FORGING PROCESS

FORGING PROCESS

1.INTRODUCTION
Forging is a metal mass that has been worked or brought to a configuration attained by controlled plastic deformation, by hammering, pressing, upsetting, rolling extruding, etc. Aluminum, Copper and their alloys, steels, titanium and many other alloys can be forged.
Forging can be produced either by hot working or cold working.

CASTING PROCESS

CASTING PROCESS

1.INTRODUCTION

The basic of casting processes Is feeding of molten metal Into a cavity of the required shape In a mould, followed by cooling to produce a solid object. The various processes differ principally In the way In which tho mould Is formed. In some cases e.g., sand moulding, a mould Is made up for each cast and subsequently broken up to remove the casting. In other cases, e.g., die casting, a permanent mould Is used repeatedly for a succession of casts and the casting Is removed after each cast without damage to the mould. Provision Is made for the feeding of the casting by forming a gating system in the mould. At the same time, an enlarged opening (a pouring cup) Is made to enable easy pouring, and channels are cut to allow the metal to flow out of the mould cavity after filling it, thus maintaining a metallostaUc head during solidification.

GMAW WELDING PROCESS

GMAW WELDING PROCESS

GAS METAL ARC WELDING (GMAW)
In this process, an arc is maintained in a stream of inert gas between a consumable electrode and the workpiece. The arc heats the work and melts the electrode, which thus supplier filler metal for the joint.   The power sources used are direct current with electrode positive.   The metal transfer is irregular if the electrode is negative or if the alternating current is the use of whilst effective welding of aluminum is only possible if the workpiece is negative so that oxide film is removed by the action of the arc cathode.

Arc Welding with Coated Electrode (SMAW)

Arc Welding with Coated Electrode

Arc welding is carried out by striking an arc between a rod electrode and the workpiece, thus simultaneously heating the workpiece and melting the electrode, which supplies filler metal for the joint. The power supply used In welding with coated electrodes consists of a DC or AC source with a dropping characteristic.

SOME RADIATION CALCULATION FORMULAS AND EXAMPLES

SOME RADIATION CALCULATION FORMULAS AND EXAMPLES

SOURCE TO FILM DISTANCE CALCULATION

SFD (min)= t(1+d/ug)

t= thickness of job

d= source size

ug= 0.5 max

INTRODUCTION TO NON- DESTRUCTIVE TESTING (NDT)

INTRODUCTION TO NON- DESTRUCTIVE TESTING

INTRODUCTION

Non-destructive testing (NDT) Is a  method of quality control of materials without disturbing their aimed use.  The material under Inspection does not undergo any change In Its size, shape, physical and chemical properties. It is commonly used for:

Detection of flaws such as cracks, shrinkages, gas porosities, inclusions, and another weld, forging and casting defects.
Determining the material characteristics such as density, conductivity, hardness, grain structures, etc. to give clues about the strength of materials.
Dimensional measurements such as wall thickness, internal and outside dimensions, corrosion assessment coating/plating thickness, etc.
On-line monitoring of plants/ industrial systems.

IMAGE QUALITY INDICATORS

IMAGE QUALITY INDICATORS

Image quality indicator (IQI), also called penetrameter is a device used to judge the quality of radiography.  This is measured in terms of radiographic sensitivity. smaller the numerical value of radiographic sensitivity. better the radiographic quality. Image quality indicators are of simple geometric form and made of the same or similar material as the specimen being examined. The image of the IQI on the radiograph is permanent evidence that the radiographic inspection was conducted under proper conditions.

A number of  IQI designs are used by different authorities in the world. There are American Standards,  British standards, French, German, International and Indian standards. Some of the most commonly used IQI designs are mentioned below.

INDUSTRIAL RADIOGRAPHY

RADIOGRAPHY TERMS

MOTTLING - mottling is occurred in industrial radiography due to diffraction, this can be reduced by increasing KV and using lead foil screen.
in compare to 40kv film, 60kv film exposure film with time compensation film has lower contrast and greater latitude.

AVERAGE GRADIENT- It is a characteristic curve between exposure vs optical density.

LATITUDE- (X-Ray Film) the range of specimen thickness that can be adequately recorded on the radiography is referred to as the latitude.

DARK ROOM

DARKROOM

Dark Room is a room where industrial film loading & film development is done, a typical layout is shown above.

Every darkroom has a safe light in which all the above work is carried out (red light) called safe light.

Industrial Radiography Film Processing

Industrial Radiography Film Processing

It has 4 parts
1) Developing 5-8 min Temp 68deg F (20deg C)
2) Stop Bath (Arresting development) 65-70dec F 30- 60 sec
3) Fixation – 65-70 deg F, 8-15min
4) Washing – 20-30min

Developing- developing solution has the ability to reduce the silver bromide crystals on the exposed part of films to metallic silver.
The time required to develop is 5 to 8 min at 20deg cent of solution (developer)
Longer developing time will produce chemical fog and this will decrease the film contrast.
Low temperatures can slow the action while the high temperatures can fog the film or soften the emulsion on the film so that it will wrinkle or wash off.

Etching Test in welder qualification

Etching test -

ETCHING TEST is used to find the soundness of the weld and also, it makes the boundary between the base metal and weld metal clearly visible.

Test procedure-

Cut the test piece with the help of power saw from the welded joint (complete transverse section of the weld). 

STOP COMPLAINING

STOP COMPLAINING

Special Note- this is only for entertainment, it is not related to any person or group.

happy holi... 

CPC KYA HAI

CPC KYA HAI

QUALITY CPM

CPC: मूल्य प्रति क्लिक क्या है?
सीपीसी प्रति क्लिक मूल्य है, या आपके भुगतान-प्रति-क्लिक (पीपीसी) मार्केटिंग अभियानों में प्रत्येक क्लिक के लिए आपके द्वारा भुगतान की जाने वाली कीमत है। 

quality control vs quality assurance

quality control vs quality assurance

QA and QC are both part of the Quality management system and these are the powerful techniques  that can be used to ensure that the manufactured parts are as per quality requirements. 

Project Management

Project Management

1.   SCOPE
The purpose of the following procedure is to describe the Project Management activity, which is the set of activities aimed at analyzing, planning and implementing the objectives of a project.
2.   APPLICABILITY
This procedure is mainly applied to the railway sector.

Failure Mode and Effect Analysis

Failure Mode and Effect Analysis of a product

1.   PURPOSE

FMEA is a methodology used to analyze the failure or defect of a process, product or system and to plan the preventive  (or corrective)  actions necessary to mitigate the risk of occurrence of a  given defect.  The acronym comes from the English name Failure Modes and Effects Analysis.

Risk Management & Contingency Plan

Risk Management & Contingency Plan

1.   SCOPE

The scope of this procedure is to describe the modes adopted by the organization for identifying the potential risks of interruption of production activities linked to the organization itself and to define the procedures needed to be activated in case of emergency. Furthermore are analyzed the risks linked to the main ‘  ‘your firm’  processes, defined in the chapter 4_0  Context of the organization.