05.2006

Dr N Ramakrishnan Prof K S Pandey Dr O P Modi Dr G Dixit Dr S S Amritphale —Prof H K Khaira

Delhi : Date of Annual General Body Meeting : 17.06.2006

Sri R P Varshney Sri S C Suri Sri Deepak Jain Sri Kuldip Singh Dr G N Mohanty Sri V C SinghalSri A Mondal Sri G LSri R K Gupta Mukhopadhyay

Executive Members

Sri P N Shali, Sri M M Bandyopadhyay, Sri B D Jethra, Sri L Pugazhenthy, Sri Raj Tiwari, Sri S K Verma, Sri Udayan Sen,Sri A R Kaujalgi, Dr D Ravi Kumar and Sri P K Chatterjee

Chairman Vice Honorary Jt Hony Honorary Jt HonyChairman Secretary Secretary T reasurer Treasurer

National

4-6.10.06 Servin Xpo 2006 Organized by the Federation of India ExportOrganizations (FIEO) and Sponsored by the Ministryof Commerce and Industry, Govt. of India, UNCTAD,NRDC and ECI

Internat ional

20-22.09.06 “Aluminium 2006-6th World Trade Fair & Congress” Reed Exhibitions Deutschland GmbH, Postfach101642, D-40007 Düsseldorf, Völklinger, Strabe 4,D-40219 Düsseldorf

7-9.12.06 “Recent Trends in Nanoscience & Technology (ICRTNT-06) School of Materials Science & Technology & Centrefor Nanoscience & Technology, Jadavpur University(Phone : No. 91-33-55128636, Fax : 91-33-24146940, Email : [email protected] [email protected]

Feb. 25 to TMS 2007-136th Annual Meeting & Exhibition Christina Raabe , Technical Programming Manager,Tel : (724) 776-9000, ext. 212/(800) 759-4TMSEmail : [email protected]

12-16 June, “METEC-International Metallurgical Trade Fair” Xavier Rabello , Head of [email protected] Francis , Project Manager,[email protected]

Mar 01,2007

2007


Durgapur : Date of Annual General Body Meeting : 03.06.2006

Sri P C Sahu Sri P K Sinha Sri S C Bhasin Sri A Bhattacharyya Sri S DattaSri D Bose

Sri N K Mayson Sri T S SureshSri K Goswami

Executive Members

Dr R K Nandi, Sri S Sarkar, Sri D Sengupta, Sri C Samajdar, Prof T Roy, Sri K Mukherjee, Sri A K Patra, Dr B N Mondal, Sri AnindyaGhosh, Sri A Biswas, Sri R S Tiwari, Sri S K Dubey, Sri A N Banerjee, Sri A Kannan, Sri M Charyulu, Sri S Rao, Sri L Badu andSri H S Samanta

Hazira : Date of Annual General Body Meeting : 16.06.2006

Sri Pallav Chattopadhyay Sri S K Tiwary Sri M K Ghosh Sri U B Jagdale Dr I B Dave

Ichapur : Date of Annual General Body Meeting : 06.07.2006

Sri G N Khadanga Sri T K Ghoshal Sri S C Verma Sri A K Mukherjee Sri N K Murthy —Executive Members

Sri K Saha, Sri A K Mallick and S L Bishoi.

Paloncha : Date of Annual General Body Meeting : 17.07.2006

Sri Y Poornachandra Sri G C Bhakta- Sri P Sudhakar Sri K Srinivas Sri V A Ramesh Sri M A ERao vatsalam Choudary Reddy Babu Prasada Rao

Executive Members

Sri S Soma Sekhar, Sri D B A Sagar and Sri T Sriva Sai Babu

Raigarh : Date of Annual General Body Meeting : 20.07.2006

Sri P S Rana Sri D K Saraogi Sri S Ghosh Sri V Agrawal Sri S Singh —Sri R Pathak

Executive Members

Sri R K Sabat, Sri A K Jagnani, Sri B Bhadra, Sri U K Singh, Sri A K Bhagat, Sri R K Saini, Sri V Garg, Sri D K Verma,Sri Adinarayan, Sri Joy Dutta, Sri A Pandey and Sri S Awasthi

Ranchi : Date of Annual General Body Meeting : 07.05.2006

Sri Rajesh Singh Dr D Mukherjee Sri B Kedia Sri N K Ray Sri M K Lal —Sri R Khowala Dr B K Jha

Sri S K RaiSri M K Thakur

Executive Members

Sri S Chakrabarty, Sri V K Singh, Sri S Prasad, Sri A Dasgupta, Sri S K Dhua, Sri Sujan Pal, Sri G K Sinha, Sri P K Behera,Dr Ashok Kumar, Sri S C Choudhury, Sri G Chakraborty, Sri D P Singh and Dr S N Prasad

Trichy : Date of Annual General Body Meeting : 14.06.2006

Sri G Uma Shanker Dr V T Sathyanathan Sri N Parameswaran Sri K Radhakrishnan Sri A Rajan Sri A MeyyappanSri V Thiagarajan Dr John BerchmansSri P Nainar Sri N Raju

Executive Members

Sri P Chellapandian, Sri V Devarajan, Sri T Selvin Devasahayam, Sri M Tirugnanasambandam, Sri N Rajasekaran,Sri G Rajendran, Sri M L Mohammed Ismail, Dr R Vaideeswaran, Dr P Bala Srinivasan, Sri L M Subramanian, Sri M Selvaraj,Sri R Baskaran, Sri M Jayaraj, Sri K Raju, Sri S Mohan and Sri R Anandan

Varanasi : Date of Annual General Body Meeting : 29.05.2006

Prof A K Ghosh Dr N K Mukhopadhyay Dr S Sarkar Sri Ravi Aggarwal Sri R Manna —Executive Members

Prof R C Gupta, Prof T R Mankhand, Prof Bhanu Prakash, Sri Amitabh Deva and Dr B N Sarma

Visakhapatnam : Date of Annual General Body Meeting : 24.06.2006

Sri P K Misra Dr NBRM Rao Sri CVSP Verma Sri S K Pandey Sri S Shaktimani Sri A KrishnanSri K Siva Prasad Dr J Babu Rao

Sri Raj Udyan RayExecutive Members

Sri B Akkunaidu, Sri Prabhakar Rao, Sri R N Acharya, Sri Beer Singh, Sri S Chakraborty, Sri C Vijay Saradhi, Sri A K Mishra,Sri S Kamaluddin and Sri U D Bokil.

Chairman Vice Honorary Jt Hony Honorary Jt HonyChairman Secretary Secretary T reasurer Treasurer


National Convention on Seamless Engineering , 16th August2006, Tata Centre, Kolkata

The National Convention is being organized by the EngineeringCouncil of India (ECI), New Delhi and is supported by Tata Steel andIndian Institute of Metals to commemorate the Diamond Jubilee of theIndian Institute of Metals.

Latin American Iron and Steel ILAFA-47 and ILAFAEXPO 2006,October 29-31, 2006, Santiago, Chile

Shri B Muthuraman, Managing Director, Tata Steel Limited, India &President, IIM, is a speaker in panel II : World Steel Market.

International Symposium on Advances in EnvironmentFriendly Technology to Mineral Processing and MetalExtraction (AETMME-2006), (1-3 November 2006 Bhubaneswar,)

The International Symposium on Advances in EnvironmentFriendly Technology in Mineral Processing and MetalExtraction (AETMME-2006), 1-3 November, 2006 at Hotel “TheNew Marrion”, Bhubaneswar, India.

AETMME-2006 is aimed to take a stock of advance knowledgeand technology in the concerned areas with particularreference to Conservation of Mineral Resources, Extractionof Metals, Alloys, Special and High pure metals andHarnessing Energy from Fossil Fuel and Nuclear Metals andMaterials. This Symposium is being organized under theauspices of the Institute of Advance Technology &Environmental Studies (IATES). Delegates desiring to attendand present technical papers are requested to be in touchwith Prof Dr P K Jena , Chairman, AETMME-2006,C/O, IATES, 80-81A, Lewis Road, Bhubaneswar-751 002, India. (Phone No. 0674 2430363/2430243, Fax No.0674 2430363, E-mail:[email protected],[email protected]

International Symposium on Future Technologies in Iron &Steel Making, 3-4, November 2006, Kala Mandir, Bhilai TechnicalInstitute, Bhilai

The Intenational Symposium will be organized by Indian Institute ofMetals, IIM Bhilai Chapter.

For more details, please contact:-

Dr R Haldar, Organizing Secretary,C/o, Deputy Genera] Manager (Quality)Room No. 215, R & C LaboratoryBhilai Steel Plant, Bhilai - 490 001Phone: (+91) 0788-2278070 / (+91) 0788-2892140Fax : (+91) 0788-2278070E-mail: drranianhaldhar@sail-bhilaisteel,fist2006@sail-bhilaisteel. com

Structural Engineers World Congress 2007, (4-9, November,2007, Bangalore)

The prestigious Structural Engineers World Congress 2007(SEWC-2007) will be held during 4-9 November 2007 inBanglore.

Visit www.sewc2007.org for more details about the WorldCongress and associated events.

COMING EVENTSAddress : Structural Engineers World Congress

(SEWC-2007) #3944/F, 17th ‘D’ Cross,4th Main, BSK II Stage, Bangalore-560 070India. Phone : +91 80 2676 5288E-mail:[email protected]

International Conference on “Recent Advances inMaterials and Processing-RAMP 2006”, (15-16 December2006 Coimbatore)

The International Conference on Recent Advances in Materials& Processing (RAMP 2006) will be held15-16, December 2006, Coimbatore. The Conference will beorganized by P S G College of Technology(Met. Department), Coimbatore, in collaboration with TheIndian Institute of Metals, Coimbatore Chapter.

For further details, please contact :-Dr P C AngeloOrganizing Secretary-RAMP-2006Dept. of Metallurgical EngineeringP S G College of Technology, Coimbatore-641 004E-mail : [email protected] : www.psgtech.edu/ramp2006----.

International Symposium for Research Scholars (ISRS-2006), (18-20 December 2006, IIT Madras)

International Symposium for Research Scholars (ISRS-2006)on Metallurgy, Materials Science & Engineering will be heldfrom 18th to 20th of December 2006 at IIT Madras. This isorganised by the Department of Metallurgical and MaterialsEngineering, IIT Madras in association with Indian Institute ofMetals Chennai Chapter, Materials Advantage Chapter of IITMadras and Metallurgical and Materials Engineering, IITMadras in assoication with Indian Institute of Metals ChennaiChapter, Materials Advantage Chapter of IIT Madras andMetallurgical and Materials Engineering Students’ Association(METSA).

For details, you may contact :-

Prof S D PathakChairperson, ISRS-2006Department of Metallurgical & Materials EngineeringIndian Institute of Technology MadrasChennai 600 036 OR

Dr S S BhattacharyaConvener, ISRS-2006Department of Metallurgical & Materials EngineeringIndian Institute of Technology MadrasChennai 600 036

International Technical Meet of Steel Plant EquipmentManufacturers & Suppliers (EMS 2007), 18-20, January, 2007,Ranchi.

The International Technical Meet event is being organized by TheIndian Institute of Metals, Ranchi Chapter in association with SAIL /Centre for Engineering & Technology, SAIL / Research & DevelopmentCentre for Iron & Steel and MECON Limited.

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Seminars & Conferences


For further information, please contact :-

Sri Rajesh SinghChairman, IIM Ranchi Chapter, Organizing Chairman (EMS2007) &General Manager I/c (Engineering & Projects)SAIL, Centre for Engineering & TechnologyRDCIS Building (4th Floor)P.O. Doranda, Ranchi - 834 002E-mail: [email protected], Web: www.ems2007.com

Kalpakkam Chapter of IIM

Prof Brahm Prakash Memorial Materials Quiz is scheduled on 30thSeptember, 2006 at Kalpakkam.

Second World Congress on Engineering AssetManagement and Fourth International Conference onCondition Monitoring

The Conference will be held on 11-14 June 2007, at The CairnHotel, Harrogate, U. K. The Conference will be organized byThe British Institute of Non-Destructive Testing (BINDT).

For details, please contact :-

The Conference Department, The British Institute of Non-Destructive Testing,

1, Spencer Parade, Northampton NN1 5AA,United Kingdom.Tel : 01604 630124, Fax : 01604 231489E-mail : [email protected],www.wceam-cm2007.org.

National Conference o-n Failure Analysis (NCFA-2006),(22-23 December 2006)

The National Conference jointly organized by the DefenceMetallurgical Research Laboratory, Hyderabad; NationalAerospace Laboratories, Bangalore; Indira Gandhi Center forAtomic Research, Kalpakkam; Centre for MilitaryAirworthiness and Certification; Banglore in association withThe Indian Institute of Metals, Hyderabad Chapter - 22-23December 2006.

For more details, visit website:www.nal.res.in/ncfa2006

Address for correspondence:Dr M Srinivas , Convener-NCFA 2006Scientist, SFAGD M R L, Kanchanbagh, Hyderabad-500 058, A.P.Phone : 040-24340266, 040-24586367Fax : 040-24340356E-mail : [email protected], [email protected]

16th Rolling Conference and 3rd Conference on Usesof Steel (7-9th November 2006, at Hotel C Nicolas, Argentina)

The Institute Argentino de Siderurgla is organizing the 16thRolling Conference and 3rd Conference on Uses of Steel, forNovember 7th to 9th 2006, at Hotel C Nicolas Argentina. Theprogram includes technical sessions covering all andproducts issues, meetings on “environment and recycling andon well events, an exhibit of suppliers and steel products andplant tours.

For further details, please contact :Cristian GenzanoInstituto Argentino de SiderurgiaPhone: 54 3461 460803, Fax : 54 3461 462989e-mail: [email protected]

METEC International Metallurgy Trade Fair

METEC, International Metallurgy Trade Fair has establisheditself as the foremost forum for the steel and iron industry

A workshop on “Mechanical Behaviour of Systems atSmall Length Scales - 2”, (February 5-9 2006)

This workshop, a follow-up to the one conducted in January,2004, will cover the broad area of the mechanical responseand reliability of materials in small volumes. In addition totraditional areas of fundamentals of thin films and interfaces,there will be emphasis this time on thermal barriers and MEMS.Internationally renowned experts will deliver lectures onconceptual fundamentals as well as on cutting edge researchin areas that include the mechanics of deformation andfracture, experimental methods for the evaluation of reliabilityand mechanical properties, adhesion and finite element/atomistic modeling. This workshop is aimed at students,researchers and industrial practitioners who wish to developtheir background in the general area of the mechanicalbehaviour of materials with small length scales withapplications in coatings for thermal protection, wearresistance and cutting tools and in thin film devices and micro-mechanical systems.

Please contact for further information: http://met.iisc.ernet.in/or Prof V Jayaram, IISc, Bangalore, e-mail address :[email protected],[email protected]

PAST EVENTS

and, in its 7th edition from 12 to 16 June 2007, presents high-tech facilities and amenities for the production, preparationand finishing of all kinds of metals.

METEC 2007 is accompanied by two international professionalcongresses, the METEC Congress, organized by the StahlInstitute (VDEh) (Steel Institute) for the fourth time, and thefourth edition of the European Metallurgy Conference, a three-day professional conference that is held every two years atdifferent locations and is organized by the Gesellschaft fürBergbau, Metallurgie, Rohstoff-und Umwelttechnik e.V.(GDMD), the association for mining, metallurgy, raw materialand environmental technology.

Further information on METEC and EUnited Metallurgy isavailable on the Internet at www.metec.de and www.eu-nited-metallurgy.net.

3rd International Conference on Integrity of HighTemperature Welds

The conference will be held on 24-26 April 2007, 1 CarltonHouse Terrace, London, U. K. The conference will consider:-

● Current research and technology developments forwelded joints under creep and cyclic loading conditions

● Requirements for technological applications and lifeevaluation methodologies

Identification of any new areas of concern associated withcreep, creep fatigue and fatigue loading at high temperatures.

For further information, Please contact :-Melanie Boyce, Conference & EventsIOM Communication Ltd1, Carlton House Terrace, London SW1Y 5DB, U.K.e-mail : [email protected] : www.iom3.orglevents


International Conference & Exhibition on Pressure Vesselsand Piping “OPE 2006 - Chennai”, 7-9, February 2006,Chennai, India.

It was for the first time, the OPE was organized in India jointlyby the Indian Institute of Metals (IIM) - Kalpakkam Chapterand Metal Sciences Division of IIM, The Institute of MaterialsEngg., Australasia (IMEA) Ltd., Australia, Welding TechnologyInstitute of Australia (WTIA), Australia, Bharat HeavyElectricals Ltd (BHEL), Tiruchirapalli, Larsen & Toubro (L&T)Limited, Mumbai and Indira Gandhi Centre for AtomicResearch (IGCAR), Kalpakkam, India.The conference wasactively participated by over 600 delegates which included76 overseas delegates and a large participation fromIndustry. The countries (19 including India) which participatedin the conference included Australia, Czech Republic,Finland, France, Germany, Hungary, India, Iran, Israel, Italy,Japan, Kyrgyz Republic, Poland, Portugal, Russia, SouthKorea, The Netherlands, UK and USA.

OPE 2006 - Chennai received excellent response andsupport from Indian Industry. The three days technicaldeliberations were structured in plenary (3 sessions),parallel (28 sessions) and poster sessions. A total of 250technical papers were presented. The papers were broadlycategorized in four topics, viz. (A) Design and Analysis (B)Materials and Properties (C) Fabrication and Joining (D)Health Assessment and Inspection.

Dr Baldev Raj distributed the awards to authors for bestcontributory papers in structured parallel sessions and ProfJohn Price of Monash University distributed the awards toauthors for best papers in poster sessions in variouscategories. Dr Baldev Raj concluded the valedictory byannouncing that the next OPE conferences would be held inAustralia in 2008 followed by 2010 in India.

Nanostructured Coating for Tribological and SensorApplications (March 25-26, 2006)

A theme meeting on “Nanostructured Coating for Tribologicaland Sensor Applications” was organized jointly by IndianInstitute of Technology (IIT), Kharagpur and Indira GandhiCentre for Atomic Research (IGCAR), Kalpakkam on March25-26, 2006 at the IIT Extension Center, Salt Lake, Kolkata(with financial support from the BRNS-DAE, Mumbai). DrBaldev Raj , Director and Distinguished Scientist, IGCAR-Kalpakkam, and President, Indian Institute of Metals, played akey role in making the meeting a grand success. The meetingprovided an overview of the current status of nano-coatingsfor tribological and sensor applications and defined a roadmap for future scope of research and development leading totechnological breakthrough and commercial exploitation. Themeeting was attended by leading scientists, buddingresearchers and students working in the field of nano-tribology and nano-sensors.

Trichy Chapter

An International Symposium on “Fountiers on Desing ofMaterials (FDM2005)” we held at IIT, Madras during 14-16,November 2005.

The Student Chapter of NITT and Metallurgical EngineeringAssociation (MEA), Department of Metallurgical Engineering,National Institute of Technology, Trichy in association with theIIM-Trichy Chapter organized the National Level Students’Annual Technical Symposium-METTLE 2006 during 2nd and3rd March 2006 at National Institute of Technology, Trichy.

The Quiz on Metals and Materials-2005 was held for thefourteenth year in succession. IIM Metals and Materials Quiz2005 was held at NIT, Trichy on 30th July 2005. A Technicaltalk on “Materials Challenges in Fast Breeder Reactors:Approach and Achievements” by Dr Baldev Raj ,President of IIM.

The programme FRONTIER2K5 was jointly organized withWelding Research Institute (WRI), Bharat Heavy ElectricalsLimited, Trichy. An one-day Workshop on “New Frontiers inPower Plant Materials and their processing” wasorganised on 25th April 2006.`

The delegates were welcomed by Dr K Bhanu Sankar Rao,Chairman of Kalpakkam Chapter of The Indian Institute ofMetals. Mr Chris Smallbone, President, International Instituteof Welding inaugurated the conference. Dr Baldev Raj,Distinguished Scientist and Director, Indira Gandhi Centrefor Atomic Research Kalpakkam presided over the function.Dr R Viswanathan, Technical Executive - Materials Application,Electric Power Research Institute, USA delivered a speciallecture on the “Perspectives of International Collaborationsin the area of Pressure Vessels & Piping” and shared hisexperience. Prof. John W. H. Price, the founder and architectof this conference in Australia expressed his happinessabout the large participation and shared his wide experiencedetailing the “Present and Future Perspective of OPE” in hisaddress. The Technical Exhibition was inaugurated by Mr MAnbunathan, Chief Controller of Explosives SafetyOrganization, Nagpur, India. Finally, the “Vote of thanks” onthe occasion was delivered by the Convenor of theconference, Dr B K Choudhary of Indira Gandhi Centre forAtomic Research Kalpakkam, India.

Dignitaries on the dais during inauguration of OPE 2006 -Chennai (from Left to right: Dr K Bhanu Sankara Rao, ProfJohn W H Price, Dr Baldev Raj, Mr Chris Smallbone, Dr RViswanathan, Mr M Anbunathan and Dr B K Choudhary


ANGULNarottam KaloLokanath SahuTripurmohan MishraB E COLLEGEPartha Roy ChoudhuryBURNPURAnup KumarSaibal SarcarBHUBANESWARMurali Sekhar JenaBHILAIKamal Kishor SarafS K PradhanBANGALOREM C KumarCHENNAIS RameshDr M KamarajDr S AsokanDELHIKuldeep Kumar Khanna

S K RoongtaDUBURIPritam Kumar RanaSabyasachi PatnaikSurendra GujjarlapudiHYDERABADRama Krishna LingamaneniDr G PadmanabhamP K KrishnanDr R KalidasDr U RambabuM/s J N Tech. UniversityM/s Pennar India LimitedHISARYogesh KumarICHAPURMedimi Manga RajuSunil Kumar RoyJAIPURDr V K SharmaKANPURParmanand SharmaKOLKATAArup Kumar Chatterjee

Members enrolled(01.05.2006 to 30.06.2006)

WELCOME TO IIM

Dr Sushi BanerjeaAkshay Kumar PramanickJawaharlal JoshiMUMBAIDr Saurabh MishraIndradev SamajdarPOONADr Manoj Jagannath RathodRohit Subhas RanadeMs. Manisha G KultheRANCHIDhananjay NaolokheROURKELADhirendra Nath DalaiAtish Chandra SarkarMahendra SinghShyam JiT P Siva SankarNarendra TripathyK BalgangadharGour Prasad BanerjeeV P Kesava DasRajendra Prasad BhalutiaSirish Chandra Patnaik

Dr Jyoti Mukhopadhyay, Life Member of IIMand Director, Jawaharlal Nehru AluminiumResearch Development and Design Centre,Nagpur has been nominated by Governmentof India as a task force member in the area ofAluminium with reference to Asia PacificPartnership on Clean Development andClimate. Accordingly, Dr Mukhopadhyayrepresented India in the aluminium sector at

Berkeley, USA, during the period April 19-21, 2006.

Asia Pacific Partnership consists of the following countriessuch as USA, China, Japan, Korea, India and Australia.Delegates from these countries presented their views on thealuminium sector. Similarly Dr Mukhopadhyay also deliveredhis views and presented a lecture entitled “Overview ofAluminium Industry and Environmental related issues in India”at the Asia Pacific Partnership meeting. Based on thesepresentations, Six projects were identified by Asia PacificCountries in which India will take the leadership in the area ofBauxite residue. Furthermore, India will also participate alongwith Australia and China in the area of High Silica Bauxite. Ourheartiest congratulations to Dr Mukhopadhyay.

Dr K Srinivasan , has been elected as aFellow of Institution of Engineers (India). Heis a Professor in Department of Metallurgical& Materials Engineering at NITK, Surathkalfrom 2000 onwards. He has been teaching inthe Department for the past 22 years. He is aLife Member of IIM Kolkata. He is anAssociate Editor of IIM Metal News, amember of Publications Committee of IIM

Kolkata and Hon. Secretary of IIM Surathkal Chapter. He has adoctorate from IITM, Chennai in the field of Metal Forming. Ourcongratulations.

OUR PRIDE

Dr G N Mohanty , an executive committee member of DelhiChapter of IIM, was conferred the Bharat Jyoti Award and aCertificate of Excellence by the India International FriendshipSociety in New Delhi on 6th May 2006. We congratulate DrMohanty.

Dr Sandip Kumar Nandy , Senior Manager &I./C, RDCIS Kolkata Office (SAIL), and a LifeMember of the Indian Institute of Metals,Kolkata Chapter has recently been awardedPh.D (Engg.) degree by Jadavpur University,Kolkata for his work “Study on Oxidation,Slag Resistance and HydrationCharacteristics of Magnesia Carbon Bricks”.

A B. Tech (Ceramics) graduate of the Calcutta University(1983 1st Class First), Dr Nandy has serve IISCO and RDCIS,SAIL since 1984 in various capacities. Our congratulations toDr Nandy.

Sharat Chandra KondAbani Ranjan DasKishor Lal KhandelwalAmitava BosePrasanta Kumar AmatyaSudip Pal ChowdhurySamuel Suresh JasonG KibriaS K BandopadhyayPrabhat Kumar RayBenudhar MoharanaAbhay Kumar DasTRICHYM SubbiahK BalasubramanianS RathinavelyG Prabhul IngaiahVISAKHAPATNAMGanesula Phani KumarDakey Srinivasa Varma

Total No. of Membershipstands at 6830 of which Newmembers are 69.

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Members’ News


OBITUARY

Professor Bernhard Ilschner : An Appreciation

The sad news has been received that Prof. Bernhard Ilschner, an Honorary Member of IIM, passed away on January 4, 2006. Dr Bernhard wasborn on December 13, 1928 in Gdansk (now in Poland). In 1954 he obtained his Ph. D. in Natural Sciences (Physics) from the University ofBonn. In 1964 he finished his “Habiliation” similar to a D Sc from the University of Goettingen.

Bernhard’s professional career reveals the extraordinary breadth of knowledge and the research capability he had. He served in variousprestigious research positions before being appointed the first-ever Professor of the newly emerging field of Materials Science in the whole ofGermany at the University of Erlangen-Nuremberg in 1965. He himself became the founder-Director of the Institute for General Properties ofEngineering Materials. In 1982 he moved to the Federal University of Technology-Lausanne, Switzerland as the Head of the Mechanical MetallurgyLaboratory and continued in the position till his retirement in 1997. He continued to be a Professor Emeritus of that institution till the end.

Professor Bernhard carried out research in various fields like theoretical physics, microstructures and mechanical properties, comprehension,control and optimization of industrial products and processes etc.

Dr. Bernhard held senior administrative positions. He received numerous awards including the Honorary Membership of the Indian Institute ofMetals. His passing away is a grievous loss to his numerous friends, colleagues and former students.

Dr R Chattopadhyay , Ph. D (LOndon), FIIM(U K), Member ASM-Intl & AWS; Life Member ofIIM, IIW, TSI & PMAI (India), solor author of twooutstanding books on wear (published by ASM-Intl, 2001) and surface engineering (Springer,2004), has recently been conferred the title of

‘Honorary Professor’ by Simon Bolivar University, Caracas,Venezuela, for “his selfless support and collaboration to theresearch and academic training at the center” (Center forsurface Engineering), on 27 May, 2006, during his recenttenure at the center. IIM is inded proud of Dr Chattopadhya.

CORRIGENDUMPhotograph published on Page No. 31, June 2006 issue of IIM Metal News. The person standing on the right side of Dr J J Irani is Dr Pradip.The mistake is regretted.

Managing Editor

SAIL announces its expansion and modernisation programmesSAIL Plans new plant in Bokaro for Rs 20K cr

Steel Authority of India (SAIL) is planning to invest an additional Rs 20,000 crore to put up a five mt greenfield plant in existingBokaro Steel (BSL) site. Under the existing Corporate Plan of the company, SAIL intends to expand its capacity from existing 14.5mt to 22.5 mt by 2011-12 with a total investment of Rs 37,000 crore. The greenfield project is in addition to the company’s existingexpansion strategy. A final decision would only emerge after BSL completes its initial expansion with an investment of Rs 8,000 crore.An early completion of the project would give an advantage to the company for further expanding BSL’s capacity to 8 mt. The 5 mtgreenfield expansion would be undertaken later which would enhance total capacity of BSL to 13 mt by 2020, he said. The 13 mtcapcity will be in line with the global strategy of steel companies, where a minimum size of 10 mt is considered ideal.

It has also decided to invest in new area of businesses which includes setting up a plant for auto body sheets and set up a cementfacility under joint venture. With Bokaro Steel Plant as the spearhead, SAIL plans to set up auto body sheets facility with a capacityof 1.2 mt per annum. The estimated investment for the plant is Rs 1,600 and it will be operational within 28 months. Currently, thecomapny has been producing steel for chassis only.

BSL is also looking at operationalising a 2 mt cement plant under the joint venture route. The company is in talks with Cement majorslike Birla Cement, Jaiprakash group, Shree Cement, ACC, Lafarge, Grasim and Mysore Cement for setting up the new company. Itwill hold 26% equity in the JV which is expected to be finalished in the next three months.

(Economic Times, 17th July 2006).

SAIL plans to put Rs 37k cr into growth

SAIL has announced a revised expansion strategy with an investment of Rs 37,000 crore to face emerging challenges in the light ofinterest shown by global steel giants POSCO and Mittal Steel in the domestic iron and steel space. it includes enhancing productioncapacity to 22.5 mt from the present 14.5 mt within three years from the earlier plan of completing the exercise in five years. SAIL’sexpansion plan envisages an investment of Rs 9000 crore at Bhilai Steel Plant, Rs 6,340 crore at Bokaro Steel Plant, Rs. 4590 croreat Rourkela Steel Plant and Rs 2840 crore at Durgapur Steel Plant. Also an increased investment of Rs 9600 crore has beenenvisaged for IISCO. The proposal includes an investment of Rs 1,553 crore for Salem Steel Plant.

(Economic Times, 10th July 2006).


Book Review

“Advanced X-ray Techniques in Research and

Industry” (ed) by A. K. Singh, DMRL, Hyderabad

The book is a collection of papers presented at the

seminar on “Advanced X-ray Techniques in Research

and Industry” organized by Defence Metallurgical

Research Laboratory, Hyderabad during December 4-

5, 2003. It consists of several invited review articles

covering basic crystallography, local texture

measurements with high energy synchrotron radiation,

evolution of textures, texture mapping by scanning X-

ray diffraction, absorption tomography for three

dimensional measurements in bulk materials, ultra

thin films specular X-ray reflectivity, small angle X-ray

scattering, glancing incidence X-ray diffraction and X-

ray line profile analysis. Chapter one briefly covers

crystal geometry and symmetry required for X-ray

diffraction work. Texture mapping by scanning X-ray

diffraction and related methods are nicely covered in

second chapter. It is important to mention here that this

is latest technique for texture mapping and at present

no commercial equipment is available for such

experiment. Texture measurements by high-energy

synchrotron radiation and by normal X-ray diffraction

techniques has been widely covered for a few

materials.

X-ray diffraction and absorption tomography for three-

dimensional measurements in bulk materials have

been described in one chapter. A novel method for non-

destructive characterization of local plastic deformation

is also presented in this work. A brief description of

structural characterization of ultra thin film using

specular X-ray reflectivity technique is presented in one

chapter. Powder and glancing incidence X-ray

diffraction techniques and its application in research

and industry has also been presented. The book covers

the recent progress in instrumentation, evaluation

techniques and some applications of small angle X-ray

scattering. X-ray line profile analysis has also been

discussed in detail covering both experimental and

theoretical aspects and some results have been

presented.

A large number of chapters cover-application of

Rietveld refinement technique for different materials

such as catalytic, oxides, high temperature

intermetallic compounds, superconducting

ferromagnetic compounds and cristobalite formation.

The application of high temperature X-ray diffraction to

different materials has also been discussed. Apart from

this the application of X-ray diffraction techniques to

characterize the materials has been dealt in different

areas such as magnetic materials, nano materials,

aluminum alloys, titanium alloys, biomaterials,

forensic application of textile fabrics, sensors, steels

and surface modifications. It also covers the

geometrical aspects of X-ray diffractometer and related

applications. This includes the historical background

and instrumental considerations of various

equipments. A brief outline of special X-ray based

techniques is also discussed.

(IM)

Energy in Minerals and Metallurgical Industries-H

S Ray, B P Singh, S Bhattacharjee & V Misra

Metallurgical industries generally consume a large

amount of energy. The energy demand is rising

exponenitally. In Indian context, the energy demand is

almost sure to outstrip the supply. Therefore the

authors’ effort to document in one single text the energy

requirement in both ferrous and non-ferrous metals

industry and the measure available for energy

conservation, Energy recovery and its relation to the

environment is a laudable venture. Theoretical analysis

of the underlying phenomena adds further value to this

treatise energy and environment management

constitute an important subject in most engineering

curricula. The book is expected to meet a long felt need

of both academicians and professional engineers.


Design Handbook for Cold-Formed Steel SectionPart 1 : Section Properties

This publication is a detailed study for a selected range

of cold formed steel sections which are presently being

manufactured in India. INSDAG has taken the initiative

for developing design handbook for cold formed steel

sections in two parts namely, Part I : Calculation of

Section Properties and Part II : Standardization of

analysis and design procedures for various cold

formed steel sections produced in India. In the process

of developing Part I of this Handbook, a series of

calculations have been generated for geometrical

properties (full section properties) of angle, channel,

lipped angle, lipped channel and lipped zed sections.

This includes calculations generating series of charts

for reduced section properties covering specific yield

strength values of 240, 345 and 550 MPa for the

sections mentioned above. (Pub : INS/076;

Price : Rs. 500/-). (www.steel-insdag.org)

(Ref : Insdag News)

IS 1608 - 2005 Metallic Materials-Tensile testing atambient temperature (third revision), Gr 13

IS 2328 - 2005 Metallic Materials-Tube-Flatteningtest (second revision, Gr 1)

IS 2329 - 2005 Metallic Materials-Tube (in fullsection)-Best test (second revision), Gr 2

IS 2335 - 2005 Metallic Materials-Tube-Driftexpanding test (second revision), Gr 2

IS 5530 - 2005 Recommendations for production,rectification and repair of steel castings bymetal arc welding process (secondrevision), Gr 8

IS 10551 - Zircon mullite refractories for glass furnaceapplications-Specification (first revision),Gr 1

IS 12279 - 2005 Sintered metal materials, excludinghard metals-Determination of transverseRupture strength (first revision), Gr 2

IS 15574 - 2005 Sintered metal materials, excludinghardmetals-Unnotched impact test piece(first revision), Gr 1

IS 195 - 2005 Fireclay mortar for laying fireclayrefractory bricks-Specification (fourthRevision), Gr 1

IS 1500 - 2005 Method for brinell hardness test formetallic materials (third revision), Gr 7

IS 1749 - 2005 Burnt magnesite refractories -Specification (third revision), Gr 1

STANDARDSIS 2044 - 2005 Mullite refractories for glass melting

tank furnaces-Specification (secondRevision), Gr 1

IS 3074 - 2005 Steel tubes for automotive purposes- Specification (second revision), Gr 4

IS 4132 - 2005 Method for calibration of standardizedblocks to be used for brinell hardnesstesting machines (second revision), Gr 2

IS 15585 - 2005 Sintered metal materials -Specifications, Gr 8

(Ref : Standards India)

IS 15410 : 2003 Plastic bottles/Containers forpackaging of packaged natural mineral water andpackaged drinking water-Specification

Government of India has brought packaged naturalmineral water and packaged drinking water undermandatory certification of BIS. In pursuance to this, IS15410 : 2003 ‘Plastics bottles/Containers forpackaging of packaged natural mineral water andpackaged drinking water-Specification’ was published.

Now, BIS has published IS 15609:2005 ‘Polyethyleneflexible pouches for the packing of natural mineralwater and packaged drinking water - Specification. Thestandard covers the requirements for co-extrudedpolyethylene film used as raw material and capacity,performance requirements and methods of tests forflexible pouches for packing natural mineral water andpackaged drinking water in net quantities of 200, 250ml, 300 ml and 500 ml.

(Ref : Standards India)

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Publications


Following is the contents page of April 2006 issue of IIM Transactions. Interested members may contact the Chief Editor, IIMTransactions for copy/copies of any article.

TECHNICAL PAPER

TP 2041 SIMULTANEOUS PLASTIC DEFORMATION AND JOINING B. Vamsi Krishna, P. Venugopal and 155-165OF DISSIMILAR SINTERED P/M PREFORMS BY COLD K. Prasad RaoEXTRUSION

TP 2042 ErSb/GaSb METAL/SEMICONDUCTOR NANOCOMPOSITE M. P. Hanson, D. C. Driscoll, E. R. Brown 167-175GROWN BY MOLECULAR BEAM EPITAXY A. C. Gossard

TP 2043 SYNTHESIS, CHARACTERISATION AND NONLINEAR Pushpa Ann Kurian and C. Vijayan 177-180OPTICAL PROPERTIES OF STABLE PbS NANOCLUSTERS

TP 2044 DETERMINATION OF TRANSMISSION SPECTRA USING P. Padma Kumar, Krishnan Balasubramaniam 181-184ULTRASONIC NDE and C. V. Krishnamurthy

TP 2045 MICROSTRUCTURAL DEVELOPMENT AND MECHANICAL Rajeev Aluru, Nofrijon I. Sofyan and 185-191PROPERTY RELATIONSHIPS IN WIDE-GAP TRANSIENT William F. GaleLIQUID PHASE BONDING OF SINGLE CRYSTAL TOPOLYCRYSTALLINE NICKEL-BASE SUPERALLOYS

TP 2046 Al-BASED NANOCOMPOSITES BY NON-EQUILIBRIUM S. S. Nayak, D. H. Kim, S. K. Pabi and 193-198PROCESSING ROUTES B. S. Murty

TP 2047 JOINING OF FERRITIC OXIDE DISPERSION STRENGTHENED Venu G. Krishnardula, Nofrijon I. Sofyan, 199-203ALLOYS William F. Gale and Jeffrey W. Fergus

TP 2048 THE EFFECT OF PRECIPITATE DISTRIBUTION ON HIGH D. Chakrabarti, C. L. Davis and 205-213STRENGTH LOW ALLOY (HSLA) STEEL GRAIN M. StrangwoodSTRUCTURES

TP 2049 HIGH TEMPERATURE OXIDATION BEHAVIOUR OF PLASMA Harpreet Singh, D. Puri and S. Prakash 215-227SPRAYED NiCrAIY COATINGS ON Ni-BASED SUPERALLOYSIN AIR

TP 2050 CONTROL OF ABNORMAL GRAIN GROWTH AND DIELECTRIC Pankaj Kumar Patro 229-235PROPERTIES OF FERROELECTRIC STRONTIUM BARIUMNIOBATE

TP 2051 NEAR NET SHAPE FABRICATION VIA VACUUM PLASMA K. Balani, A. Agarwal and T. McKechnie 237-244SPRAY FORMING

TP 2052 STUDIES ON PHOSPHORIC IRONS FOR CONCRETE Sahoo Gadadhar and R. Balasubramaniam 245-253REINFORCEMENT APPLICATION

TP 2053 INFLUENCE OF REINFORCEMENTS ON SOLIDIFICATION Hirofumi Miyahara, Yusaku Maruno, 255-261MICROSTRUCTURE AND FATIGUE PROPERTIES OF Yoshinori Nishihata and Keisaku OGICAST ALUMINUM ALLOY COMPOSITES

TP 2054 PITTING CORROSION RESISTANCE OF AISI TYPE 316 (N) S. Girija, U. Kamachi Mudali, V. Shankar 263-69SS WELD AFTER VARIOUS SURFACE TREATMENTS AND and R. K. DayalTHERMAL AGING

TP 2055 EFFECT OF HIGH TEMPERATURE AGEING ON THE R. Amirthalingam, H. Shaikh, T. Anita 271-282CORROSION BEHAVIOUR OF NITROGEN-ADDED AISI A. Poonguzhali, P. Manohar and H. S. KhatakTYPE 316L STAINLESS STEEL

TP 2056 EVALUATION OF WEAR BEHAVIOUR IN COPPER-SiC N. B. Dhokey, S. G. Sapate and 283-294REINFORCED COMPOSITE BY DIMENSIONAL ANALYSIS R. K. ParetkarAPPROACH

TP 2057 STRUCTURAL RELAXATION IN A Pd40Cu30Ni10P30 R. Raghavan, J. Basu, N. Nishiyama, 295-302METALLIC GLASS S. Ranganathan, and U. Ramamurty

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IIM Transaction Contents


For All Members appearing at theAMIIM Examinations

1. December 2006 AMIIMExaminations will be heldtentatively from 19th December2006 as per the Time Tablepublished herein. The exact datewill be notified while sending theAdmit Cards. In case, thecandidates do not receive theirAdmit Cards well in time, they arerequired to correspond/contactthe Institute’s Office or theOfficer-in-Charge of therespective Examination Centre.Duplicate Admid Cards will besent to the respective Officer-in-Charge of different ExaminationCentres from whom thecandidates may collect theduplicate Admit Cards beforecommencement of theExamination on production ofauthentic document/s about his/her candidature.

2. No Candidate will be allowed toappear at the immediatelyavailable AMIIM Examinations,after enrolment as Member.However, a Member must appearat the AMIIM Examination within 18(eighteen) months from the dateof enrolment as Member, subjectto fulfilment of other eligibilitycriteria.

3. Examination Applicant Form-New Format of only one page(both original and duplicatecopies) should be sent to IIM HOonly accompanied by twopassport size photographs dulyattested by a valid Member of theInstitute (not by Student Member)or by the employer of thecandidate and examination fees.Name & Membership No. of thecandidate should be mentioned onback side of each photographs.Official Receipt will be senttogether with the Admit Card.Incomplete Application Forms willbe rejected.

4. After sending their ExaminationApplication Forms to IIM HeadOffice, the candidates should alsointimate their respective ChapterSecretary in writing giving detailsof their Membership No., name ofthe subjects/to appear, choice ofCentre etc.

5. The candidates should contactthe respective Officer-in-Charge(Please see IIM Website :

www.iim-india.net for L/*ist ofOfficers-in-Charge & Final TimeTable) at least 4 (four) days priorto the start of the AMIIMExaminations to enquire whetherhis/her name appears in the Listof Candidates. In the event, nameof any candidate is not included inthe List, the Chapter must verifythe name with the IIM Head Officeimmediately.

6. The candidates who would beappearing for the first time inAMIIM Examinations in December2006 are required to appear underthe New Syllabus only . Thesyllabus of AMIIM Examinations isavailable with the IIM Head Officeagainst advance payment ofRs 60/- per copy.

7. Endorsement of ExaminationApplication Form by any IIMMember or the Employer isnot required.

8. As per the revised regulationsw.e.f. June 2001, no candidatewill be permitted to appear in morethan 5 (five) papers at a time inPart-I and Part-II AMIIMexaminations. The candidates aretherefore advised to select thesubjects of appearance tomaximum 5 (five). The successfulcandidates of Part-I AMIIMExaminations held in June 2006will not be allowed to appear inPart-II AMIIM Examinations inDecember 2006.

9. The candidates of Part-II AMIIMExaminations should select their 2(two) Special Papers, from theTime Table published herein, toavoid clash in the examinationschedule.

10. Examination Fees should be paidin full only by a Demand Draftdrawn in favour of “The IndianInstitute of Metals, Kolkata”. NoCheque/Postal Order/MoneyOrder/Cash will be acceptedunder any circumstances. Therevised fees for AMIIMExaminations (effective from 1January 2005) is Rs 1000/- forboth Part-I and Part-II (includingcost of the Form). Part payment ofExam. Fees will also not beaccepted under anycircumstances.

11. The last date of receiving thecompleted Application Forms forDecember 2006 AMIIMExaminations is 30th November,

2006. Candidates are advised tosend the Application Formsdirectly to the Institute HeadOffice only at Plot-13/4, Block-AQ,Sector-V, Salt Lake, Kolkata 700091 well in advance, so as toreach by the closing date.Application Forms received afterthe last date (closing date) will notbe accepted under anycircumstance, even if the same isdespatched well in advance. TheInstitute reserves the right toreturn the Application Forms dueto late receipt.

12. Attested copies of Certificates/Mark Sheets (both sides, ifrequired for Subject Codes)should be submitted in support ofclaim for exemptions in anysubject/s. This is obligatory forcandidates appearing for thefirst time . Candidates claimingexemptions on the basis of theirearlier examinations are requiredto mention their Registration No.and the year of passing thesubject/s in which exemption is/are sought in the Application Form,failing which it will be presumedthat no exemption is sought forand further correspondence inthis respect will not beentertained.

13. In case candidates do not want toappear in any subject/s alreadyindicated in the Application Form,matter should be informed to theInstitute Head Office in writingbefore commencement of theAMIIM Examinations, failing whichthey will be marked ‘ABSENT’ inthe Grade Sheet in that particularsubject/s. No consideration will begiven to this effect on requestsreceived after completion of theexamination.

14. The examinations will be held atthe following Centres providedthere are a minimum number of15 candidates at each Centre : B ECollege, Bangalore, Baroda,Bhilai, Bokaro, Bhubaneswar,Chennai, Delhi, Durgapur,Hisar, Hyderabad, Ichapur,Jamshedpur, Keonjhar,Mumbai, Nagpur, Poona,Raigarh, Ranchi, Rourkela,Salem, Sunabeda, Vijaynagarand Visakhapatnam.

15. Request for change of subject/sor Examination Centre shouldreach the Institute Head Office in

AMIIM Examination Announcement


writing at least one month beforecommencement of theexaminations.

16. Candidates appearing at the AMIIMExaminations should clear theirannual Membership Subscriptionsup to the current year. Results ofdefaulting members shall not becommunicated. Membersdefaulting for more than 12months will not be permitted toappear at the AMIIM Examinationsas well as will loose theirMembership and no exemption willbe granted in any subject/s,already cleared. They will have toenrol as fresh Members, if eligibleand can appear at theexaminations as per the NewScheme.

17. The Members who did not appearat the June 2006 AMIIMExaminations following 18(eighteen) months rule, are noteligible for appearing at theDecember 2006 AMIIMExaminations. Under the

circumstances, they are requiredto re-register as Members, ifeligible and follow the NewRegulations in effect from June2001.

18. Candidates will normally not beallowed to choose their Centre ofExamination other than theChapter to which they belong. Inthose Chapters, where there is noExamination Centre, candidatesare required to indicate theirchoice of the nearest Centre.

19. Request for re-totalling ofassessed Answer Scripts fromthe failed candidates may beentertained within one month fromthe date of publication of theresults on payment of Rs 100/- persubject.

20. The successful candidates whohave enrolled as Members on andafter 1.4.1991, are required toappear at the Viva-Voceexamination as well as to submit aTechnical Report duly forwardedby the Employer and the ChapterSecretary, based on their working

experience. The final AMIIMCertificates will be issued only onsatisfactory performance at theViva-Voce examination and onapproval of the Technical Reports.

21. Mark/Grade Sheets are issued tothe Candidates showing themarks/grades only for thesubject/s in which they haveappeared, after the results forPart-I and Part-II are declared.Any discrepancy noted in theseMark/Grade Sheets should bebrought to the notice of theInstitute Head Office and freshMark/Grade Sheets will be issuedto them on request aftercompletion of Part-I and Part-IIexaminations. The charge forConsolidated Mark/Grade Sheetsis Rs 100/- for each Part and thecharge for duplicate Mark/GradeSheets is also Rs 100/- for eachPart.

Sd/-Prof S K Roy

Controller of Examinations1st August 2006.

Tentative Time Table of December 2006 AMIIM ExaminationsPart -I Part -II

Day10.00 a.m. to 1.00 p.m.

Morning2.00 p.m. to 5.00 p.m.

Afternoon10.00 a.m. to 1.00 p.m.

Morning2.00 p.m. to 5.00 p.m.

Afternoon

1st Day Engineering Drawingand Graphics*

Iron Making 1. Corrosion &Corrosion Prevention

2. Computer Applications inMetallurgy

2nd Day Basic Metallurgy Mechanical Working &Testing of Metals & Alloys

1. Industrial Management2. Energy Management in

Metallurgy

English for TechnicalCommunication

3rd Day Mechanics of Solids & Fluids Extractive Metallurgy ofNon-Ferrous Metals

1. NDT of Metals & Alloys2. Industrial Pollution &

Pollution Control

Chemistry

4th Day Mathematics Phase Equilibrium & PhaseTransformations

1. Mineral Beneficiation &Agglomeration

2. Nuclear Materials3. Fuels, Fumaces &

Refractories.

Physics

5th Day Electrical Technology &Basic Electronics

Heat Treatment Technology 1. Powder Metallurgy2. Selection & Application of

Materials

6th Day Foundry Metallurgy 1. Welding Metallurgy2. Polymeric, Ceramic &

Electronic Materials

7th Day Deformation & FractureBehaviour of Metals & Alloys

1. M e t a l l u r g i c a l`̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ `̀ Ther-modynamics & Kinetics

2. Composite Materials8th Day Steel Making

Note : *4 Hour Paper


The 44th National Metallurgists’ Day (NMD) will be celebrated in theusual grand manner, this time in the Steel City of Jamshedpurbetween 13th and 16th November 2006 . Besides the eventsthat accompany the NMD celebrations and the Annual TechnicalMeeting (ATM) every year, the 2006 Meeting will include anInternational Symposium on Steels for Automotives (STATS2006). The subject for the international symposium has been chosenin view of the emerging Indian automobile industry and the fact thatJamshedpur is the place where the story of Indian steel began,almost one hundred years ago. The 2006 function is being jointlyorganized by The Indian Institute of Metals (IIM), Jamshedpur Chapterand Tata Steel Limited.

International Symposium

At international symposium on Steels for Automotives (STATS2006) will be held on 13th November at Tata Auditorium, XLRI Campus,Jamshedpur. Experts from Japan, Europe and USA as well as fromIndia will deliver invited lectures in the symposium.

NMD-ATM

On the occasion of the 44th National Metallurgist’s Day - 14thNovember, 2006, distinguished Metallurgists of India will be honouredby the Ministry of Steel and IIM for their outstanding contributions inthe field of metallurgical education, research and industry. All theevents of 14th November will take place at the same venue.

The ATM will be held on 15-16th November in different venues closeto XLRI and Tata Steel’s Centre for Excellence. The ATM, as usual,will comprise both oral and poster sessions. About 150-175 paperswill be presented over 2 days in three parallel sessions and theremaining papers will be in the form of posters. The ATM Technicaland Publication Committee shall have the discretion to finally allocatethe paper to Oral/Poster Session. For both Oral and Poster sessionpapers, any interested participant should submit an abstract of 50(fifty) words for publication in the Transactions of IIM and extendedabstract in 500 words for scrutiny by the ATM Publication Committeelatest by 31st July 2006 . The texts of these abstracts must be inMS Word using font size 12 normal on one side of a full size paperin Times New Roman with double spacing. The title of the papermust be in Capital letters, centre aligned, in font 14 bold with doublespacing along with the names of the author in bold and their affiliationin font 10.

Two hard copies of the Abstract along with a CD containing the softcopies clearly labelled with the title of the paper and the name of thefirst author should be sent to the following address :

Dr Amit ChatterjeeChairman, Technical and Publication CommitteeNMD-ATM 2006, Tata Steel, Mail Box No. G-51, Jamshedpure-mail : [email protected]

Metallography Contest

A Metallography contest will be held as a part of ATM. Monotone/Colour Micrographs in A-4 size obtained using optical microscope(Colour/Black & White), SEM, TEM or any other advanced imajingtechnique will be displayed during the ATM. Advance registration iscompulsory for participation in the Metallography Contest. At leastone of the authors must register as a deligate. Entries for Studentswill be judged in a separate category.

Entries should be sent to Dr D Bhattacharjee , Chairman, HallCommittee, NMD-ATM 2006, Tata Steel, Mail Box No. W-212,Jamshedpur-831 001

Technical Exhibition

There will be a technical exhibition during the NMD celebrations. Theexhibition will showcase the latest advancements in the area ofequipment, products/processes, controls, etc. It will highlight thecurrent trends in the metallurgical industry. To participate in thisexhibition, the exhibitors should contact Mr S K Roy , ChairmanExhibition Committee, NMD/ATM-2006, Tata Steel, Mail Box No. G-50,Jamshedpur 831 001 and the matter should be sent latest by 15thOctober 2006.

Souvenir

This will carry technical articles by eminent experts on contemporarytopics of metallurgical research, information related to the NMD.ATM, the International Symposium and articles about sponsors, etc.This will be widely circulated among the participants, professionalsworking in the metallurgical field and industries in India and abroad.Advertisements are solicited for insertions in the souvenir. The matterfor advertisement should be sent to the Chairman, Technical andPublication Committee before 15th October 2006.

Jamshedpur, 13-16 November 2006

The tariffs and other details are as follows :

Indian Rs. 30,000Overseas : US$1000

Amount Benefits

1. free delegate. Each stall will be 9 sq.m. in area and willbe provided with 1 table, 2 chairs, 3 spot-lights, 5A plugpoint and Name fascia.

Advertisement rates are :

Special Colour Page Full Page (Black and White ) Half Page (Black and White)

Indian Rs. 25,000 Rs. 20,000 Rs. 10,000Overseas US $ 1,500 US $ 750 US $ 375

Members of IIMSTATS 2006NMD-ATM 2006Both Events

Category Amount Category Amount

Members of IIM fromAcademic InstitutionSTATS 2006NMD-ATM 2006Both EventsStudent MembersSTATS 2006NMD-ATM 2006Both Events

Rs. 1,000/-Rs. 2,000/-Rs. 2,500/-

Rs. 800/-Rs. 1,500/-Rs. 2,000/-

Rs. 500/-Rs. 700/-Rs. 1,000/-

Non-MembersSTATS 2006NMD-ATM 2006Both EventsOverseas Delegates

STATS 2006NMD-ATM 2006Both EventsSpouse of IndianDelegates(for one or both the events)Spouse of OverseasDelegates(for one or both the events)

Rs. 1,500/-Rs. 2,500/-Rs. 3,000/-

US $ 200US $ 300US $ 400Rs 1,000/-

US $ 100/-

The registration fees for these options are given below :

Payments should be made by Cheque/DD drawn in favour of “The IndianInstitute of Metals NMD-ATM, 2006”, payable at State Bank of India,Jamshedpur and should be sent along with the registration form to theOffice of Vice President (Kalinganagar Project).

Address for Correspondence :

Office of Vice President (Kalinganagar Project), Mail Box No. E-38Tata Steel Limited, Jamshedpur 831 001.

Telephone : (0657) 2424602, Fax : (0657) 2433856e-mail : [email protected]

Important Dates to Remember

Submission of abstracts of ATM Papers July 31, 2006Intimation of acceptance (Yes/No/Poster) August 31, 2006Last date for registration October 15,2006Last date for entry for metallography contest October 15, 2006Advertisement in the souvenir October 15, 2006Technical exhibition October 15, 2006Final poster submission November 1, 2006Special papers by students 1st October/(submission/final decision) 1st November 2006

Registration Fees

Participants who wish to attend may register : i) only for InternationalSymposium (Nov. 13th), ii) only for NMD-ATM (Nov. 14th to 16th), oriii) for both the events. Members may download the registrationform from the official IIM-NMD website at http//www.iim-india.net

NMD - ATM 2006


September 23, 2006.

Dear Member :

At the 1st Advisory Committee meeting of past presidents held on 5th May,06 at Jamshedpur, it wasdecided to obtain the feed back and views of all IIM members before articulating new objectives and visionfor IIM.

Established in 1946, as a single entity for all disciplines, in the year 1972, the Institute celebrated its silverjubilee, in the year 1976, IIM divided itself into 3 Divisions each led by a Vice President. 2006, DiamondJubilee Year is an occasion to review and enhance IIM activities.

Six decades later, with the advent of IT and IT enabled services, development of special and intelligentmaterials, ever increasing speed of vehicles on ground, water and air – taking us further, faster, and safermaking travel cleaner, quieter and more fuel efficient, globalization is truly in place and the world hasindeed become a global village.

There is hectic activity in all round development of infrastructure namely: Roads, Ports, Airports, Railways,Large size vehicles, handling equipment, housing etc. Massive investments in new Greenfield & Brownfieldcapacities have been committed – India is the happening place.

Can India’s HR build – up match growth trends in industry……

The President and your Council are keen to enhance the activities of the Institute, beneficial to the society,in this important Diamond Jubilee Year 2006; this is possible only with your participation and valued feedback and views.

It will be of great help if you could, send us the questionnaire duly complete as early as possible.

With best wishes and regards,

J C MarwahSecretary General

“METAL HOUSE”,Plot 13/4, Block AQ, Sector V,Salt Lake, Kolkata - 700 091Tel : 033-2367 5004 / 7089, 9768Fax : 033-2367 5335E-mail : [email protected] : www.iim-india.netTELEGRAM INDINSTMET CALCUTTA


TO: Members of the Institute

QUESTIONNAIRE TO BE FILLED UP BY ALL IIM MEMBERS

Sl. No Questionnaires Members’ Suggestions

1a Do you agree that IIM needs to be given anew Direction? (Yes / No). If the answeris ‘YES’, please indicate whether thefollowing should be included in the new‘VISION’:

i. Play advisory role to Government in policydecisions related to metals and materials.

ii. Promoting young executives.

iii. Greater visibility of HQ.

iv. Closer interaction with other ProfessionalBodies.

v. Steps to popularize metallurgy amongyouth.

vi. Any other aspect not covered in the above.

1b. Do you think that the name of theInstitution should:

i. Remain as the Indian Institute of Metals.

ii. Be changed to the Indian Institute ofMetals and Materials.

iii. Be changed to Indian Institute of Materials.

iv. Any other suggestion (without changingIIM as acronym).

2. Name three aspects of IIM that you likemost at present.

i.

ii.

iii.


SL No Questionnaires Members’ Suggestions

3. Name three aspects of IIM that you thinkcan be improved, with constructivesuggestions.

4a. Are you happy with the communications(including publications) from IIM? (YES /NO).If the answer is ‘NO’ , could youplease suggest how this could beimproved?

4b. Is IIM serving the student communitysatisfactorily? (YES / NO). Pleasesuggest three concrete ways in whichthis can be improved further:

4c. How to enhance the functioning of HQand its networking / communications withChapter Executives and Members of IIM?

4d Should IIM enhance its continuingeducation programme? (YES / NO). Ifyour answer is ‘YES’, give yoursuggestions to improve this further:

5. Is the present method of IIM working as‘FERROUS’ , ‘NON-FERROUS’ and‘METAL SCIENCE’ Divisionsappropriate? (YES / NO)

If the answer is ‘NO’, do you have anysuggestions as to how the Institute’sworking could be modified? Would‘EXTRACTION ’, ‘PROCESSING’ and‘PRODUCTS’ be a better way ofstructuring IIM?

6. Is the present way of having independentLocal Chapters correct or should IIMfollow (like Institution of Engineers / CII)Regional Centres?

7. Do you have any particular observationsabout the Annual November Meetingcomprising International Symposium /NMD Celebrations / ATM?

8. Is IIM doing justice to the MemorialLectures such as Daya Swarup MemorialLecture / N P Gandhi Memorial Lecture?(YES / NO)

If not, would you please suggestalternatives?

i.

ii.

iii.

i.

ii.

iii.


SL No Questionnaires Members’ Suggestions

9. In a scale of 1-10 (best 10), how wouldyou rate the position of IIM as far ascatering to the interests of its Membersis concerned?

10. Please suggest THREE most importantareas on which IIM should focus in thenext 5-10 years.

11. How to ensure that IIM grows to attainlarger global recognition, while remainingfocused on National Objectives in mostof its activities?

12. Please indicate whether you would liketo play a role in shaping IIM in the comingyears? (YES / NO). If ‘YES”, please listareas where you would like to contributein order of priority:

If you have any other suggestions, pleaseindicate (in FIFTY words):

Name

Membership No

Affiliation & Address

E-Mail

i.

ii.

iii.

metallic foams: current status and future prospects

Documents