September 22, 2020

FDP on “Advanced Materials and Manufacturing for Industry 4.0”

By MVJCE

Date of the Event

22nd to 26th Sep 2020

Title of the Event

FDP on Advanced Materials and Manufacturing for Industry 4.0

Number of Sessions

10

Resource Speakers

6 people from Industry

·         Mr. Devendra Gope, Business Development Manager, Fronius India Pvt. Ltd.

·         Dr.ShyamSundarMandyam, Chairman, National Certification Board -Indian Society of Non Destructive Testing (ISNT)

·         Dr.Dheepa Srinivasan, Chief Metallurgical Engineer, Pratt and Whitney India.

·         Sri H S Shivakumar, Sr Sales Director and Customer Solutions – India, GE Additive.

·         Sri Uma Maheshwar, Chief Consulting Engineer, GE Aviation-India

·         Senior Scientist at Defence Research and Development Organisation.

4 people from Academia

·         Dr. M R Ramesh, Associate Professor, Department of Mechanical Engineering, NIT-K.

·         Dr.PeerawatNunthavarawong, Professor, King Mongkut’s University of Technology, North Bangkok, Thailand

·         Dr Mohammad Rizwanur Rahman, Associate Professor, Department of Metallurgical and Materials Engineering, NIT-K.

·         Prof. Carlo Santulli, School of Science and Technology (SST), UniversitàdegliStudi di Camerino, Italy.

Organized by

Department of Mechanical Engineering, MVJCE

Material selection and manufacturing processes are playing  critical role in  today’s  competitive and  sophisticated product development environment. There has been substantial advancement in research and development of polymers, ceramics, semiconducting materials and composites as functional materials in the field of structural, biomedical, sensor and energy applications.

Industry 4.0 is the information-intensive transformation of manufacturing (and related industries) in a connected environment of big data, people, processes, services in a way to realize smart industry and collaboration.

Data exchange in digital form is pivotal for New Manufacturing processes and inspection techniques.

Keeping this in mind, the Department of Mechanical Engineering,MVJCE, organized a five day Faculty Development Program (FDP) on “Advanced Materials and Manufacturing for Industry 4.0” from 22ndSept. 2020 to 26th Sept. 2020  from 1.30 PM to 4.30 PM. The FDP was designed to provide insights into state-of-the-art recenttrends and advancements in new materials, digital data exchange in new manufacturing processes and opportunities for Research and Development.   On an average 75 participants (35 from MVJCE and 40 from outside) benefited from this Faculty Development Programme.

FDP was conducted in association with Institution of Innovation Council (IIC), Institution of Engineers India (IEI), Karnataka Chapter and Indian Welding Society (IWS).

Sessions were conducted online(Microsoft Teams) due to COVID situation prevailing across the world.

Eminent scholars from premier academic institutes were invited to deliberate the research on new materials and industry distinguished dignitaries discussed the new manufacturing processes, agile manufacturing environment, inspection techniques and data exchange in the digital world.

Day 1 :  22nd Sep. 2020 (Tuesday)

Dr. Vivekanand Huddar, HOD & Convenor of the FDP welcomed all the Guest of Honors, Speakers  and  all participants to the program..Distinguished Principal of MVJ College of Engineering, Dr. P Mahabaleswarappa, inaugurated the FDP. He highlighted the importance of cost effective materials development , role of digital data exchange in the new manufacturing processes related to  Industry 4.0.

First session on the Day1was on topic  “Promising Career in Welding Technology & Industry 4.0 – The Untold Success”.  Resource person is Dr. DevendraGope, Business Development Manager for Western & Central India from M/s Fronius Pvt Ltd, Gujarat. Dr. Santosh N, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person  to the participants. Dr. DevendraGope,explained about the vast opportunities available  in Welding Technology.There is large gap between demand and supply of skilled persons in welding technology. Almost 80% of the companies have shortage of resources in Welding Technology. Automation is creating opportunities and people needs to upgrade to the skills. There are several training programs available at low cost,  explained about the certifications available and interested students can start the career in welding technology from the second year onwards. Career in welding technology is not gender specific. Has high earning jobs based on the application. Highlighted the robotic welding machines and their application, skill set and opportunities in  underwater welding, industrial pipeline welding and aerospace welding joints. Session has opened up opportunities for the creation of development centre in the college, certifications for students and internship at the company. Overall session was well received by the participants.

Second session on the Day 1 was  “Overview of NDE for Materials and Manufacturing” by Dr. Shyamsunder Mandayam, Chairman National Certification Board, ISNT. Mr. Sridhara Rao M V, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person to the participants. Dr. Shyamsunder Mandayam has 20 years of experience at GE Global Research Centre, Bangalore and 16 years at Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam  in developing new NDE procedures and Techniques.

Advantages of NDT highlighted which include but not limited to cost of the specimen, accessibility, reuse, can’t be destroyed, ..etc. Different kinds of NDT techniques (Visual inspection, dye penetration, Magnetic Particle, Eddy current, Ultrasonic test) to detect surface defects as well as inner surface defects explained with merits and demerits. Type of technique to be used depends on the material, thickness, accessibility.

Latest techniques viz Advanced Ultrasound, Tetraherz NDE,  X-ray Impaging, Infrared Imaging explained with examples. Role and scope of Artificial Intelligence, Machine Learning and Deep Learning in NDE methods highlighted.

Great careers exists in NDE technology for  all disciplines of Engineering viz Mechanical, Electronics engineers, Data Scientists, Metallurgists  for Research and PhD programs.

First day sessions were concluded after taking feedback from participants.

Day 2 : 23rd Sep 2020 (Wednesday)

First session on the Day2 started with Resource person, Dr. M.R.Ramesh, Associate Professor in NIT Karnataka on the topic , “Role of Thermal Spray Coatings in improving resistance to Surface Degradation”Dr. Sunil Shankar Waddar, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person  to the participants.

Surface damage can be addressed by changing the surface metallurgy, surface chemistry and surface coatings. Organic coatings, Thermal spray coatings, Elctroless plating, physical vapour deposition and chemical vapour deposition are dominant in surface coatings. Research in Thermal Spray coatings, vapor deposition and Laser / microwave surface modifications are in progress at NITK. Residual stress details and methods to control are explained in detail. Self healing coatings is a potential research area. Second Session on Day 2 was on “Thick Film Composite coatings” by Prof.Peerawatt Nunthavarawong,  King Mongkut’s University of Technology, North Bangkok, Thailand. Dr. Santosh N, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  resource person  to the participants.

Main focus is on Tungsten Carbide (Cold Spray) Technique and its research. Cold spray has several advantages over Thermal spray viz .,  no grain structure change, no phase change or oxidation and produce more fine coating compared to thermal spray. For repair works, cold spray is preferred over thermal spray. Process of cold spray, window of particle diameters , materials for cold spray explained in detail.  Surface depositions with Nb improves wear resistance by 50%.  Intensive research is required for maturation of  Cold spray and surface depositions.

Second day concluded by taking feedback at the end of Session 2.

Day 3 : 24th Sep 2020 (Thursday)

 First session on the Day 3 started from Dr Mohammad Rizwanur Rahman,  Associate Professor, NIT-K on “Carbon Nano Structures and Graphine”Dr. Santosh N, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person  to the participants. Details of  single wall Carbon Nano Tubes and Multi Wall CNT explained in details. Band structures of Graphene and CNT illustrated with examples. Differences b/w Graphene and Graphene oxide highlighted. Chemical Vapour deposition techniques for making of CNT explained in detail.

Characterization techniques  of Graphene and CNT by Optical Microscopy, Atomic Force Microscope, X-ray diffraction, Micro-Raman Spectrometer and TEM explained in detail. Success of CNTs will enable developing wear resistant coatings and ultra-light bullet-proof films.

Second session on Third day was by Sri HS Shivakumar, Senior Sales Director, GE India Additive Division on the topic “3D Printing in Metal .. Additive Manufacturing” . Mr. Sridhara Rao MV, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person to the participants.

Additive manufacture allows to design better products & improve supply chain operations. In GE, Additive manufacturing started with  improving the efficiency of a component in one particular engine. In next version of jet engine configuration, more than 80% parts were made by additive manufacturing, reduced the part to the extent of 300:1. This has lead to form a  separate business unit viz GE Additive.

 Ecosystem of AM include Machines, software, Powders, Innovation and continuous research. Increasing complexity of design does not increase the cost unlike in conventional manufacturing processes

Research space exists for enthusiastic scholars in making different powders, additive designs, controlling the properties and repair of AM components. GE is open for collaboration.

Day 4 : 25th Sep 2020 (Thursday)

First session on fourth day was on “Gas Turbine Materials” by Dr Dheepa Srinivasan, Chief Scientist from Pratt & Whitney, IISc Branch, Bangalore. Dr. Santosh N, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person  to the participants

Materials played key role in jet engine advancements over decades.  Core efficency , fan weight and development time drive materials R&D.  Oxidation coatings and thermal barrier coatings helping the turbine blades to withstand up to 2700 F. Single crystal technology resulted in paradigm shift in creep strength, thermal fatigue strength and corrosion resistance.  Gadolinium Zirconium TBC results in significantly longer life than Yittria Zirconia in HPT blades for Gas Turbine Applications.

Tougher TBCs with low thermal conductivity is an area to focus further. Coating the complex shapes where access is restricted is another area for development

Second session on Fourth day was by Sri Umamaheshwar, Chief Consulting Engineer, at GE Aviation Bangalore on the topic “The 21st Century Brilliant Factory” . Mr. Sridhara Rao. M V, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person to the participants. Disruption in Technology over a period of century explained with appropriate examples. Digital revolution is the future. True picture of Industry 4.0 in next five years illustrated with help of Brilliant Factory example. Participants were taken to 2025 with the kind of ecosystem that prevails with digital world.

Speaker suggested that college shall take initiative of setting up Additive Lab. Research Scholars in the college shall come forward to have Industry 4.0 Lab in the college in collaboration with Industries to be in par with quickly changing digital world.

Day 5 : 26th Sep 2020 (Saturday) Prof. Carlo Santulli, School of Science and Technology (SST), Universitàdegli Studi di Camerino, Italy started the first session on the topic “Role of Natural Composites in Industry 4.0” Dr. Santosh N, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person  to the participants.

Application of natural fibre composites and challenges explained in detail. Host of plant fibres and their matrix composites in wide applications discussed. Chemical treatment methods and their impact on mechanical properties illustrated. Bamboo fibres and production issues discussed. Falling weight method for determination of mechanical properties presented.

Session2 on the fifth day was from  a DRDO Eminent Scientist  on “Important Topics for Research Proposals in Materials”. Dr. Santosh N, Associate Professor in Mechanical Engineering Department, MVJCE,  introduced  Resource person  to the participants.

Speaker highlighted the various opportunities for Research Proposals in the Material Characterization.

Session started with  highlighting unavailability of lasers for 3D printing of Aluminium alloys which are used in airframes, chemical and process industry.

Properties of materials made by 3D printing are not well established. Process parameters in the 3D printing are laser  power, scanner strategies, scanning speed, build plate pre-heat temperature, and inert gas. Properties needs to be established for Aluminium alloys, Titanium based alloys, Nickel based super alloys and steels made from 3D printing. In all the cases crystalline structure, corrosion behaviour, tribological behaviour, tensile, fatigue , creep rupture strength properties needs to be established.

Speaker also highlighted the development of advanced materials viz., High entropy alloys, Al / Mg alloys with rear earth metals, bulk metallic glass, beta Ti alloys, shape memory alloys, functional graded composites, Quasi crystals and Mg matrix composites.

Overall the session was well received by all the participants.

FDP Culmination

At the end of fifth day sessions, last speaker presided over valedictory function. HOD of Mechanical Engineering Department, MVJCE highlighted the importance of the different sessions and valuable informed shared by all speakers.  Principal MVJCE provided concluding remarks and thanked each and every resource speaker for accommodating the sessions in their busy schedules. FDP concluded with vote of thanks to Management at MVJCE, Organizing committee, Resource speakers and all participants.

Feedback and Quiz sessions conducted at the end of the 5th day.

Outcome of the FDP:

It has enlightened the opportunities available in Welding profession, advanced manufacturing processes like 3D printing, coatings development, material characterization of 3D printed parts and  new alloys development, state of art of NDT techniques and digital hub of Industry 4.0 for the faculty of MVJ CE and other colleges.

Link to Videos

DayTopicLink
Day 1 : Session 1 &  2Promising Career in Welding Technology & Industry 4.0 – The Untold SuccessOverview of NDE for Materials and Manufacturinghttps://web.microsoftstream.com/video/51a5c3ff-7c1a-4b3e-b26d-59bee688c122
Day 2 : Session 1 & 2Role of Thermal Spray Coatings in improving resistance to Surface DegradationThick film Composite Coatingshttps://web.microsoftstream.com/video/b2d2016a-fe9a-444c-92ec-0c74ce544ecd
Day 3 : Session 1Carbon Nanostructures and Graphenehttps://web.microsoftstream.com/video/55e0d2e1-c82b-4b54-9563-f460fc621724
Day 4 Session 2The 21st Century Brilliant Factoryhttps://web.microsoftstream.com/video/cc00a1b8-29bb-4d6f-af41-6b6b21481beb
Day 5 Session 1 & 2Bio inspired design of natural compositesImportant Topics for Research Proposalshttps://web.microsoftstream.com/video/4d1cc4b8-116d-4fd1-b72b-687aa818a04a https://web.microsoftstream.com/video/4137c52e-3231-46b4-817a-a860e3a2c90a