Atlas Copco Internship Report

Hamsini Gopalakrishna Atlas Copco, Nanjing, China Summer Internship – 2012
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ATLAS COPCO, Nanjing, China
Report of
Summer Internship
28th
May to 26th
July 2012
By
Hamsini Gopalakrishna
Purdue University
Purdue ID: 0024012407
West Lafayette, IN – 47906, USA

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CONTENTS
 Certificate . . . . . . . . . . . . . . 3
 About Atlas Copco . . . . . . . . . . . . 4
 Summary . . . . . . . . . . . . . . 5
 Detailed report . . . . . . . . . . . . . 6
 Summary of samples analyzed . . . . . . . . . 8
 Details of samples analyzed . . . . . . . . . . 10
 Thoughts and future work . . . . . . . . . . 25
 Acknowledgement . . . . . . . . . . . . 26
 Travel report – Xu Zhou BUT company . . . . . . . 27
 Appendix I – Manuals . . . . . . . . . . . 29
 Appendix II – Photographs . . . . . . . . . . 65
 Xu Zhou trip . . . . . . . . . . . . 73
 Wuxi visit . . . . . . . . . . . . . 77
 Appendix III – Presentation . . . . . . . . . . 81

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CERTIFICATE
This is to confirm that Hamsini Gopalakrishna has successfully completed
her industrial internship at Atlas Copco, Nanjing, China. This 8 week internship
lastedfrom the 28th of May till the 26th of July2012. She workedin the Materials
and Metallurgical Group in Rocktec and was assigned the following tasks –
1) Familiarizing, using and writing the quick reference manuals for a
microscope, a stereoscope, hardness testers, sample making machines and
the SEM. The Ultrasonic tester and the Magnetic Particle tester were also
included.
2) Measurements using all of the above equipment with samples (where
applicable).
3) Non Destructive Testing (NDT) at supplier’s factory. (Xu Zhou BUT
Construction Machinery Holding Co.Ltd.)
4) Study tour of Atlas Copco assembly plant of Nanjing and Wuxi.
5) Familiarization of welding, casting, ultrasonic testing and magnetic particle
testing standards as well as other industrial procedures.
She has completed the above tasks successfully and on time. We found
Hamsini Gopalakrishna to be efficient, industrious and to have a hunger to learn
new techniques. She is very cooperative and has good team spirit. She will be an
asset to anyorganizationshe would work with. We wish her success in her future
endeavors.
Dr. Johnny Huang Mr. Suresh Shyamsundar
Materials and Metallurgical group leader Head of R&D center (Rocktec)
About Atlas Copco

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Atlas Copco is a Swedish industrial conglomerate which manufactures
compressors, generators and industrial tools in addition to construction and
mining equipment. It was founded in the year 1873. Its headquarters is in
Stockholm, Sweden. It has production sites in 20 countries. Their single largest
market is in mainland China. It has 18 facilities in China. The plants at Wuxi,
Nanjing and Tianjin are R&D centers with state of art laboratories in addition to
having production facilities.
Atlas Copco, Nanjing is a research facility that has various divisions like
Rocktec, Surface Drilling Equipment (SDE), Underground Rock Excavation
(URE), Geotechnical Drilling Equipment (GDE) and Atlas Copco Drilling
Solutions (ADS). It also has a full assembly line on site. Approximately 400
people work in the plant at Nanjing. Rocktec supports the other divisions in the
technical aspects. Rocktec has six divisions namely Applied Mechanics,
Materials and Metallurgical group, Measurement group, Patent group, Product
Lifecycle Management (PLM) Solutions and Industrial design. The PLM
division focuses on Product Design (CAx) and Product Data Management.
Atlas Copco, Wuxi is a research facility in addition to being an assembly
plant. Approximately 600 personnel work in the plant. They produce screw
compressors. Their staff averages 110 hours of technical training per person on
the job.
Summary
It was a very educative and hands-onexperience overall. During the internship (28th

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May – 26th July2012), Hamsini successfullycompletedthe tasks outlines below.
i) Hamsini independently used the lab equipment. The lab equipment consisted of
an SEM, hardness testers, microscope, stereoscope, sample making equipment
and Non Destructive Testing(NDT) equipment.
ii) She prepared quick reference guides for all of the above equipment
iii) She helped write the lab regulations for safetyinthe labs
iv)She used the Analyzed samples including
a) Failed crank shaft
b) ADS shaft
c) Comparisonbetweentwo pistons
d) Fracturedbolt
e) Deformedbushing
f) Aluminum feedbeam
g) Steel exhaust pipe
v) She familiarizedherself withvarious standards like
a) EN ISO 5817:2007 – Welding – Fusion-welded joints in steel, nickel,
titanium and their alloys (beam welding excluded) – Quality levels for
imperfections
b) BS EN 1290:1998 – Magnetic particle testingof welds
c) BS EN ISO 17640:2010 – Ultrasonic testing
d) BS EN ISO 377:1997 – Steel and steel products – Location and preparation
of samples and test pieces for mechanical testing
e) BS EN ISO 3651-2:1998 – Determination of resistance of inter-granular
corrosionof stainless steels
f) ISO 21610:2009(E) – Accelerated corrosion test for inter-granular
corrosionsusceptibilityof austeniticstainless steels
g) en 10 9001 K – Atlas Copco Standard for Delivery requirements for Steels
and ironproducts
h) en 6134 K – Atlas Copco Specifications for Steel and Iron casting
requirements
vi) She studied and familiarizedwith case studies and reports byother engineers.
vii) She accompanied the NDT Engineer, Mr. Allen Zhang and the Sourcing
Quality Engineer (SQE) Mr. Zhengzheng Xu to the BUT Construction
Machinery Holding Co. Ltd. in Xu Zhou. (21st June, 2012). Welds in the frames
for B-282 were to be tested for surface and sub-surface flaws using the
Ultrasonic testingmethods.
viii) She toured the Wuxi Atlas Copco plant to better understand the working of
the industry. Accompanied Mr. Alex Xie and Mr Charles Fu (19th July, 2012).
Detailed report
On my first day, May 26th, 2012, Hamsini Gopalakrishna was assigned to the

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Materials and Metallurgy team. She was introduced to the members; Dr. Johnny
Huang (Dr. Huang Xing), the team leader, Mr. Allen Zhang (Mr. Zhang
Guoqiang) and Mr. Charles Fu (Mr. Fu Pei). Mr. Allen is the Welding and Non
Destructive Testing (NDT) engineer. Mr. Charles is the Materials Science
engineer. she was able to get a clear idea of the scope and nature of work after a
tour of the lab and the production facility. The materials analysis lab has been
functional since March, 2012.
The equipment in the labs consisted of
a. Microscopes
i. Optical Microscope
ii. Optical Stereoscope
iii. Scanning Electron Microscope (SEM)
b. Sample making equipment
i. Cutting machine
ii. Mounting machine
iii. Grinding and polishing machine
iv. Precisionweighing scale
c. Hardness testers
i. Vickers microhardness tester
ii. Universal tester
iii. Brinell tester
d. Non Destructive Testing Equipment (NDT)
i. Ultrasonic tester
ii. Magnetic particle tester.
Over the next few weeks, she was trained on using the above equipment by
Mr. Charles and Mr. Allen. She got familiar with their usage and settings. She
also used these machines with several samples and took readings (where
applicable). My first task was to write short user manuals or quick reference
guides for the equipment. This was because most of the manuals provided by the
supplying companies were in Chinese and/or were too long. When the manuals
were finalized, they were laminated and displayed next to the machines. She
highlighted various precautions to be taken for safe usage of the lab equipment.
The manuals can be found in Appendix I.
Her second task was to create a presentation. The design engineers,
mechanical engineers and engineers from the sourcing department were to be
given a presentation about the equipment in our labs by the Materials and

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Metallurgical group. The main idea was to inform the engineers about how the
equipment in the labs can help analyze samples to provide useable information.
She made the presentation illustrating the main uses and features of the
equipment in the labs. This can be found in Manual III.
Hamsini visited the BUT Construction Machinery Holding Co. Ltd. in Xu
Zhou (21st June 2012). She accompanied Mr. Allen Zhang and Mr. Zhengzheng
Xu from sourcing. Some machine frames were to be tested using the Ultrasonic
tester for surface and sub-surface flaws in the welds.
Mr. Alex Xie (Mr. Xie Xiaogang), a measurement engineer, and Mr. Charles
Fu and Hamsini visited the Atlas Copco R&D center in Wuxi, China. It had a full
product assembly line as well. We met Mr. Koen Lemmens, the R&D center
Product Development Support Manager and Mr. Cheng Xiao Bo, the Materials
Engineer. They also met Mr. Lin Zhi Min, the Noise and Vibration Engineer and
Xu Bin Jie, the Infrastructure, Calibration and Computer Aided Testing (CAT)
engineer. They took a tour around the facility. They saw various types of
compressors, generators and testing equipment. After lunch, they had a
discussion with the materials engineer on a broken aluminum oil separator. They
were trying to find out the probable cause of failure.
There were often samples that came from the factory to be analyzed.
Microstructure analysis, failure analysis and hardness test were some of the tests
run on the samples. The details of the samples included the following
a. Acrank shaft used in automobiles. Atlas Copco was testingthe reason for
failure. The pipe was induction welded. This failed during testing.
b. A comparison between an Atlas Copco and a competitor’s pistons. The
Atlas Copco piston cracked while operating.
c. A fractured bolt from ADS.
d. An analysis of afailed bushing from the SDE department (from the CDM
75). The bushing had deformed.
e. An aluminum feed beam from the drilling machines. The beams supplied
by a local company were being compared to imported beams.
f. Drilling shaft that Atlas Copco was buying from a supplier. This failed
during testing. (ADS)
g. A steel pipe had to be tested for corrosion resistance. She helped prepare
a sample for chemical analysis. She read up on standards for a corrosion
test.

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Summary of samples analyzed
Table 1: Samples analyzed during the internship
Sl.
No
Item Failure Details Processes Equipment used Conclusion
1 Crank shaft A crack was noticed during
inspection. It was induction
welded. In induction welding,
electromagnetic induction is
used to heat the piece.
Microstructure
analysis
Sample making
equipment
(Cutting,
Mounting,
Grinding
machines),
Microscope
The welding was flawed. The probable cause of
the crack in the weld is incorrect weld
temperature. The microstructure around the weld –
ferrite and pearlite indicate that the pre-welding
pressure was up to standards.
2 Comparison
between Atlas
Copco and
competitor 4”
pistons
The Atlas Copco piston failed
in operation. It cracked at the
striking surface.
Hardness
testing and
Microstructure
analysis
Sample making
equipment,
microscope and
Vickers hardness
tester
The raw materials were different. The
competitor core is more tempered. This increased
toughness. In their carburization layer, the
microstructure is finer. Their surface is less harder
than Atlas Copco’s pistons.
3 Bolt from
ADS
The bolt cracked half way
during assembly. This bolt and
three others in the same
structural position were
analyzed for causes of failure.
Surface and
failure analysis
Stereoscope The surface was harder* than the core as per
requirement. Both the core and the surface
hardnesses were above the required standards.
This caused the surface to be brittle and prone to
cracking. The hardness of the other bolts used in the
same functional position was too low (sourced from
the warehouse). This led to fracture
* The hardness tests, microstructure analysis and chemical composition analysis were done prior to my internship.
The most probable cause of failure has been bolded. In some cases the cause of failure is not evident.

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Table summarizing the samples analyzed during the internship – Continued
Sl.
No
Item Failure Details Processes Equipment used Conclusion
4 Deformed
bushing
The bushing deformed when the feed
beam moved. The assembly
technician was adding oil to the
cylinder when the beam moved. The
pin roll had detached.
Microstructure
analysis and
Hardness testing
Sample making
equipment,
microscope and
Vickers hardness
tester
The chemical composition,
microstructure, hardness and its
tensile strength meet the
requirements. The microstructure
around the deformed area suggests
ductile failure. Material cause of
failure may be ruled out
5 ADS Shaft A shaft circle welded with plates was
broken at/near the Heat Affected
Zone (HAZ).
Element
analysis, tensile
test,
micro-hardness
test and analysis
Tensile tester,
Vickers hardness
tester, sample making
equipment and
microscope
The high internal stress
concentration near the welding area
caused it to break. High weld area
hardness also caused failure.
Application of an external force
tends to break it. It was found that
the welders were not sticking to
the welding protocol.
6 Aluminum
feed beam
for the
drilling
machines.
This was not a case of failure. The
aluminum beams from local
companies were being compared to
the importedbeams being used.
Hardness test Brinell hardness
tester
The average hardness value was
104.36. HB. The imported feed
beams are being used in the
machines. Due to lack of a portable
hardness tester, testing the imported
beams will be postponed. This was
an ongoing analysis at the time of
the internship.

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Detailed analysis
1) Crank Shaft
The crankshaft is the metal piece in the middle. Due to the geometry of the cut
metal piece, the pieces on the sides were added for support.
Fig 2. Photomicrograph of the induction weld. Magnification 200x
Cracks were observed during inspection. It was sent to the labs for further
inspection. Upon preparing the sample and examining it under a microscope, it
was found that improper welding was the cause. There was a crack in the
welding. The probable cause is improper weld temperature. This can be known
by the fact that the microstructure around the weld is typical of proper pressure
parameters.
Fig 1. The mounted sample of the crank shaft
weld piece.

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2) 4” pistons – Atlas Copco vs. Competitor
The starting material was different. The Atlas Copco piston was made of
18CrMnNi2MoA while the competitor’s piston is made of 20Cr2Ni4A.
The direction of the hardness gradient is shown
Fig 7. ZJK2 piston surface structure, Fig 8. ZJK2 piston, core carburized
case. 500x structure 500x
Fig 5. AC
ZJK piston
Fig 6. HJG piston
Fig 3. The
ZJK (Atlas
Copco) piston
Fig 4. The HJG
(competitor)
piston

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Graph 1. Carbon content with the distance from the surface.
0.3
0.35
0.4
0.45
0.5
0.55
0.6
0.65
0.7
0.75
0.8
0 1 2 3 4 5 6
CarbonContent(%)
Distance from surface (mm)
Carbon content vs. Distance
Wt% Carbon ZJK
Wt% C after decarbonization
Wt % Carbon HJG piston
Fig 9. HJG piston, surface
structure, carburized case×500
Fig 10. The surface defect on
sample 1, the center. 500x
m
i
c
r
o
-
s
t
r
u
c
t
u
r
e
,
t
h
e
g
r
a
i
n
s
i
z
e
i
s
1
0
.
3

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Graph 2. Hardness as a function of the distance from the outside to the inside of the
sample – ZJK piston
Graph 3. Hardness from the inner surface to the outer surface as a function of distance
– HJG piston
400
450
500
550
600
650
700
0 2 4 6 8 10 12 14 16
Hardness(HV)
Distance from outside to inside (mm)
Hardness vs. Distance
400
450
500
550
600
650
0 2 4 6 8 10 12 14 16 18 20
Hardness(HV)
Distance from inner surfaceto outer surface (mm)
Hardness vs. Distance

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3) ADS failed bolt
Three bolts marked DB Broken, DB and ZS had the same functional position.
The supplier realized that ZS didn’t meet standard requirements and replaced
them with bolts marked zs. The bolt marked DB Broken failed during assembly.
Two other bolts in the same functional position were also tested for comparison
(DB and zs).
Fig 11. Side view – DB Broken Fig 12. Top view of the cut part DB Broken
Table 2. Bolts analyzed for their composition.
Mark C Si Mn P S Cr Mo
DB Broken 0.43 0.24 0.84 0.015 0.007 0.99 0.2
DB 0.39 0.23 0.61 0.014 0.007 0.99 0.16
zs 0.33 0.2 0.55 0.016 0.006 0.91 0.16
Hardness testing: The four bolts were testedfor hardness in the core region and
on the surface. Representative graphs are given below the table
Table 3. Hardness values for core and surface of the different bolts
Mark Core Hardness (HV 0.3) Surface Hardness (HV 0.3)
DB Broken 448, 440, 445 430, 440, 437
DB 437, 430, 422, 412, 410, 417 448, 432, 441, 420, 438, 421
ZS 369, 353, 357 229, 233, 239
zs 361, 347, 333, 367, 374, 378,
299, 300, 309, 337, 328, 338,
288, 282, 287
396, 393, 391, 415, 412, 403,
469, 487, 472, 408, 405, 420,
407, 415, 422
Standard
Requirements
GB/T 3098.1-2000
Minimum: 385, Maximum: 435
Surface hardness shall not be more than 30 Vickers points
above the measured core hardnesses. This is for HV 0.3

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Graph 4. Hardness of the core.
Graph 5. Hardness of the surface
261
347
333
367
374 378
299
300 309
337
328
338
288
282
287
369
353 357
437 430
422
412 410
417
448
440
445
385
435
250
270
290
310
330
350
370
390
410
430
450
1
Hardness(HV0.3) Hardness values - Core
zs
ZS
DB
DB Broken
Standard
369
393 391
415 412
403
469
487
472
408 405
420 415
422
229 233
239
448
432
441
420
438
421430
440
437
385
435
200
250
300
350
400
450
500
1
HArdness(HV0.3)
Hardness Values - Surface
zs
ZS
DB
DB Broken
Standard

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These photographs were taken at 500x
Fig 13. DB Broken surface: Tempered troosite Fig 14. DB Broken core: Tempered troosite
Fig 15. DB surface: Tempered troosite Fig 16. DB core: Tempered troosite
The above analysis was completed by the Materials group before I started my
internship. The data has been included for the sake of completeness.
Fig 17. Zs surface – tempered
troosite and block ferrite. 50x
Figure 18. zs core tempered troosite
with ferrite. 500x

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Fig 19. Top view of the broken bolt Fig. 20 Side view of the broken bolt
The surface of the bolt was analysed. Along with the data from the hardness tests,
it was found that the bolt was brittle due to high hardness. This was the cause of
failure.
The hardness of the bolt exceeded the requirement of 435 HV 0.3 in the GB/T
3098.1-2000 standard.
Hardness of the zs bolt was too low.
The carbon and Mn content in the broken bolt was higher than the other bolts
tested. This is a cause for high hardness.
Ferrite observed in zs and low core hardness indicates that the heat treatment
process isn’t well controlled. The part isn’t thoroughly hardened.

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4) Deformed bushing
The bushing was cut to reveal the deformed side. This side was mounted,
grinded and polished. The chemical composition matched the requireme nt
for Q345D in GB/T 1591-2008.
Fig 21. The deformed bushing Fig 22. The deformed surface – after cutting
Fig 24. The average HV0.3 hardness values of the samples with their respective
locations
Surface to observe
microstructure
Deformed
Surface
Fig 23. Mounted sample of
the deformed surface

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Fig 25. Core. 100x Fig 26. Core. 400x
Fig 27. Deformed surface. 100x Fig 28. Deformed surface. 400x
Fig. 29. Non deformed surface. 100x Fig 30. Non deformed surface. 400x
Table 4: Chemical composition of the sample and Q345D requirement.
Element C Si Mn P S
Bushing sample,% 0.15 0.21 1.06 0.013 0.007
Q345D requirement,% >0.18 >0.50 >1.70 >0.030 >0.025

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Fig 31. Deformed Corner: 50x Fig 32. Deformed surface corner 400x
Table 5: Hardness values of the various surfaces
Location Core Deformed
Surface
Non deformed
surface
Deformed Corner
Trial 1 212 218 168 230
Trial 2 199 209 176 224
Trial 3 199 198 176 231
Trial 4 189 191 184 -
Average 200 204 176 228
Due to lack of information about heat treatment process, it is impossible to judge
whether the part’s mechanical properties are suitable. The ductile nature of the
deformation indicates that the failure may not be entirely due to material causes.
The chemical composition matches the requirements. The ferrite and pearlite
microstructure is typical. The sample hardness is around 176 – 204 HV 0.3 and
the tensile strength is 560 – 625 MPa The tensile strength was obtained using a
conversion chart DIN 50150: Conversion of hardness values for metallic
materials.

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5) ADS Shaft
The shaft circle welded with plates was broken. Element inspection,
tensile testing, micro-hardness test and microstructure analysis were done
on the shaft base metal. A micro-hardness test was run on the weld.
The chemical composition matches grade 45 steel. The matrix consists of
pearlite and ferrite which is typical for normalized grade 45 steel. Weld
area microstructure consists of sorbite with ferrite inthe grain boundaries.
Fig 33. The ADS shaft Fig 34. Mounted sample of the shaft
Fig 35. Base metal 100× Fig 36. Base metal 500×
The white phase is ferrite, and the dark phase is pearlite.

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Fig 37. Weld area 100× Fig 38. Weld area 500×
The dark phase is sorbite, and white phase in grain boundary is ferrite.
Table 6: Chemical composition of the shaft
Element C (%) Si Mn P S Cr Ni
Grade
45 Steel
0.42-0.50 0.17-0.37 0.50-0.80 <0.035 <0.035 <0.25 <0.3
Sample 0.43 0.22 0.58 0.025 0.017 0.05 0.02
Table 7: Mechanical properties of the shaft
Tensile Strength (MPa) Yield Strength (MPa) % Elongation
650 259 23
The average hardness for the base metal is 198.6 HV 0.3. The average hardness
value for the weld area is 360 HV 0.3.

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6) Aluminum Beam
The local and imported beams were to be compared. The local beams are
cheaper. If they meet the standard requirements, they would replace the
imported beams. Hardness test was run on the local beam (pictured
below). The imported beams are being used in the machines. The lab is
not equipped with a portable hardness tester. Bringing the whole beam to
the lab would be a problem as the beams are over 20 feet in height. One of
the ways the imported beams can be tested is when a machine beam fails;
a part of it can be cut and tested. Another way is if a beam is bought solely
for testing purposes. This was an ongoing project when the internship
ended.
Fig 39. The Al feed beam
Fig 40. Front view of the beam
Fig 41. Mounted sample Fig 42. Piece used for hardness testing

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Table 8: Composition of the beam
Element Si Fe Cu Mn Mg Zn Ti Zr
Amount (%) 0.14 0.20 0.08 0.24 1.2 4.80 0.04 0.12
Table 9: Mechanical properties of the local Al beam
Tensile Strength
(MPa)
Yield Strength
(MPa)
Percentage
elongation (%)
Reduction in area
(%)
341 382 15.5 44
The local beam qualified by meeting the standard requirements. The
microstructure analysis for the Al sample was to be done as well.

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Thoughts at the end of my internship
Hamsini appreciates the discipline and work ethics the employees have. The
atmosphere is conducive for free exchange of ideas andthoughts. Communicationis
free and easy. The people are very nice and supportive. Safety is always a top
concerninthe labs. Some of the suggestions she has are
i) The companycan joinhands with alocal/international universityfor researchin
to better, more efficient futuristic materials and other aspects like cutting down
on environmental impacts. The venture can be like a think tank for both
researchand production.
ii) The team can look into alternative methods, processes and materials to enhance
efficiencyand cut costs.
iii) Implement methods to reduce the company’s carbon footprint on the
environment.
iv) A lot of good suggestions come from the work floor. A small reward can be
given to anyone who suggests a positive change in work methods or in any
process involved in production. This was implemented in a factory she visited
earlier and they had spectacular results.
v) Make the team buildingsessions into anactivityorientedevent. Employees can
be dividedinto groups. They will be given some tasks that theyhave to finishas
a group.
vi) A prominent personality or an inspirational icon can be invited to give a short
talk regularly.
vii) Acreativity corner – room can be set where the employees can go de-stress and
fuel thoughts on for improvements. It will also help employees think better.
Sitting in a chair all day long is not good for one’s health. Rules can be made
about how often and how long an employee can be in the creativity corner.
Games like chess, Chinese checkers, etc. canbe placedthere.
viii)A white board can be placed near the doors. Anew English word everyday can
be written on it with its Chinese word and the English word’s usage in a
sentence and its meaning in Chinese
ix) Atechnical term with its definition and Chinese term can also be writtenon the
same board. Including the pronunciationwill help a lot in the long run.
x) The company management can consider diversifying into aerospace, hydraulic
systems, transportation and locomotive industries where the current knowledge
ofAtlas Copco is partly used.
Future work
I would like to continue adding to my industrial experience by working on
failure analysis and usage of modern materials to replace existing materials. I
would like to work on modern materials that involve composites. The hands on
experience obtained while analyzing various samples has helped me understand the
theorylearnt at Purdue University. It has enhanced my knowledge.

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Acknowledgement
I am grateful to the management of Atlas Copco and in particular, Mr.
David Lou, the CEO of Atlas Copco, Nanjing for considering my application for
the internship and for providing me with this opportunity and financial support.
I am thankful to Dr. Johnny Huang, PhD and head of the Metallurgical lab
for the support and guidance during the internship. I was allowed full access to
sophisticated instruments like the SEM, Hardness testers, etc which made the
learning a great experience. I would also like to thank Mr. Charles Fu, the
Materials Engineer, and Mr. Allen Zhang, the Welding and NDT Engineer, who
supported me in the learning. I was able to work as if I was a regular staff of
Atlas Copco due to their support and words of encouragement. I would like to
thank all my colleagues who helped me.
I am thankful to Mr. Suresh Shyamsundar, the head of R&D center
(Rocktec) at Nanjing, for his assistance during the internship.
I wish to thank the heads of the production facilities at Nanjing and Wuxi
for permitting a detailed tour of the facility and interaction with the production
engineers. The staff of HR, administrative andsupport departments were of great
help and I acknowledge their assistance. The visit to Atlas Copco has been a
truly rich working experience in a professional organization that will be
cherished for a long time. I will be delighted at the prospect of a second
internship next summer at Atlas Copco if there is an opportunity.
Last but not least, I wouldlike to thank the Office of Professional Practice
and in particular Dr. Yating Haller. The Office of Professional Practice, Purdue
University provided me with a travel grant to cover travel expenses for the trip to
China. It supportedme in obtaining professional experience which will go a long
way in understanding the theory leaning at Purdue University.
Travel Report – Xu Zhou BUT Company visit

Page27 of 91
On June 21st, we visited BUT to perform the UT inspection on two URE ST2D
frames of, as shown in Figure 1.
The inspectors from BUT and SGS detected the frames separately, and they will
submit an inspection report.
Result:
Inspectors from SGS tested 2 products and measured the length and location of
the defects.
We also invited the inspectors of BUT to perform the site operation of UT
inspection. We also took photographs of the products.
Conclusion:
Basically after comparingthe test reports of SGS and BUT, we foundthat the test
results were similar.
The inspectors’operation skills and their attitude of responsibility were
acceptable.
But there are several problems affecting the welding quality and the inspection
results, (Figure 2). Some improvements in the following areas should be made:
1) The welding between unequal thickness plate;
2) Welding Process of the complete penetration joint;
The NDT Engineer’s recommendation:
1) The Visual Inspection should be performed strictly to reject the unacceptable
welds;
2) Welding Process should be suitable for the Site Welding;
a. There should be transitionin the welding between plates of unequal thickness.
(Figure 2-a)
b. The Groove Face should be decreased to maintain the joint complete
penetration. (Figure 2-b).
3) Process improvement should be carried out to some part.
a. The area of unmelted steel should be treated by grinding or some other
methods.(Figure 2-c)
b. The Arc start zone should be flatted using relevant methods. (Figure 2-d)
c. There should be no Arc-Strike in the plate. (Figure 2-e).
d. The product should be cleaned properly.

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Fig 43: Inspection Products – Frames used in the machines
Fig 44. Transition in the welding Fig 45.The groove face
Fig 46. Unmelted steel Fig 47. Arc Start Zone
Fig 48. Arc Strike
Appendix I – Manuals

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Below are the manuals Hamsini drafted out for Atlas Copco after using the
equipment in the lab thoroughly. The manuals are in the following order:
a. Microscopes
i. Optical Microscope
ii. Optical Stereoscope
iii. Scanning Electron Microscope (SEM)
iv. EDX. This is a program which allows for qualitative analysis of
materials in conjunction with the SEM.
b. Sample making equipment
i. Cutting machine
ii. Mounting machine
iii. Grinding and polishing machine
iv. Precisionweighing scale
c. Hardness testers
i. Vickers microhardness tester
ii. Universal tester
iii. Brinell tester
d. Non Destructive Testing Equipment (NDT)
i. Ultrasonic tester
ii. Magnetic particle tester.
MANUAL: OPTICAL MICROSCOPE

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This manual illustrates how to use the optical microscope. There are two
parts – Part A and Part B. This is based on the frequency of use of the particular
tool and its operational complexity. Functions in Part A are more commonly
used.
Part A contains instructions using the microscope, adding a scale bar,
measuring lengths, areas, and angles and using the Extended Focus Integration
and merging functions.
Part B contains information on finer analysis of the specimen. This
includes grain size classification, inclusion classification, spheroidal graphite
classification (only in cast irons) and phase percentage calculation. To use
functions from part B, help from the Materials and Metallurgical group must be
sought.
Index
 Using the microscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
 Adding a scale bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
 Measuring lengths, areas and angles . . . . . . . . . . . . . . . . . . . . . . .32
 Extended Focus Integration (EFI) . . . . . . . . . . . . . . . . . . . . . . . . .33
 Merging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
 Percentage phase fraction calculation . . . . . . . . . . . . . . . . . . . . . .35
 Inclusion, grain size and spheroidal graphite classification . . . . . 36
Using the microscope – General instructions
1) Take off cover and ensure the light intensity is at the lowest setting.

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2) Ensure the stage is lowered and place the sample. Choose lens with the
desired magnification.
3) Raise the stage until the sample almost touches the lens. Doing this ensures
that the stage always moves away from the lens while focusing. The sample
should never come in contact with the lens. This minimizes damage to the
lens.
4) Pull the lever at the side of the eyepiece
to the desired option.
5) Lower the stage to focus the image. You
can adjust the light intensity also to
enhance the image. The knobs below the
stage can be used to move the sample.
6) To obtain the image on the computer,
a. Switch on the camera. (Small switch on
the side). Ensure that the USB cable is
connected to the microscope camera. You will see a green light.
b. On the computer, open OLYCIA Metal and click on the DP icon.
7) Click the snap button to take pictures of the specimen. You can save the
pictures.
8) To use the features of the software, the image has to be selected after the
OLYMPUS DP window is closed.
9) Turn down the light to the lowest intensity and switch off the camera and the
microscope. Lower the stage.
10) When closing the software, it will first ask you if you are sure you want to
quit. When you say yes (left button), it asks if you want to save any of the
images. Say yes (Y) or no (N). Turn off the computer.
11) Cover the microscope after the light boxin the back has been cooledto room
temperature.
PART A
Light
Intensity
Focus
Stagecontrol
The different knobs of the microscope

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It is important that the magnification of the lens matches the
magnification selected in the program for all the below functions.
1) Add a scale bar
i. Open the desired picture.
ii. Click on the button with a red flag
iii. If the magnification is 100x, you can double click the preset option
that shows in the pop up dialog box.
iv. For any other magnification, click and create a text box.
Specify the length of the scale bar needed. Make sure the
magnification in the program (see sentence after Part A) matches the
chosen magnification of the lens. You can adjust the scale bar to suit
your needs.
v. Click the layer button to save the updated image. Do this
whenever you modify the image to save the changes.
2) Measure lengths, areas and angles

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i. Once a picture is open, click the ruler button and choose the
appropriate option from the pop up box.
From left to right,
TOP: Horizontal, Vertical, Oblique. These are all linear lengths.
BOTTOM: Nonlinear length, Angle between two lines, Area of
selectedpolygon
ii. For lengths, select the length by clicking and dragging across the
picture. Right click outside the selected area. The length will be
displayed. It can also be seen on the table in the dialog box.
and , and
iii. For calculating angles between two features on the picture, select the
angle option. Click and drag a line. Draw asecond line from the endof
the first line. Once done, right click. The angle will be displayed both
on the picture and in the table.
iv. For calculating an area, click and draw around the desired area. Once
the polygon is complete, right clicking will show the area covered by
the selectedpart. Whenthe start point and the end point are not closed,
right clicking will result in them joining. Right clicking again shows
the area both on the picture and in the table
v. Click the layer button to save the updated image. Do this
whenever you modify the image to save the changes.
3) Extended Focus Integration and merging

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Extended Focus Integration: This tool is used to obtain a
completelyfocusedimage from a specimen that has an unevensurface
i. Using the DP, take several pictures of the same spot with different
parts in focus.
ii. Close DP and click EFI button .
iii. Choose the relevant pictures from the list
iv. Clicking on the fifth button in the bottom loads the existing images on
to the dialog box. The first button adds an image while the second
button inserts an image. The third button deletes selected pictures
from the dialog box. The fourth button clears all the loaded pictures.
v. Click the EFI button (One below SuperEFI). The SuperEFI button is
more precise and takes longer. For a small number of pictures, using
the EFI or the SuperEFI gives the same image.
vi. Once the images are collated, the new fully focusedimage will pop up.
Save the image.
vii. All parts of the image should be focused in at least one picture.
Merging: To obtain a single image of bigger sections of the
specimen.

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Fig 2. Options to be changed
Fig 3. Alignment of
the pictures
i. Take several pictures with parts overlapping as shown below where the
blue box is the desired image and save them.
Fig 1. Method of taking useful picture for the MIA tool
ii. Click on the MIA button
iii. Click the settings button
iv. A window will pop up. Change the number
of columns (red) and rows (blue). Youcan select the
horizontal and vertical overlap respectively (black)
v. Once the pictures are opened using this
button, the screen will look like this
(picture to the left).
Make sure the pictures are selected in the sequential order
(the top of the specimen is on the top and the bottom of the
specimen is at the bottom).
vi. Go to the second tab
vii. Click on icon. The collated image will appear on the
screen. Save the image once you are done.
PART B

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To use any of the features below, help from the Materials and
Metallurgical group MUST be sought.
1) Percentage phase fraction
a. Click the Phase percentage button . There will be three options
that pop up.
b. The options are automatic and manual. The third option is irrelevant.
c. A dialog box pops up once the automatic mode is selected.
d. This box is preset. There is an unchecked box in the topright part of the
dialog box. Check it and click OK.
e. Make sure all the light coloured spaces turn green once you click OK.
f. You can manually fill the unchanged parts using the paint pop up. Once
this is done, click the OK button.
g. The percentage phase fraction will show up on a report. You can use
this number.
2) Inclusion, Grain size and Spheroidal graphite classification

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Inclusion, grainsize andspheroidal graphite (incast iron) classifications are
very similar to perform.
1. Choose the classify option
2. Then choose the second option from the bottom.
3. In the pop up box, there are four drop down menus. Choose the
appropriate Standard Code, Standard Name, name of the
element/compound you want to analyze. There are different options
for the first three drop down menus depending on whether the
classificationbeing done is inclusion, grain size or spheroidal graphite.
For the fourth menu, choose the inclusion size/grain size and
spheroidal graphite size. This is done by comparison of the sample
from the computer and the photo of the specimen.

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The light switch and intensity
controller
MANUAL: OPTICAL STEREOSCOPE
This manual discusses the usage of the optical stereoscope. This is used to
view surfaces in detail. This also helps in determining the source and directionof
propagation of fracture. More information on its working principle and sample
measurements can be found in the library.
Using the stereoscope
1) Take off the cover and lens covering.
2) Switch on the stereoscope.
3) Set the light to the lowest intensity
and switch on the light source.
4) Place the sample on the stage and focus the lights
on the sample
5) There are two viewing modes that can be used: eyepiece only and eyepiece
with camera. Choose the appropriate one.
6) There are two lenses with different magnifications that can be used.
7) There is a knob on the side that
helps zoom in. (A)
8) The second knob (B) on the right
side helps focus the lens.
9) Focus the image.
10) Moving the sample is done
manually.
11) Make sure the camera USB cable is
plugged in. The microscope and the
stereoscope share the same cable. Switch on the
camera.
The magnification and focus
adjusting knobs

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The camera switch
12) To take pictures,
a. Switch on the computer and open the OLYCIA Metal software
b. Click the DP icon
c. Click the snap button once the image has been focused.
13) You can add a scale bar, measure lengths, areas and angles, use the
Extended Focus Integration and merging tools.
14) To do this, please refer to Part A of the user manual of the
microscope.
15) Once you are done examining the sample, turn off the lights and
remove the sample.
16) Cover the lens and the eyepieces.
17) Turn the stereoscope and the camera off. Switch off the computer.

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MANUAL: Scanning Electron Microscope
When an optical microscope fails to show finer details, a scanning
electronmicroscope (SEM) is used. Ascanning electronmicroscope (SEM) uses
back scattered electrons to provide a very precise and highly magnified picture
of the samples. The surface need not be polished or etched but it must be
conductive. A thin metallic surface coating must be present while viewing
nonconductive materials. SEM’s are useful in the range of 10-7m and 10-3m. The
minimum magnification with this SEM is 65x and the maximum is 300,000x.
Using the SEM
1) Turn on the power switch at the back.
2) Turn the key in the front to START and then back to ON. The computer
switches on automatically.
3) Neither the computer nor the software has a password. The software starts
automatically. Wait till the system initializes.
4) Click AIR on the screen to introduce air into the chamber. You can press
the button in control panel too. Wait until the * asterisks in the message
‘The chamber is processing AIR ****** have disappeared.
5) Place sample to be viewed on the stand and measure the height of the
sample with the help of the Height gauge. Note the diameter of the stand.
6) Slide the compartment open slowly. Place the stand with the sample on
the stage.
7) Click Specimen setting and then click OK. Input the sample height and
the stand diameter. Click the Stage Move button. This lifts the stage into
position. (picture on the next page)
Power Switch

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The sample height and stage size input box.
8) Slide the compartment in until the sample is just below the roof guard.
The ideal position of the sample on the stage
9) Ensure that the sample is lower than the roof guard. Click OK.
10)Slowly close and hold the compartment, press the EVAC button and
release the compartment after 10 seconds.
The control panel in the front
11)Ensure the lowest magnification is chosen.
Stage
Roof Guard
Sample

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12)Wait until you see the message ‘HV is ready’ (at the bottom left corner),
click the ON button in the top left corner.
13)An image of the sample will appear. Once you select the area of interest,
you can focus and auto-adjust the brightness and contrast. To take a
picture, click Capture and save it.
14)The Save button works like a screen shot of the image panel. This can be
used for sensitive samples.
15)You can choose the type of scan (F, S1, S3 or S5) depending on the detail
you want in the picture. Click Run to go to the viewing mode.
16)The High voltage (HV) needs to be switched off when switching
between VP – SEM and SEM
17)Once you’re done with taking pictures, turn off the HV and click on
HOMEZ65 in the top right corner. This brings the stage to its original
position. This may take a while.
The HV ON button. The HOME Z65 button.
18)Click AIR and wait for air to be introduced into the chamber. As before,
wait for the asterisks to disappear
19)Take out the sample if you are done or change it.
20)Slowly push the compartment back in and press the EVAC button. Press
and hold the compartment before pressing the EVAC button for 10
seconds.
21)Wait till the button glows a steady green, close the program. Shut down
the computer.
22)Turn the key in the front to OFF.
23)Wait for 5 minutes and switch off the power button at the back

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MANUAL: Energy Dispersive X-ray
Spectrum – EDX
The EDX software uses backscatter to qualitatively and quantitatively
analyze samples seen in the SEM. It is most often used to analyze qualitatively.
Using the EDX
1) Follow steps 1-13 from MANUAL: SEM.
2) The SEM can be in the viewing mode.
3) Power on the extension board.
4) Switch on the computer
5) Open the EMAX software
6) A screen with a flow chart will appear in Chinese. The English
translations are provided
7) You can skip steps 1 and 2. In step 3: SEM Settings, higher accuracy is
obtained if the collection rate is between 1-3 kcps. This is the ideal
collection rate. The ideal working distance (SEM Program) is 10mm.
Click on Step 4
8) Step 4: Area of interest. You can choose the specific area of interest you
want to analyze by clicking the button. Click on Step 5
9) Step 5: X ray electron collection. Choose a more specific part of the
picture. It can be an area, a point, a random shape or all parts with the
same colour in the picture. The analysis will run immediately after you
choose the area. Click on Step 6

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10)Step 6: Element confirmation. Once the elements have been identified,
the noise peak has to be deleted. This is usually a peak without any label
on it.
11)Once this is done, delete all the elements you know for sure don’t exist in
the sample being analyzed using this button. . Select the
element and click the button. Click on Step 7
12)Step 7: Quantitative Analysis. A screen will appear showing the w% and
the a% of the various components. Click on Step 8.
w% a%
13)Step 8: Report. This is an optional step. This produces a report that can be
printed out or saved.

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The boxes in blue can be skipped. The boxes in green are very
important steps and have to be followed in order.
Project name
Sample nameSEM Settings
Area of
Interest
X-ray electron
collection
Element
Confirmation
Quantitative
Analysis
Report
Image
settings
Collection
Settings
Comparison
Optimization of
quantitative analysis
1
23
1
4
5
6
7
8
Quantitative
Analysis settings

Page46 of 91
Power Switch
The mounts
MANUAL: CUTTING MACHINE
The rotating abrasive disk can cut through hard and soft steels and a
variety of other metals and alloys. More information on its working principle can
be found in the library.
Using the cutting machine
14)Choose the right cutting disk based on the material to be cut.
15)A light will turn on when the machine has been switched on.
(power switch on the side)
16)Set the coolant outlet to Blade. Carefully fix the piece in place using the
levers on the mounts so that it doesn’t move.
17)Tighten the mounts using two levers, close the
cover and press the start button. The disk won’t
start rotating if the cover is open.
18)Wait until the coolant (white-ish fluid) starts
running. Now push down the lever on the side
gently. Make sure you blade touches the material
very slowly. If the blade comes in contact with the
material too fast, it will result in deep scratches.
19)Maintain a small consistent pressure on the lever.
The blade moves withthe lever. The rate of cutting
must be slow so as to keep the sample from
getting too hot.
20)When you will feel a lack of resistance, it means the blade has gone
through all the material. Press the stop button. Raise the blade (lever) up
and open the covering lid of the cutter.
21)Take out the cut piece carefully after loosening the mounts.
22)Rarely, material towards the rear of the machine may not get cut. This is
usually a very small part of the material. In this case, you can the clamp
and a hacksaw blade to separate the pieces.
23)You can clean up the machine by setting the water outlet as Nozzle.
24) Leave the lid open. Turn the power switch off.

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MANUAL: MOUNTING MACHINE
The mounting machine sets the sample to be analyzed in a polymer resin
base. This makes it easier to polish, etch and study. More information on its
working principle can be found in the library.
Using the mounting machine
1) Switch on the machine
2) Make sure the water tap is on. (Tap near the wall)
3) Turn the handle on the top and twist the top away from the machine.
The handle. The lift and lower buttons. The stage.
4) Press and hold the ^ button to lift the stage.
5) Dust the stage and surrounding areas to get rid of any dirt.
6) Place the sample on the stage with the side of interest facing down.
7) Lower the stage and add an appropriate amount of the mounting resin.
Make sure to cover your sample with the resin.
8) Press and hold the lower button to ensure that the stage is lowered all the
way. You will hear a different sound when the stage is totally lowered.
9) Place the top over the stage. Secure it by pressing it down and turning it
clockwise until the machine locks it. Then turn it a little in the
anti-clockwise direction.
10)Press the start cycle button
11)The parameters are preset.
12)The entire cycle takes about 7 minutes.
13)Once done, open the top handle. Press the ^ button. The mounted sample
will rise. It will be hot.
14)Use the brush and the scraper to clean any unused powder or resin pieces
on the stage and the surrounding areas.
15)Switch off the machine and the water tap.

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The green button on
the side of the
rotating arm
The settings
MANUAL: GRINDER AND POLISHER
The grinding and polishing machine is used to smoothen the surface of a
mounted sample. This helps study the microstructure of the sample better. More
information on its working principle can be found in the library.
General instructions
1) Make sure both the air compressor and the water tap are on. Pull the red
button on the air compressor (below the bench) up to start it. Take off
the top of the grinder.
2) Switch on the machine. (switch at the back)
3) Press the On button near the settings panel.
4) Adjust the settings as needed. Move arm and place the appropriate
grinding/polishing disk on the plate.
5) To stop the grinding process midway, press the button
6) Fix the rotating arm on the disk area with the lever on the left.
7) Press and hold both the green buttons on the side of the arm to lower it.
8) Once it touches the plate, release the buttons. The arm will come
up slightly.
9) Place the sample face down in the slots on the rotating arm.
10)Press and release both the green buttons to start the grinding
process.
11) To change the disk, the arm needs to be moved away from the
grinding disk. Do this with the help of the lever.
12) Lift the existing disk off the plate and place the next grinding/polishing
disk on the plate.

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Grinding
In grinding, you start off with the disk with the lowest number. As you go
along, disks with higher numbers will be used. Same goes for polishing. Use the
disks in the proper sequence. Once grinding is done, polishing can be started.
Polishing
1) Place the polishing disk on the plate and lubricate it.
2) Make sure the water is turned off.
3) Repeat steps 4 to 10 from the general instructions.
4) Spray the abrasive suspension once the disk starts rotating. Use enough
abrasive suspension to have foam near the sample.
4) When done, place the polishing disk back. Turn off the power button
(near the settings panel) and the switch at the back.
5) Close the lid of the grinder. Turn off the water supply and the air
compressor.
The lubricant used to
polish
The 3µm diamond
abrasive used to polish.

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MANUAL: WEIGHING SCALE
The weighing scale is an important tool while measuring out chemicals.
This precision weighing scale can measure solids accurately up to four decimal
places. There are two parts to this manual. Part A contains the easy to use
functions like weighing, formulation, piece counting, percentage weighing and
differential weighing. Part B contains more complicated functions like Statistics
and Density calculation. More information on its working principle and sample
These are the functions of the weighing scale.
a. Weighing: Weighs up to four decimal places.
b. Formulation: Stores formulae and weights of individual
components.
c. Piece Counting: Counts the number of pieces by using the current
weight and the weight of each unit.
d. Percentage weighing: Tells the percentage of a set weight the
object being weighed is.
e. Differential Weighing: The Differential Weighing application is
used to analyze changes in the weight of one or more samples. The
first step is to determine the initial weight of the sample (weighing
in). After the sample has been processed, it is re-weighed (residual
weight). The balance then determines the difference between the
two weighed values. Procedures can be drying, centrifugation,
filtering, incineration, vaporization, coating, etc.
f. Statistics: Shows statistics for up to 1000 samples.
g. Density: Enables you to determine the density of solid bodies,
liquids, and pasty substances.

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Using the weighing scale – General Instructions
1) Plug in the weighing scale
2) Wait till it shows 0.0000g(initializes). If a weight is displayed, press the 0
button.
3) Use the button or wave your hand over the sensor to open or close
the door
4) Open the door, place material on the scale and close the door.
5) If using a container,
a. Place the container on the pan and wait for the weight to show in black.
b. Press the tare (T) button. This means that the weight of the container will
be ignored. Only the weight of the chemicals added will be shown. Close
the door.
6) Add the chemical and wait till the weight shows in black. When the
weight is shown in blue, the scale is still weighing
7) Note down the weight of the material.
8) When done, press and hold the OFF button to switch off.
9) Clean up any chemicals that may have been spilt on the pan.
IMPORTANT: Ensure there are no chemicals on the pan while
measuring. This can affect the weights recorded.

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Formulation
This is used for weighing in components that are to be combined in a
specific ratio
1) Switch on the weighing scale
2) Press this button (Options button) to choose the
Formulation option.
3) Press this button (Application settings button) to define a
formula.
4) There are two types of formulas you can define: Fix Component and %
Component. Define the formula.
Fix Component: Absolute nominal weights are defined for the
individual components.
% Component: Relative (percentage) nominal values are defined
for the individual components, either in relation to the final weight or
the first component.
5) The formula database can hold a maximum of 8 formulae with up to
12 components for each formula.
6) When using a particular stored formula, you can weigh out all the
components.
Piece counting
This application allows you to count pieces. The application provides
several different methods for determining the reference piece weight.
1) Select Piece Counting after pressing the Options button.
2) Place the reference piece on the weighing pan.
3) Once the weight has stabilized, press the PcsWgt option.
4) After the reference has been determined, place the pieces you wish to
count on the weighing pan. The result will be displayed.
Percentage Weighing
This enables you to weigh to a specified value (100 %) and detect
deviations from this target value.
1) Choose percentage weighing from the options.
2) Set your reference on the pan and press Set100%. This weight will
now be treated as 100%
3) Now remove the reference and place another sample on the pan.
4) The weighing scale will display what percentage of the reference the
new sample weighs.

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Differential Weighing
1) Choose Differential Weighing from the options.
2) Place the first container without the sample on the pan and press T &
wgh. in. The initial weight has been recorded.
3) You can now treat or process the sample.
4) Once again place the sample in the container on the pan and press
Residual…
5) This will give the weight difference.
PART B
Statistics
1) Choose the Statistics option from the main menu
2) Place the first sample on the pan and press M+. This transfers the weight
to the statistics.
3) You can choose to Weight Transfer automatically from the application
settings instead. Choose Additive mode to tare automatically after each
sample is weighed. You need not remove each sample after weighing it.
4) Once all the samples have been weighed, press the Result button to have
the results displayed.
Density
1) Choose the Density option from the main menu
2) Choose an appropriate method depending on the type of substance whose
density is being calculated.
a. Solid body: Density determination of non-porous solid using an
auxiliary liquid
i. If using ethanol or water as the auxiliary liquid, enter the
temperature. Otherwise, enter the density of the alternative
liquid.
ii. Press the Start button. Place the sample on the pan when
prompted. Its weight will be displayed.
iii. When prompted, immerse the body in the auxiliary liquid and
press OK.
iv. The density will be displayed on the screen.
b. Liquid: Density determination of liquids using a sinker
i. Select Liquid as the method in the application settings.
ii. Input the volume of the sinker and press OK.
iii. Weigh the sinker with the container and when prompted, press
OK to Tare it.
iv. Pour the liquid into a container. The sinker will experience a
buoyant force.
v. Press OK to accept the value and the density will be displayed.

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c. Pasty substances: Density determination of pasty substances
using a gamma sphere
i. Select Pasty Substances as the methodin the application settings.
ii. Enter the volume of the gamma sphere being used
iii. Press Start and when prompted, place the sample on the balance
without the gamma sphere.
iv. When the weight is displayed, press OK to Tare it.
v. Immerse the sphere in the substance when prompted.
vi. Press OK when the weight of the substance and the sphere is
displayed.
vii. The result is displayed on the screen.
d. Pycnometer: For determining the density of liquids using a
pycnometer
i. Select Pycnometer as the method in the application settings.
ii. Enter the weight and the volume of the pycnometer and press
Start.
iii. Place the pycnometer with the liquid on the pan when prompted.
iv. Press OK when the weight is displayed. The density will show
up.
e. Solid porous: For determining the density of porous solid bodies
by using a supplementary oil bath
i. Select Solid Porous as the method in the application settings.
ii. Enter the temperature of the ethanol or water that is being used as
the auxiliary liquid.
iii. To use other auxiliary liquids, enter the density of the liquid.
iv. Press Start and when prompted, place the solid on the weighing
pan.
v. Press OK when the weight is displayed.
vi. Immerse the sample in an oil bath and weigh it out again. Press
OK.
vii. Immerse the oil coated solid in the auxiliary liquid. When the
weight is displayed, press OK.
viii. The density will be displayed on the screen.

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MANUAL: MICRO HARDNESS TESTER
This manual talks about how to use the Vickers micro hardness tester.
There are two main usage methods of this indenter: simple mode (manual and
automatic) and test program (multiple indentations). In the simple mode, one
indent is made and the hardness is measured. In the test program, once the
number of indents is set, it will automatically indent and shift positions. More
information on its working principle and sample measurements can be found in
the library.
NOTE: A dialog box will pop up when the button is clicked.
You can choose Manual Measure, Auto Measure A or Auto Measure B. The
Manual Measure is chosen for the Manual mode. The Auto Measure Ais chosen
for clean and flat surfaces. The Auto Measure B is chosen for unclean and
uneven surfaces. For the Auto measures, ensure the Do Manual Measure on
Fail box is checked. The selected option will apply to both manners of usage
(simple and test program)
Using the micro hardness tester – Simple mode
1) Switch on the computer and the microhardness tester. The switch for the
tester is on the back near the bottom.
2) Lower the stage and place the sample. There is a knob on the side near the
bottom that adjusts the focus.
3) Open the Minuteman software.
4) Click on LOG ON and choose either TMS 1 or TMS 2. They are the same.
5) For a new measurement, click on File and choose New Measurement
6) Click on New Sample and fill in the required details. You can change the
sample name here. Click New Sample once you are done.

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Test Force
knob
7) Throughout the process, to exit the viewing mode, press Esc
8) Click the Vickers mode. . The three options are manual measure,
Auto A or Auto B. If the program can’t detect the edges of the indent
automatically, it will ask the user to manually place the boundaries on the
indent. For Auto Measures, ensure the Do Manual Measure on Fail box is
checked.
9) Go to the viewing mode
10)After selecting the desired magnification (10x or 40x; right click: objective
selection), focus on the sample. You can move the sample by
clicking and dragging across the screen.
11)Make sure the Test Force value chosenin the side panel matches the
value set on the knob to the right of the eyepiece. This is a very
important step!
12) Focus on the targeted area for the indent and press Enter. Click the
indent button. Once the indent is done, you will hear a beep.
13)Click on and focus the microscope.
14) The orientation of the indent with respect to the axes must be as shown.
15)Place the red lines that appear on left clicking at the boundaries of the indent.
16)The hardness will show on the bottom left of the screen once you left click.
17)Left click again to view the hardness on the excel sheet in the background.
18)Click on TMS1 and then on LOG OFF. Switch off the computer

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TEST PROGRAM: This runs several indents in one trial. You can decide the
number of points, their respective distances etc. This is used if the hardness
gradient (hardness across a sample) through different phases/materials is
needed. This is more useful if hardness varies across the material.
1) Log on, click on View and select Test Program.
2) Double click the 3 C Setting of measurement row to edit it.
3) Change the parameters in the pop up box as required.
4) Select New Sample in the Auto box. This ensures that the blue arrow shows.
5) Click the blue arrow next toAUTO. Focus the image.
6) Choose the area of the first indentation. This can be at the boundary between
the two phases/areas being studied.
7) Positionthe sample and press Enter.
8) A start line along with a direction pointer will show. Once the start point and
direction is set, the indenter will start automatically. Again, ensure that the
Test Force selectedon the screen matches the values of the knob.
9) When the indents are done, they will be measured. This will be done
automatically if the indent is clear. This will have to be done manually if the
indent is blurred. Even if the redlines appear by themselves, you can focus it
to maximize the green number.
10)The results will be displayed in the excel worksheet.
11)Remember to LOG OFF before closing the software.
12)Switch off the computer once you’re done.

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The wheel
controlling the load
setting
MANUAL: UNIVERSAL HARDNESS TESTER
This manual discusses the usage of the universal hardness tester. This
tester is mainly used for measuring hardness on the Rockwell scale. This is a
mechanical device. You will need to calibrate the machine before every test. The
calibration process is the same as the testing process. For calibration, make sure
that the indent size and the indenter match. More information on its working
principle and sample measurements can be found in the library.
Using the universal hardness tester
1) Switch on the hardness tester. Ensure that the lever to the side
(near the top) is pointing towards you.
2) Lower the stage. Using the wheel below the stage. Turning it
clockwise raises it and anticlockwise lowers it
3) Remember to choose Rockwell in the knob at the side.
The universal hardness tester with knob
with the options – Brinell, Rockwell and Vickers.
The first symbol and the last symbols
mean Off. The second symbol from the left
means Brinell. The third symbol means
Rockwell. The fourth means it is in the Vickers
mode.
4) Place the sample (or calibration block) on the stage. Ensure that
the wheel (on the side) points to the proper load setting
(according to A, B and C).
Table 1: Indenter size and load setting for different modes.
Mode Indenter Size Load setting (N)
A 0.2 mm 588.4
C 0.2 mm 1471
B 1.5875 mm 908.7
5) Raise the stage till the lines on the screen coincide at 100. The steel knob
in the front helps fine tune the line.
The lever
The options

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The lines coincide at 100. The line alignment fine tuning knob.
6) Once the lines coincide, gently push the lever away from you.
7) Wait for 5 seconds for it to stabilize. Then pull it back.
8) You can now see the result on the screen. (Ensure that you are looking at
the value from the proper scale).
9) Lower the stage and remove the sample.
10) Turn off the hardness tester.

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MANUAL: BRINELL HARDNESS TESTER
In the Brinell hardness test, a hard spherical indenter is forced onto the
surface being tested. The load varies from 500kg – 3000kg in500 kg increments.
The Brinell hardness number is a functionof the load applied and the diameter of
the resultant indentation. More information on its working principle and sample
Using the Brinell hardness tester
1) Turn the power on.
2) Calibrate the machine by using the respective calibration blocks and
indenter sizes. To calibrate, follow the steps 3 to 14.
3) Lower the stage and place the sample. Ensure the indenter is in the
front (chosen).
4) Press TAB Ato select the appropriate test load andindenter size. Press
OK
5) Ensure the load setting matches the load chosen. Same goes for the
indenter (for calibration only).
6) Press CLR – F to set the load to zero.
The control panel of the tester
7) Raise the stage till the screen reads around 100 kg force. After this
point, the tester will automatically increase the load till the set limit.

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8) Lower the stage and change the indenter to the microscope. The lens
has to click into place.
9) Be very careful not to move the sample. Focus the microscope.
10)In the eyepiece, you will see two lines. There is one knob on each side
of the eye piece.
11)Adjusting the left knob results in both the line moving. Adjusting the
right knob results in the right line moving.
12)Make sure the lines coincide. Press CLR – D to set the distance
between the two lines to zero on the screen.
13)Thenshift the lines so that they are on the outer edge of the indentation.
Once in position, press the black button next to the eyepiece.
14) Rotate the eyepiece 900 and do the same horizontally. Press the black
button again once this is done.
15) The hardness will be displayed on the screen.
16) Lower the stage and remove the sample. Switch off the machine.

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MANUAL: ULTRASONIC TESTER
The ultrasonic tester helps detect flaws that are inside of the material. The
tester needs to be calibrated at least once in six months. More information on its
working principle and sample measurements can be found in the library.
Using the ultrasonic tester
1) Ensure the surface is free from any dirt and foreign particles that may
affect the surface roughness.
2) Lubricate the surface of the piece to be tested with oil.
3) Plug in the ultrasonic tester and turn it on.
4) Choose from the angled probe or the normal probe. The angled probe
helps detect flaws in welds while the normal probe helps detect flaws in
steels, forged steels and cast irons and steels.
5) Connect the probe to the tester and place the probe on the intended test
site.
6) Choose a standard for testing. Each standard will result in a graph with
different a baseline.
7) Calibration is typically done once in three months or depending on the
usage. The CSK I A is used to find the front length and calibrate the K
value for the angled probe. The front length is the distance between the
source of the ultrasonic waves and the edge of the calibration block. The
K value is the tan of the angle of refraction.
8) For the normal probe, the CS–1–5 block is used to draw the baseline
(AVG curve )
9) There are three baseline curves on a graph for the angled probe. These are
drawn during calibration with the CSK III A block (DAC curve).
10) The baselines are drawn according to values given by the standards. The
standards may also specify different blocks to be used for calibration.
11) The pink line can be adjusted based on user specific standards.

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A sample baseline curve
I: Any peak below this is acceptable.
II: The acceptance of any peak below I and above III depends on the flaw
size and the permitted flaw sizes according to the chosen standards.
III: Anything with a peak above this line is rejected
Cracks of any size are not acceptable.
12) Move the probe around to detect the highest peak. The highest peak will
turn pink once it crosses the pink line in the graph. The pink line on the
graph can be adjusted to any percentage desired.
13) Once flaws have been detected, the acceptance of the metal part is based
on the standards chosen and the values of acceptance of the user.

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MANUAL: MAGNETIC PARTICLE TESTER
This manual discusses the operation of the Magnetic Particle (MT) tester.
The magnetic particle is used to detect surface and slight subsurface flaws in a
metallic piece. More information on its working principle and sample
Using the Magnetic Particle (MT) tester
1) To run a trial, place the test patch face down and follow steps 2 - 6.
2) Prepare the area to be tested by cleaning it. Make sure it is free from dust,
dirt, lint and any foreign material that may interfere with the working of
the MT.
3) Spray the inspection area/test patch with the magnetic suspension. If the
surface needs contrast, you can spray white paint first.
4) Plug in the MT tester and turn it on.
5) Switch the tester to the AC or DC mode and hold it across the spot being
examined with the current on. In the AC mode detects flaws on the
surface while in the DC mode, surface and subsurface (3-5mm) flaws can
be detected.
6) Now hold it across the spot in another direction (900 from the initial
direction) with the current on.
7) Once done, there will be an impression of the flaw on the surface.
8) Turn off the current and unplug the MT. You can wipe the area clean and
mark it.
9) You can use black light instead of using the white paint for contrast.

Page65 of 91
Appendix II – Photographs
Fig 49. Optical Microscope
Fig 50. Optical Stereoscope

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Fig 51. A photograph of the SEM at the Atlas Copco, Nanjing lab
Fig 52. A close up the SEM

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Fig 53. A photograph of the inside of the SEM. The sample is placed on a stage.
Fig 54. Side view of the inside of the SEM

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Fig 55. A picture of gold particles taken with the SEM. Magnification 30,000x
Fig 56. A picture of gold particles. Magnification 60,000x

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Fig 57. The cutting machine
Fig 58. The mounting machine
Fig 59. The grinder and polisher

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Fig 60. The precision
weighing scale
Fig 61. The Vickers
microhardness tester

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Fig 63. The digital Brinell
hardness tester
Fig 62. The Universal
hardness tester

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Fig 65. The Magnetic Particle tester
Fig 64. The Ultrasonic
tester

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Xu Zhou visit photographs
Fig 66. The Xu Zhou BUT company
Fig 67. The frames that were to be tested

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Fig 68. The frames that were to be tested
Fig 69. The weld to be tested prepared by applying oil/grease

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Fig 70. One of the six flaws detected by the engineers
Fig 71. Another flaw detected by the engineer.

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Fig 72. Hamsini Gopalakrishna using the UT machine
Fig 73. The BUT engineer, SGS engineer and Atlas Copco engineer examining the
frame

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Atlas Copco, Wuxi visit photographs
Fig 74. Staff from Atlas Copco, Wuxi From L-RLin Zhi Min, Xu Bin Jie, Charles Fu and
Alex Xie.
Fig 75. From L-R Charles Fu, Hamsini Gopalakrishna and Alex Xie in front of the
silent generator

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Fig 76. Hamsini Gopalakrishna in front of the silent generator
Fig 77. Oil carrying equipment used for testing

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Fig 78. A compressor testing rig
Fig 79. The failed aluminum part whose cause of failure was being discussed

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Fig 81. Side view of the oil separator
Fig 82. Side view of the separator

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Appendix III – Presentation of lab equipment and their uses

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***************************THE END****************************

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