Materials'19 & weldFab'19 souvenir

Date: 25-26 April 2019
Venue: Hotel Crowne Plaza, Mayur Vihar, New Delhi
Annual Conference and Exhibition
Souvenir
“Steel, Industrial Materials
& Non-Metallics”
&
“Welding &
Fabrication Technology”
Materials‘19 WeldFab’19
Organizer
Media PartnersSpecial Acknowledgement
Tea/Coffee Partner University PartnerExhibitors
Knowledge Partners

Dignitaries of Inaugural Session
Mr. Puneet Kansal
Joint Secretary, Ministry of Steel
Govt. Of India
Dr. Mukesh Kumar
Director, SRTMI, Ministry of Steel
Govt. of India
Mr. K. K. Pahuja
President, ISSDA
Mr. Ashish Agrawal
Director, Jindal Stainless Steelway
Warm Welcome to all the Participants
“Steel, Industrial Materials, Welding & Fabrication” are the essential part of everyday life and their application is
extensive in today’s technological development. With the launch of the ‘Make in India’ initiative by the Government of
India, to transform India into a global design and manufacturing hub, developments in the Material development &
production, Welding & fabrication Industry is the need of the moment to make Indian products globally competitive.
The agenda of the Conference covers a wide range of very interesting topics emphasizing on the Make in India Concept
help us to re-think about various approaches that can escalate the Concept among the young engineers. The subject
conference is going to bring together experts from Industries, academia, research & development organizations
and professional societies for sharing of knowledge, expertise, new technologies/developments, Innovations and
experience in the emerging trends related to Steels, Advanced Materials, Welding & fabrication techniques for the
Industry.
We have received extensive support from OP Jindal University, Steel Research & Technology Mission of India
(SRTMI, Under the Aegis of Ministry of Steel), Indian Stainless Steel Development Association (ISSDA), Indian
Welding Society (IWS), India Lead Zinc Development Association (ILZDA) along with co-operation from Indian
Institute of Welding (IIW), Indian Institute of Metals (IIM Delhi Chpater), Indian Society for Non-Destructive
Testing (ISNT Delhi Chapter) for organising Materials & WeldFab 2019 Conference. We are extremely grateful to
all the Dignities, Invited Guests, Academicians, Scientists, Researchers & participants for their active participation, co-
operation and support extended to us. We are thankful to all the sponsors/ Branding Partners for their participation
and co-operation not only financially but also technically. We hope that the conference is going to be technically
enrich and successful with all the supports and blessings from all.
Thanks a lot
Dr. Ashok Kumar Srivastava
Convenor & Chief of Technical Committee
Assistant Dean, Center for Reserach Excellence (CRE)
Professor & Head, Metallurgical & Materials Engineering
OP Jindal University, Chattisgarh
Ms. Jaya Ray
Chief of Organizing Committee
Managing Director, Matcorr, New Delhi
Materials’19 & WeldFab’19 || 01

Day 1 (25th April 2019)
Registration with Morning Snacks & Tea 09.00-09.30 hours
Session 1: Inauguration and Opening Ceremony 09.30-11.00 hours
09.30 - 11.00 Inauguration & Opening Ceremony
• Lamp Lighting Ceremony
• Welcome address by Chief Technical, Dr. Ashok K Srivastava, Director, Center for Steel Technology and Product
Development, Professor and Head, Dept. of Metallurgical and Materials Engineering, OP Jindal University, JSPL
• Address by Inaugural Dignity, Mr. K. K. Pahuja, President, ISSDA
• Address by Guest of Honor, Mr. Ashish Agrawal, Director, Jindal Stainless Steelway
• Address by Guest of Honor, Dr. Mukesh Kumar, Director, SRTMI, Ministry of Steel, Govt. of India
• Address by Chief Guest, Mr. Puneet Kansal, Joint Secretary, Ministry of Steel, Govt. Of India
• Vote of Thanks by Mr. A. Mukherjee, Director, Matcorr
• Opening of the Exhibition with Ribbon Cutting
Tea /Coffee Break 11.00 – 11.30 hours
Session 2: Steel, Advanced Materials- its developments & applications 11.30 – 13.00 hours
Keynote Lecture: “Introduction to Stainless Steel & Good Fabrication Practices”
-Mr. Ashish Agrawal, Director, Jindal Stainless Steelway
“Advanced Materials”
- Prof. A. S. Khanna, Chairman, SSPC
“To Study the Fracture Toughness (CTOD) of HSLA Steel Welded with Multi Wire Submerged Arc Welding”
-Mr. Hitesh Kumar Desai, Associate Manager, Welspun, Dahej Facility
“Material &Welding Consideration for Stainless Steel Components”
- Mr. Idris Peerzade, Associate Design Engineer III, Fluor
“Alternate Materials & Next Generation Technologies (Oil & Gas) for Environment friendly space & AIM”
-Mr. R. N. Verma, Consultant, Ex-IOCL
Lunch 1300 – 1400 hours
Session 3: Advances in Welding & Fabrication Technology 14.00-15.30 hours
Keynote Lecture: “Creativity & Innovation in Selection of Material & Fabrication Process to Improve Productivity,
Hygiene and Safety in the Industry”
- Mr. Rajeev Gupta, General Manager- Marketing, Jindal Stainless
“Moving Along with Technological Innovations: Advancements in Welding Processes and Welding Equipment”
-Mr. Ilhar Ul Hassan M S, Solution Engineer, Kemppi India
“Sub Merged Arc Welding on Critical Housing”
-Mr. S. Shivashankar, Manager- Fabrication, Larsen & Toubro Rubber Processing Machinery
“Insight of Training needs for Personals for Certification for Welding Manufacturers”
-Mr. Prashant Barodia, Partner, Techcellent Inspectorate
“Fabrication of Waveguide Run by Forming and Welding Technique Developed Innovatively for Space Use”
-Mr. Rajan K. Mishra, Scientist/Engineer-‘SC’, SAC/ISRO
Tea /Coffee Break 15.30- 16.00 hours
Annual Conference & Exhibition on
“Steel, Industrial Materials & Non-Metallics”
“Welding & Fabrication Technology”
Technical Agenda
02 || Materials’19 & WeldFab’19

Session 4: Metallurgy of Weldingt 16.00 – 17.30 hours
Keynote Lecture: “3D Computed Tomography (CT) – Efficacy in Identifying Materials”
-Dr. C. Muralidhar, Scientist – ‘G’, Director, DAINDE, Defence Research & Development Laboratory (DRDL)
“How Advances in Welding and Metallurgy has Helped the Industry to Improve Their Machine Availability”
-Mr. Rajendren S, General Manager-Technical Services & Exports, Wearresist Technologies
“Flexible and Robust Plastic Welding for the Future, Today!”
-Mr. Anubhav Gupta, Director, ARTEK - Bielomatik
“Producing Dual-Phase Microstructure in Friction Stir Welding/Processing of Medium Carbon low Alloy Steels”
-Md. Anwar Ansari, Research Scholar, Dept. of Mechanical Engineering, Patna, IIT Patna
Networking Dinner 18.30-20.30 hours
Day 2: 26th April 2019
Morning Snacks & Tea 09.00 – 09.30 hours
Session 5: Advances in Welding Technology 09.30-11.00 hours
“Resistance Spot Welding of Aluminum 6061 Alloy for Gas Turbine Application”
- Mr. A. Manjunath, Scientist-’F’, GTRE, DRDE
“Resistance Projection Welding”
-Dr. Girish P. Kelkar, Consultant, Owner – WJM Technologies
“Resistance and Laser Welding for Micro Joining Applications”
-Dr. Girish P. Kelkar, Consultant, Owner – WJM Technologies
“Coupled Thermo-Mechanical Modeling on Dissimilar Metal Plates of Friction Stir Welding Process with Polygon Tool
Pin Geometry”
-Mr. Rahul Kesharwani, Research Scholar, Dept. of ME, IIT Patna
Tea /Coffee Break 11.00 – 11.30 hours
Session 6: Corrosion Resistance Alloys & Welding 11.30-13.00 hours
Keynote Lecture: “Material Selection for Corrosion Protection”
- Prof. A. S. Khanna, Chairman, SSPC
“Seamless FCWs for Welding of High Strength Steels”
Mr. Ankit Jindal, Deputy Manager, Voestalpine Bohler Welding India Technology
“Investigation of Directional Anisotropy in Friction Stir welded/ processed Aluminum Alloys”
-Ms. Sweta Saroj, Research Scholar, Md. Anwar Ansari, Dept. of Mechanical Engineering, Patna, IIT Patna
Panel Discussion: Industrial Application of Stainless Steel/Advanced Materials in the Industry & related Welding
Technology
Lunch 13.00-14.00 hours
Session 7: Foundry & Fabrication Technology 14.00-15.30 hours
Keynote Lecture: “State of P91 Steel Fabrication in Indian Industries”
-Mr. D. D. N. Verma, General Manager – Quality Management (Welding & NDT) , DEE Piping Systems
“Stresses in Sand Casting – Analysis and Optimized Solutions for Improved Casting Designs and Product Quality”
- Mr. Muni Raj M, Manager – Ferrous Applications, MAGMA Engineering Asia Pacific
“Automatic Virtual Optimization of Ingot and Continuous Casting Processes”
- Mr. Muni Raj M, Manager – Ferrous Applications, MAGMA Engineering Asia Pacific
“Achievement in New Technology Introduction for PU (Production Units) & Repair Units”
-Mr. Ashish Kumar Apte, Segment Manager, Fronius India
Networking Tea /Coffee Break 15.30-16.00 hours
Session 8 Closing Remarks & Way Forward 16.00-17.00 hours
Open Question/ Answer Session & Way Forward
Note: Technical agenda is tentative and there might be last minute changes or due to any unavoidable situation.
Technical Agenda

Participating Companies
Welcomes you to
www.materialssummit.co.in www.weldfab.co.in
Date: 25-26 April 2019
Venue: Hotel Crowne Plaza, Mayur Vihar, New Delhi
Media Partners
Participating Companies
Special Acknowledgement
Tea/Coffee Partner University PartnerExhibitors
Knowledge Partners

Abstracts

Title: “Advanced Materials”
- Prof. A. S. Khanna, IIT Bombay (Retd.), Chairman SSPC India
Abstract:
An advanced material is that which can perform one or
more of the following functions without any failure:
• Micro structural stability
• Good Physical Properties
• High Mechanical Properties Including creep resistance at
high Temperatures
• Strong resistance to material degradation at room and
high temperatures
The material classification starts from Metals & Alloys,
Ceramics, Refractory Materials, Composites and Polymers.
Many of these materials have either high strength or strong
corrosion resistant but may be brittle or have poor ductile to
brittle transition temperature. The most advanced metallic
materials are those which possess high strength, have micro
structural stability and are also strong corrosion resistance.
Starting from steel, materials development occurs by
addition of alloying elements which enhance strength
as well as corrosion resistance. It also requires change of
micro-structure which remains stable even at very high
temperature. One set of such materials is known as super
alloys which have sustained strength and excellent corrosion
resistance. A systematic procedure how super alloys are
developed and what makes them of super strength and
strong corrosion resistance will be discussed.
Title: “To Study the Fracture Toughness (CTOD) of HSLA
steel Welded with Multi-Wire Submerged Arc Welding”
- Hiteshkumar Desai, T. S. Kathayat, Swatantra Joshi,
Devendra Goyal, DhruvKumar Vavdiya, Surendar G.,
Welspun, Pipe Division, L-SAW Operation, Dahej, Gujarat,
India.
Abstract:
The Development and demand of high strength low alloy
(HSLA) steel pipe for transmit oil and gas product into
undersea service. Under Corrosive fluid flow, beyond
extremely high external pressure and low temperature,
the occurrence of defects on the pipe and weld ,which
compromises the structural integrity of pipelines leading to
catastrophic failures. For this reason the fracture toughness
is most accomplishing in longitudinal SAW welded pipes.
This experiment attempt has been made to determine
the effect of different welding consumables on fracture
toughness (CTOD) on API 5L X 65 HSLA steel grade which
were welded by multiple wire along with two run technique
submerged arc welding(SAW). This investigation also
includes Metallurgical and Mechanical behaviours of weld
with respect to different welding consumables. Fractography
(SEM & EDS) of CTOD specimen is been conducted to analyze
the factors leading to degradation of fracture property. The
obtained results indicate that the fracture properties of the
weld influenced by the micro alloying elements.
Experimental plan has been made which is focusing to
determine the welding wire & flux combination which
influences to cause the desirable metallurgical changes
in the weld metal and also how it enhances the fracture
properties of welded line pipe. By Combined addition of
micro alloying elements such as Titanium, Molybdenum and
Boron in weld which instigate the formation of large volume
of acicular ferrite which substantially improves the fracture
toughness.
Title: “Material &Welding Consideration for Stainless
Steel Components”
- Idris Peerzade, Fluor Daniel, Gurgaon, India
- Ameer Hamza, Mohammed Al Aseel, Sarah Zaki Al-Jishi,
Fluor Arabia, Saudi Arabia
Abstract:
Stainless Steel is a type of steel that withstands highly
corrosive environment due to the presence of large content
of Chromium. Theyare widely used in refinery, chemical,
petrochemical, pharmaceutical, food and beverage
industries due to their inherent nature and capability of
combating corrosion with variety of services. Majority of
stainless steel components are employed in high, moderate,
low temperature, corrosive and purity service application. It is
usually considered as a first choice in selection of material to
mitigate the issue subject to corrosion and erosion wherever
normal carbon steel material have shown significant failure
or whenever certain service demands the application of
additional requirements such corrosion allowance, PWHT,
HIC, SOHIC, chemistry restriction, simulation, Hardness,
NDE, WFMT and also where product purity needs to be
maintained. Stainless Steel can be classified as Ferritic,
Austenitic, Martens tic, Duplex and Precipitation Hardening
(PH). The groups differ by its chemical composition which
affects their mechanical properties.
All the metals including stainless steel will undergo certain
changes on the base material (BM) and heat affected zone
(HAZ) during the process of welding. Stainless Steel material
has been selected for optimum corrosion resistance. Hence
to maintain these properties it is foremost and necessary
to take extra measure for the material and the precaution
during welding operation to minimize or prevent any
effects that will lose the corrosion resistance properties and
strength of this stainless steel material.
The improper application of welding and material
requirements on stainless steel may result in serious
challenges and issues during the operational and design
life of these stainless steel components. This paper will
address the most important factors that need to be taken
in consideration on material and welding during the design
and fabrication stage.
Abstracts

Title: “Moving Along with Technological Innovations:
Advancements in Welding Processes and Welding
Equipment”
- Ilhar Ul Hassan M S, Solution Engineer, Kemppi India
Abstract:
As the technology around us evolves and improves there
is always a scope of advancement in every field. Welding
being one of the major processes in the fabrication industry
assimilate the scopes and innovates welding processes and
equipment technologies. New processes and variants of the
established processes are being developed and perfected to
tackle the challenges from the industry. Welding equipment
manufacturers are also developing and improving their
equipment to boost its capabilities and deliver quality
welding. Now the industry stands at a point where the
welding systems are getting upgraded to embrace the
wave of industry 4.0. A large share of welding practiced in
the industry is still by arc welding processes. The timeline
of arc welding equipment starting with the generator sets
reached microprocessor-controlled inverter technology
machines. The digitally controlled and programmable
machines empower the development of application specific
process variants and functions. Machines with multi-process
capabilities are being manufactured. Pre programmed curves
can be installed in current MIG/MAG welding machines
to suit the material and the consumables to provide the
best arc characteristics. Advanced controls are available
even in SMAW machines for efficient starting and to avoid
sticking of electrode to the work piece which will reflect in
the productivity. The ability to precisely control the welding
current wave form give raise to new welding process variants
itself. Pulsed GMAW and GTAW are processes in which the
current is switched between peak and base levels alternatively
resulting in a lower heat input welding process. Multi wire
welding processes are being used in the industry to increase
the deposition rate and hence the productivity. Apart from
the welding process variants geared and supported by
the advancements in the welding equipment independent
welding process variants have also emerged. ATIG, FBTIG
are examples of such processes. Automation of the welding
system brings in consistent quality along with productivity.
In some processes automation becomes inevitable. With the
integration of automation with a fully matured industry 4.0
will bring a new era in welding.
Title: “Merged Arc Welding on Critical Housing”
- S. Shivasankar, Manger- Fabrication, L & T Rubber
Processing Machinery
Abstract:
L&T’s Rubber Processing Machinery manufactures and
markets tyre curing presses and other equipments for the
global tyre and rubber industry. The machines are produced
at its facility in Kancheepuram, Tamil Nadu.
The state of the art Hydraulic Tyre Curing Press for truck tyres
requires an Upper Housing having three piece constructions
and subjected to tensile load of 600 tons. Three different
materials namely forged steel flange of BS: 970 709M40,
rolled shell of E450 BR IS 2062(FE 570) and bolster of E250
IS 2062 are welded together. Being welding of dissimilar
materials preheating to requied temperature is mandated.
Root welding with SMAW process using E8018-B2 electrode
was carried out followed by Flux Cored Arc Welding using
E81T1-B2C wire plus 100% CO2 process was employed
during the development of the prototype. The process was
consuming more time for 1600mm shell and not producing
100% radiography acceptance level requiring huge reworks
due to slag inclusions and minor cracks. Due to preheating
environment, the operator fatigue also resulted in low
productivity and inferior quality. In the mean while we have
received a bulk order after successful field trials in the tyre
industry for a similar tyre curing press.
Hence to improve the productivity and quality, we have
planned to change the process to Sub Merged Arc Welding
which can provide very high penetration, good quality
welding and repeatability along with high productivity.
To automate the process we have developed a special
purpose machine with variable speed drive and multiple axis
manipulators and a shell rotator. Laser beam was employed
to track and ensure the weld bead.
The challenge was to establish the WPS, WPQR and QAP for
achieving the consistence result along with high productivity.
After conducting trials, the current, voltage and travel speed
were established for various welding passes required to
welding the J-groove welding between the shell and the
flange.
Different parameters were arrived and charted for passes like
narrow groove welding with lower current and voltage with
higher travel speed over the root run, second and third passes
with relative higher current and voltage at reduced speed to
take care of the higher weld bead of the groove and ensure
wall fusion. Next passes were done with the offset for double
bead at a marginally reduced current and voltage. Finally
cap welding with higher travel speed at a lower current and
voltage was performed for multiple passes. Sufficient care
was taken in cleaning the slag 100% during the passes.
The result was very encouraging with first time right
radiography result and very high consistency on every work
piece with four times higher productivity compared to FCAW
process.
Abstracts

Title: “Fabrication of Wave Guide Run by Forming and
Welding Technique Developed Innovatively for Space
Use Programme”
- Rajan Kumar Mishra, Scientist / Engineer – SC, SAC/ISRO
Jigish M Patel, Scientist / Engineer- G, SAC/ISRO
Abstract:
Waveguide plumbing components are one of the most
important and critical flight model (FM) hardware, are
being used for propagation of Radio frequency (RF) waves,
between two electronic packages. Basically, the waveguide
is rolled semi-finished tubes of very thin walled (0.635 mm)
having rectangular cross section in shape, made out of Al-
alloy 6061- T6 material. In-house fabrication techniques are
developed innovatively to form these above referred delicate
straight tubes, into various complicated shapes called as
Waveguide Runs, to be used in waveguide plumbing setup,
to cater requirement of satellite panels. Primary requirement
during fabrication of these waveguide runs is that, while
forming it into various complicated shapes, the cross
sectional dimensions and inside surface finish along the
length of wave guide runs should change only up to defined
stringent tolerance limits. Moreover, both the ends of the
formed waveguide runs are to be joined with highly precise
flanges through very sophisticated and Space Qualified
Gas Tungsten Arc Welding (GTAW) to achieve leak proof
permanent joints in Ultra high vacuum conditions. Since, the
tubes are much thinned wall, internally having mirror finish
and made with highly precise cross sectional dimensions,
makes the whole fabrication process very challenging.
However, through above briefed innovative space qualified
fabrication technique developed In-house, a very significant
progressive impact has achieved on aspects like; Assurance
of quick delivery, enhancement of productivity, quick
adaptability to the panel layout changes, high reliability and
also substitution to the imports.
Title: “3D Computed Tomography (CT) – Efficacy in
Identifying Materials”
- Dr. C. Muralidhar, Scientist - ‘G’, Director, M. P. Subramanian
and G. Chandrasekhar, DAINDE, Defence Research &
Development Laboratory, Hyderabad
Abstract:
Computed Tomography (CT) generates a thin cross-sectional
(slice) image of an object, which represents point-by-point
distribution of linear attenuation coefficients. CT images
are free from interference of overlying and underlying
areas of the object and are highly sensitive to small density
differences (<1%) between structures. CT system with Linear
Detector Array (LDA) generates cross-sectional images of the
test object that can be stacked one over the other to create
3D volume of the object, where as Flat Panel Detector (FPD)
can directly generate 3D volume from 2D X-ray projections
(Digital Radiography). This 3D volume can be sliced in
arbitrary planes to get the extent of internal features and
measurements in 3 dimensions.
DRDL has developed 3D CT system using 450 kV X-ray source,
2D Flat Panel detector array, Mechanical manipulator and
cone beam reconstruction algorithm that can handle objects
of 1000 mm diameter, 10 m height and 2000 kg weight for
the first time in India. 3D CT provides 360 X-ray projections
i.e., Digital Radiographs (DR), cross-sectional images and
generate 3D model of an object. The resolution of the CT
system is 300 µm. The time taken for generating the full 3D
model of an object is about 45 minutes, can be cut at an
angle to view the internal details, defects in 3 dimensions
and obtain their dimensions including inaccessible areas.
In the present paper, we have employed 3D Computed
Tomography (CT) with 2D FPD on a jet vane assembly,
whose internal parts are made of metal, Composite and Poly
Urethane Foam (PUF). The purpose of this paper is to reveal
internal details, identify and differentiate various materials of
Jet vane assembly and also to identify, locate the defects and
their extent in 3 dimensions.
3D CT facilitates 100% inspection obtaining Digital
Radiographs (DR) over 3600 unlike limited angle X-ray
Radiography and 3D model of Jet Vane assembly can be
visualized for revealing internal details with dimensions and
extent of defects in 3 dimensions. A significant change in
attenuation coefficients/gray scale values at various window
levels of Tomograms noticed for a range of materials of Jet
vane assembly. Further, the details obtained in 3D CT are
phenomenal as compared to that of Digital Radiographs and
conventional Radiography. The density profiles plotted on
Tomograms showed sharp fall in pixel values for defects as
compared to intact regions; where no such sharp fall seen.
3D CT provides qualitative and quantitative measurements
on Jet vane assembly as compared to other Non Destructive
Evaluation (NDE) methods and its salient features are
highlighted.
Title: “How advances in welding and metallurgy has
helped the industry to improve their machine availability”
- Pankaj Jain, Director, Wearresist Technologies
Abstract:
Regular and uninterrupted availability of plant for production
particularly in core sector industry like Power, Cement,
Steel, Mining, Sugar, Paper etc has become critical by every
passing day due to enormous cost of putting up such plants
and also to bring economy of scale. It is not uncommon
that maintenance engineers are spending sleepless nights
fighting with challenges of the weak links in the process
particularly due to wear and tear of equipment particularly
in INDIA where the raw material like coal, limestone, slag etc
are of the hardest kind in the world.
This paper envisages to share example of such case studies
in the industry where multiple fold life has helped the
industry to be able to now dream big after this turnaround
unlike in past where they were always fire fighting for their
maintaining production targets and machines availability.
All this was achieved through newer chemistry in welding or
by using composite metallurgy.
Abstracts

Title: “Flexible and Robust Plastic Welding for the future,
Today”
- Anubhav Gupta, Director, ARTEK – Bielomatik
Abstract:
With the introduction of new variants in plastic and demand
for high quality, high speed production comes the need for
innovative and customized solutions for plastic welding.
Bielomatik provides a wide range of options from the
standard Vibration, ultra-sonic and hot plate welding to
the latest Laser, Infra-red and automated welding solutions.
With 4 global manufacturing facilities and over 70 years of
industry experience, Bielomatik has provided state of the
art welding solutions to hundreds of customers across the
globe.
With fast changing market trends and designs today’s
manufacturing needs to be flexible to reduce change-over
time and cost of even limited volume production.
Title: “Producing Dual-phase Microstructure in Friction
Stir Welding/Processing of Medium Carbon low Alloy
Steels”
- Md. Anwar Ali Anshari, Murshid Imam, Department of
Mechanical Engineering, IIT Patna
Abstract:
Micro structural evolution in steels during friction stir welding
(FSW)/friction stir processing (FSP) is a more complex
process than that in aluminium alloys due to the occurrence
of phase transformations. The dominant parameters of
thermal cycle that affect the micro structural evolution are
peak temperature and cooling rate. In the present work,
critical control of the welding conditions produced a fine
ferrite–marten site/bainite duplex structure with varying
volume fractions of marten site/bainite and ferrite within
the stir zone. The developed micro structure provides the
preferable combination of tensile strength and ductility. The
findings were achieved to clarify the effect of the welding
parameters on the weld ability. Additionally, process window
is constructed to show the correlation between the range
of welding parameters and the optimum condition of dual
phase microstructure distributions. It is shown that FSW/
FSP can be an effective tool for the development of dual
phase steels which can offer an outstanding combination of
strength and draw ability as a result of their high combination
of strength and ductility, as well as their high strain harden
ability which gives them good strain redistribution capacity.
Title: “Resistance spot welding of Aluminium 6061 alloy
for Gas Turbine application”
- A. Manjunath, Scientist’F’, K. M. Ashique, Scientist’E’, K.
Parthiban, Scientist’H Gas Turbine Research Establishment,
Defence Research and Development Organisation
Abstract:
Aluminium 6061 T6 is widely used in the aircraft industry.
This alloy has a very good corrosion resistance and finishing
ability. T6 is the temper designation, it is solution heat
treated and artificially aged. Aluminium and its alloys have
high thermal and electrical conductivity compared with steel
and, as the spot welding process depends on resistance
(Joule) heating, they require much higher welding currents.
In addition, the surface contact resistance plays a major
part in heat generation. Short weld times are employed to
generate the heat quickly and thus minimise the heat lost
by conduction.
In order to conform to the requirements of specification for
resistance welding for Aerospace applications AWS D17.2/
D17.2M:2007 various tests are conducted. It is to determine
if a particular machine, in combination with a specific weld
procedure, will on a given set of material produce resistance
welds meeting the standard.
Inlet nose a component made out of 1.2mm thick Al 6061
material called for 4 + 16 number of spot welds of 4mm
spot diameter. In order to spot weld the job and meet the
required aerospace weld quality standards the following
were investigated:
• Resistance Spot welding machine
• Electrode material, design and dressing
• Cleaning /preparation of samples
• Spot welding parameters
• Peel off test
• Non-destructive testing (Visual, Radiography and Dye
Penetrant Inspection)
• Failure loads in 6061-T6 aluminium resistance spot welded
joints were investigated.
• Nugget size and microstructure characteristics were
quantified
• Surface indentation
Title: “Resistance Projection Welding”
- Dr. Girish P. Kelkar, Owner – WJM Technologies, Member –
American Welding Society
Abstract:
Resistance projection welding, a type of resistance welding
process, offers many benefits by utilizing a projection
geometry that ensures that the welding current and heat is
focused at a specific location. During the welding process,
the projection collapses and the weld contact area grows
to required size, and typically produces a solid-state bond.
Benefits of projection including localization of the weld,
extended electrode life, improved heat balance, and the
ability to produce multiple weld spots with a single electrode.
Presence of projection also allows a lower melting plating to
be squeezed out from the weld and results in cleaner weld
metallurgy at the bond line. Projection welding does provide
challenges with extra step to make a projection, special heads
with good follow-up, and power supplies that can provide a
rapid rate of energy delivery. Process development also can
prove to be challenging since weld heat control is important
in order to avoid melting and expulsion of the weld in form
of weld flash. Projection designs can include single dome
shaped projections for spot welding, linear rail projections,
or annular projection to form a continuous hermetic
Abstracts

weld. Rapid heating and cooling of the weld can result in
excessive brittleness in the weld when welding carbon steel
components. A secondary welding pulse can be employed
to reduce weld hardness with a process of tempering. Both
the welding and tempering pulses are fired in succession
and the resulting weld can be strong yet not so brittle.
Projection welding has found extensive use in wide variety
of applications and industries including welding engine fuel
rails, pressure sensors, air bag assemblies, and structural
flanges.
Title: “Resistance and Laser Welding for Micro Joining
Applications”
- Dr. Girish P. Kelkar, Owner – WJM Technologies, Member –
American Welding Society
Abstract:
Resistance welding and laser welding are two commonly
used welding processes to produce microscopic welds.
Often these welds are made literally under a microscope as
the parts are extremely small, usually less than a 0.5 mm, and
require careful handling and positioning prior to welding.
Such welds are quite common in the medical device industry
making implantable for heart, spine, and vision applications.
With rapid miniaturization of motors, sensors, batteries,
and microchips, an increasing number of micro joining
applications are coming to fore. Resistance and laser welding
are unique processes that are able to make very focused
welds in small components without causing any collateral
damage to nearby components. While the two processes
have similarities, they are also quite different. While laser
welding is primarily a fusion welding process, resistance
welding is more versatile and can produce all types of bonds
including fusion, solid-state and solder/braze. One of the
advantages of resistance welding is the electrodes push down
on the parts being welded and able to hold the tiny parts in
place. Resistance welding also offers direct feedback from
the process that helps to gauge weld quality. In contrast,
laser welding is a non-contact process that can be targeted
into hard to reach locations and for parts not suitable for
contact welding. Both processes are able to effectively deal
with welding dissimilar materials, which is the norm in micro
joining applications. This paper reviews the applications and
capabilities of the two processes as they pertain to micro
joining applications with real world examples.
Title: “Coupled Thermo-Mechanical Modelling on
Dissimilar Metal Plates of Friction Stir Welding Process
with Polygon Tool Pin Geometry”
- Rahul Kesharwani, Chiranjit Sarkar, Murshid Imam, Dept. of
ME, IIT Patna
Abstract:
Friction stir welding (FSW) is a solid-state welding technique,
it is the modified form of conventional friction welding,
initially it was used for soft aluminium alloy and thin plates,
but now it’s a huge application in the aerospace, automobile
and thick plate welding etc. In the FSW process, the heat
generation was the major impact on the tool failure and this
heat generation is purely depending on the contact area
during welding. The probe of the FSW process experiences
high temperature and it was the weakest component
of the FSW tool. The tool geometry plays an important
role in deciding the tool life criteria because of maximum
temperature changes by changing the tool shape. In this
work, the two dissimilar metals of aluminium and copper
plate were selected with different polygon tool pin geometry
such as a hexagon, triangle, pentagon, square and cylindrical
to understanding the temperature and fluid flow behaviour
during friction stir welding. From the computational results,
the temperature, velocity, strain rate and dynamic viscosity
values are found by coupled Heat transfer and material flow
physics when two dissimilar welding was performed. Here
we are discussed that the effect of temperature on the tool
and work-piece of friction stir welding process when tool
geometry changes with the help of simulation modelling. The
coupled thermo-mechanical modelling was performed with
the use of a Consol Multi physics software package. Welding
was done on dissimilar metal plates of aluminium alloy AA-
6061 and pure copper and the tool was made of H-13 steel.
The probe was in tapered shape where outer radius for the
top and bottom position of the probe was same for all the
probe design. In this case, the triangular tool pin shows the
highest temperature (816K) among all the tool pin geometry
and cylindrical probe shows the lowest temperature (629K),
the welding parameter and boundary conditions were same
for all the cases.
Title: “Selection of Materials for Corrosion Resistance”
- Prof. A. S. Khanna, IIT Bombay (Retd.), Chairman SSPC India
Abstract:
Corrosion is the degradation of materials, leading to its metal
loss, thereby loosing its load bearing capability, leading to
catastrophic failure. Annual losses due to corrosion in India is
estimated around Rs. 75000 to one lakh crore, which covers
various sectors ranging from oil and gas, refineries, corrosion
in transportation industry ranging from automobile, railways
to ships and aircrafts, structures – bridge flyover, multi-
storey buildings and real estate. Further corrosion takes
place in various forms, uniform or localized, intergranular
or transgranular, during welding or joining, due to stress
or impact or due to micro-organisms. Further it must be
understood that corrosion cannot be totally eliminated, it
can only be minimized. Hence the whole game is how to
minimize corrosion. Though, there are four methods to
minimize corrosion:
• Selection of better materials
• Use of Coatings
• Use of anodic or cathodic Protection
• Use of inhibitors which reduce corrosion
However, the crux of minimizing corrosion is by proper
material selection. Material selection does not mean we
select only costly materials that stainless in place of steel
but it simply means proper chemical composition which can
resist corrosion for a selected application. The paper will
describe how several steels are modified to suit a particular
Abstracts

application, for example heat exchanger or underground
pipelines, what is most corrosion resistant stainless and what
is most corrosion resistant alloy.
Title: “Investigation of Directional Anisotropy in Friction
Stir Welded/Processed Aluminium Alloys”
- Sweta Saroj, Murshid Imam, Dept. of ME, IIT PATNA
Abstract:
Friction stir welding (FSW)/friction stir processing (FSP) would
results a beneficial effect on the properties due to physical
interaction between the tool and work piece material. The
developed microstructure is a strong function of both the
temperature and strain rate. The local values of the relative
velocities of the plasticized material within the shear layers
are expected to vary significantly when a non-symmetric tool
probe profile is used. Therefore, the main goal of the present
work is to investigate the directional anisotropy within the
stir zone (SZ) region. It is believed that in addition to grain
structure, a crystallographic texture also plays an important
role in causing anisotropic behaviour of SZ. The miniature
tensile samples were tested along welding direction
and transverse direction within the SZ (stir zone) region.
Interestingly, it is observed that despite the micro structural
refinement in SZ (stir zone), the SZ also exhibit directional
anisotropy. Additionally, micro structural studies performed
on these tensile samples revealed that crystallographic
textures, precipitates morphology, and the thermally stable
fragmented second phase particles are the main reason for
this anisotropic behaviour. The present findings will help in
selecting the appropriate stretching/loading directions of
the processed/welded samples for forming applications.
Title: “State of P91 Steel Fabrication in Indian Industries”
- D. D. N. Verma, General Manager – Quality Management
(Welding & NDT), DEE Piping systems
Abstract:
Steam-temperature & pressure exiting S/H of a high capacity
boiler is ~ 570 °C - 600 °C & 170 - 230 bar respectively. The
final S/H & Pipes carrying steam to turbine must withstand
this extreme temperature & pressure. This necessitates the
material constituting these tubes & pipes must possess
very high strength properties & must be creep-resistant.
P91, presently is one such heat & creep resistant material in
power-industries.
PAYBACKS OF P91
Equated to its predecessor, the grade P22, ‘Modified P91’
exhibits high strength up to ~ 600 °C in the range. It’s
oxidation resistance confines are higher & authorizes plant
designers to plan components like S/H coils, Headers and
Steam Pipes with lesser thickness contributing a higher
thermal fatigue life of ~ ten times. In addition to imparting
enhanced operating parameters, it suits plants that operate
on a cyclic basis like a combined cycle plants.
WHAT MAKES P91 ATYPICAL?
A Cr content of 9% and Mo at 1% compared to 2.5 %Cr in
the next best P22 enhances elevated temp. Strength of P91
and increases its oxidation resistance. Mo imparts creep-
resistance. Ni & Mn, though present in small quantities
contribute to its harden ability.
Micro structural-formations are more imperative than
alloying elements in P91 steel. The steel is fashioned by
normalizing at 1050 °C & air cooling down to ~ 100-200 °C.
Its then is tempered by heating to 760 °C. The temperatures
and cooling rates are critical to obtain the requisite
microstructure & creep strength. Steel is absolutely intolerant
to variations in its microstructure, unlike P22 or other grades.
All heat treatment requirements must, therefore, be precisely
followed to achieve the micro structural constituents &
features.
Any working on the steel would necessitate a precise heat
treatment in order to reinstate the lost microstructure back
to its original conditions. Else, the steel may have properties
much lower than its predecessor P22. Conclusively, in P22
and other low alloy steels, the effect of variations in heat
treatment is not as violent as in P91.
JOINING P91
Welding affects microstructure. Preheating, Inter-pass,
and PWHTs are very critical for P91. Failure to follow the
procedures will result in catastrophic failures. Thick walled
pipes need use of an induction heating system. This gives
better control, and uniform heating between the inner and
outer diameters. In induction heating the coils themselves
do not heat up. This is ideal for maintaining the inter-pass
temperatures and carry out the welding. It’s worker-friendly
& is ideal for complex shapes likes weld lets, Tees etc.
The Nickel and Manganese content, even though in
smaller percentages, have profound effects on the critical
temperatures & all heat treatments. Because of this, the
composition of the welding electrodes used should be in line
with the parent material.
P91 weld has great affinity to Hydrogen leading to hydrogen
induced cracking. PWHT must be executed as quickly as
possible to avoid any contact with water. All joints must be
post-weld heat treated prior to hydro test.
Finally, since in spite of all challenges & confronts, the
industry embraces P91, the use of this steel continues & will
continue to continue its successful journey.
This paper presents various aspects of P91 metallurgy
& fabrication in Indian industries including the design of
the steel, welding, Heat Treatment, effects of Delta ferrite,
microstructure on the shop – floor, Type IV Cracking in the
HAZ etc. etc..
Abstracts

Title: “Stresses in Sand Casting – Analysis and Optimized
Solutions for
Improved Casting Designs and Product Quality”
- Dr. Jesper Thorborg, Jörg Zimmermann und Dr. Corinna
Thomser, MAGMA GmbH, Aachen
Abstract:
Sand casting of metal parts is one of the most flexible
manufacturing processes for differently Shaped and sized
castings. The process is applicable for a wide range of
alloys and the obtained material quality and dimensional
tolerances can be controlled by modifying either the design
of the part or the casting layout. The flexibility in design
provided by the shaping sand material and the internal
sand cores often leads to a complex cooling history, which
highly affects the evolution of properties and defects. Many
defects in the final part like e. g. cold cracks and hot tears
are related to the stresses that build up during cooling. This
article presents how MAGMASOFT® is used to analyze and
optimize both the casting design and the casting process by
combining the thermal analysis of the casting process with
an integrated prediction of stress and distortion. It is shown
how the thermal gradients, cooling time and constraints
from the mold and core materials affect the risk of stress
related defects and unwanted distortion. Methodological
application on industrial examples show the significant
advantages of being able to systematically analyze different
designs and casting lay outs up front, to avoid quality
problems in production and fulfil dimensional tolerance
requirements.
Title: “Automatic Virtual Optimization of Ingot and
Continuous Casting Processes”
- I. Hahn, E. Hepp, M. Schneider, MAGMA Gießereitechnologie
GmbH
Abstract:
Simulation technology today makes it easily possible to
carry out three-dimensional simulations of the teeming and
solidification of ingots as well as of the flow and solidification
in continuous casting processes. Quick and reliable virtual
casting trials in the computer can be performed considering
all relevant process parameters. During casting, numerous
complex physical phenomena occur simultaneously that are
coupled with each other. Changes of one process parameter
usually lead to a change of many quality-relevant properties
of the product. A coupling of casting process simulation
with statistical design of experiments allows the virtual
exploration and evaluation of the effects of process changes
on all relevant quality characteristics. Automatic virtual
optimization, which is focused on the fulfilment of several
targets at the same time, provides promising approach for
defining robust casting processes and finding operating
points that build a best compromise between competing
objectives. This paper will show examples of the application
of these methodologies for continuous and ingot casting
processes and gives an insight into how process development
benefits from them.
Title: “Achievement in New Technology Introduction for
PU (Production Units) & Repair Units”
- Ashish Apte, Segment Manager, Fronius India
Abstract:
Fronius India with support from Fronius International GmbH
introduced the concept of CMT (COLD METAL TRANSFER) in
Indian Railways production & repair units for Rolling Stock.
CMT Process with the Cold Metal Transfer (CMT) technology,
Fronius has revolutionized the welding market. The
technology, first unveiled in 2004, ushered in a new era that
continues to this day.
This distinctive system has managed to position itself over
time as a brand. Of course, not only high-quality welds were
decisive for this development.
The Cold Metal Transfer stands for much more than just
minimal welding spatters, a more stable “cold” process and
high welding speeds. It is also the physical embodiment
of the impossible made possible: the joining of steel and
Aluminum to a high standard.
The focus of this process, the typical CMT application areas,
is extremely varied.
With this technology, Fronius has not only succeeded in
creating a unique selling point, but has also built upon its
position as the technology leader.
Abstracts
a

Annual Conference & Exhibition on
Glimpses

Anual Conference and Exhibition on
4-5 June 2020, New Delhi
2020
In
“Steel, Industrial Materials
& Non-Metallics”
&
“Welding &
Fabrication Technology”
WeldFab’20Materials’20
Ansal Chambers, Bhikaji Cama Place, N. Delhi- 110066, India
Mobile No.: +91 96673 17805; Phone No(O): 011-46545757
Email: technical@materialssummit.co.in; technical@weldfab.co.in
Web: www.materialssummit.co.in, www.weldfab.co.in
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