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LAND BASED TURBINE COMPONENTS WITH ADDITIVE MANUFACTURING IN A CONSORTIUM APPROACH

Primary Information

Domain

Manufacturing

Project No.

5868

Sanction and Project Initiation

Sanction No: F.No-35-10/2016-TS-1

Sanction Date: 27/02/2017

Project Initiation date: 01/03/2017

Project Duration: 36

Partner Ministry/Agency/Industry

Department of Heavy Industries

 

Role of partner:Nil

 

Support from partner:50%

Principal Investigator

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Dipankar Banerjee
Indian Institute of Science

Host Institute

Co-PIs

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B. Gurumoorthy
Indian Institute of Science

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Amaresh Chakrabarti
Indian Institute of Science

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Pradeep Dutta
Indian Institute of Science

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Abhik Choudhury
Indian Institute of Science

 

Scope and Objectives

Demonstrate additive manufacturing of land base power turbine parts in through additive manufacturing in a consortium approach

Deliverables

Process optimisation of industrial selective laser melting process to specific materials and part geometries Process optimisation of direct metal deposition processes to the same material and part geometries Comparison of the processes Development of required property data bases Demonstration of consistency Development of process and quality control and test and evaluation standards Cost benefit analysis

 

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Scientific Output

Design of experiments for process optimization that Control of solidification in tempered martensite materials in the two processes to minimize solidification defects. Design of laser path and power/beam size parameters for solidification and surface finish control Development of new heat treatment procedures for additively manufactured parts in the proposed materials. Achievement of residual stress control and mechanical properties including tensile, creep and fatigue that compare with conventionally manufactured parts

 

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Results and outcome till date

MOU between partner industries and IISc signed Powder procurement and characterization Parameter optimization trials completed Heat Treatment effects evaluated

 

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Societal benefit and impact anticipated

Such a demonstration would pave the way for the development of industry specific standards for additive manufacturing

Next steps

Optimize heat treatment and mechanical behaviour on trial blocks Demonstrate prototype parts

Publications and reports

Nil

Patents

Nil

Scholars and Project Staff

Suneetha Rani, Nihal Gopal Acharya

Challenges faced

As indicated earlier funds sanctioned under the equipment head were inadequate for procurement. Alternative sources of funds were located and equipment order placed with a commitment of Rs 8000000.00 from the project

Other information

An additional amount of Rs 1856330.00 has been committed towards additive trials

Financial Information

  • Total sanction: Rs. 43015000

  • Amount received: Rs. 23335000

  • Amount utilised for Equipment: Rs. 1980040

  • Amount utilised for Manpower: Rs. 10193123

  • Amount utilised for Consumables: Rs. 186699

  • Amount utilised for Contingency: Rs. 66746

  • Amount utilised for Travel: Rs. 59518

  • Amount utilised for Other Expenses: Rs. 1856330

  • Amount utilised for Overheads: Rs. 1790000

Equipment and facilities

Simufact additive manufacturing software for simulation