Centre for Engineered Coatings (CEC)
5-Axes CNC Machining Facility
A. Model & Make
FAMS-PG.ESI TDCC, FAMS-PG-Canada
Specifications
- Table Size : 1600 mm dia (Rotary Table)
- X, Y & Z Axes: 800 x 800 x 500 mm
- Spindle Tilting ( angle): -15 to+90o
- Spindle Speed : 48,000 rpm
- Control System: GE Fanuc 15i-M (Five Axes)
Details
The 5-axes CNC machining centre is a custom built unit which can be operated with and with out coolant. This machine is especially used for green machining of ceramics after they are pre-sintered. The advantage of green machining is mainly to increase the productivity and reduce the machining cost. This machine can also perform grinding operation on the sintered ceramic parts with higher spindle rpm and can achieve final surface finish of 0.1m. This machine is capable of carrying out profile generation like parabolid, spherical, asperical, hyperboloid surfaces within ±10 mm accuracies.
Centre
Centre for Non-Oxide Ceramics
B. Model & Make
DMG, HSC 55 Linear
Specifications
- 5-Axes Simultaneous Milling with high dynamic and low vibration Direct drives
- Linear motors with acceleration more than 2 g
- 80 m/min Rapid move with direct absolute scales
- Motor spindle with 42,000 rpm
- Axis travel sizes: X = 450 mm, Y = 600 mm, Z = 400 mm
- C-Axis 360o (continuous), A-Axis +10 to -110o (continuous)
- Position accuracy: < 5 m for X/Y/Z, < 7 arc-seconds A/C axis
Details
The 5-axes CNC machining centre is capable of running at high speeds up to 42,000 rpm with and without coolant. The machine is being exclusively used for testing of coated tools under high speed dry conditions (green machining). The advantage of green machining is mainly to increase the productivity and reduce the machining cost. One of the main highlights of this CNC system is its high Speed Cutting in highest precision.
Centre
Centre for Engineered Coatings
Activated Combustion High Velocity Air-Fuel (HVAF)
Specifications
- Capable to generate 200 kW equivalent combustion power to spray wide ranging cermets, alloys and metal powders
- Convertible mode of spraying to deposit higher particle sized powders
- Internal geometry coating capability
- Specialized torch for spraying Carbide coatings and thin wear resistant coatings
- Six-axis Robotic handling
Details:
Activated Combustion High-velocity Air-Fuel (HVAF) spray utilises compessed air and LPG fuel combination to generate high velocity gas streams. The optimized combination of high kinetic energy – ideal thermal input allows deposition of coatings with excellent microstructural features including fully dense, defect-free, retained phases and high adhesion strength. The exceptional capabilities can be understood from its highest productivity amongst the competing thermal spray techniques to reach as high as 35 kg/hr for Cr3C2-NiCr based coatings.
The process involves a pre-mixed Air-fuel mixture fed to the combustion chamber through the ceramic insert which is ignited initially with a spark plug. As the Combustion proceeds, the ceramic insert at the entrance of the combustion chamber gets heated up above the auto-ignition temperature of the mixture and takes the role of spark plug to enable stable combustion (also known as “Activated combustion”) throughout the process. The flame temperature during HVAF is much lower than that of HVOF since it uses an air-fuel mixture instead of an oxy-fuel mixture, which allows HVAF to coat thermally sensitive material with lesser thermal deterioration. Control of gas dynamics through the use of diverse nozzles results in range of particle velocities, which translates into highly adhesive, hard, oxide and pore-free coatings. Prominent application sectors with HVAF technique include industries requiring wear, corrosion resistance and refurbishment.
Centre
Centre for Engineered Coatings
Atomic Force Microscopy (AFM)
Model and Make
- Park XE7 (Direct On-Axis Manual Focus Optics)
Specifications
- XY Sample stage : 13 mm x 13 mm
- Scan Range in XY : 50 µm (max)
- Scan Range in Z : 12 µm (max)
- Options : Non Contact, Contact, Dynamic Contact, Phase Imaging. Heater Stage and Lithographic.
Details
The atomic force microscope (AFM) is extensively used in material science and biological sciences. Characterization of sol-gel thin film surface morphology in sub-micron scale is necessary to evaluate their function properties in a wide variety of applications. It has been known that sub-micron and nanoscale properties control various aspects of functional performance. For example, enhanced transmittance in borosilicate glass (BSG, 91%) over soda lime glass (SLG, 89%) is due to sub-nanometer surface morphology of BSG. This may occur due to its different chemical composition though the refractive indices are comparable.
Automated Portable Cold Spray Unit
Model & Make
Indigenously developed
Details
A portable PLC based automated control panel attached to the cold spray gun enables coating deposition with all the controls juxtaposed at one place. Portability option enables coating deposition for onsite applications with utmost ease. This was indigenously developed at ARCI
Centre
Centre for Engineered Coatings
Automated Thermal Cycling Furnace
Details
An automated thermal cycling furnace is being used for assessing the thermal behavior of coatings obtained by different coating techniques such as electron beam physical vapour deposition, air plasma spraying and etc. The facility can be used for simulating the test temperature for investigating the coating performance at elevated temperatures ranging from 1100-1500oC
Centre
Centre for Engineered Coatings
Axial Suspension Plasma Spray (ASPS)
Specifications
- High energy plasma power upto 150 kW to spray wide ranging ceramics, cermets, alloys, metal powders and fine particle suspensions
- Plasma jets: up to three, converging mode using Argon, Nitrogen, Hydrogen
- Axial Feedstock injection along the plasma flow
- Dual feed Axial Plasma Spray Torch configured to spray powders and suspensions
- Six-axis Robotic handling
Details:
High energy Axial Plasma spray technique is capable to spraying powders and fine particle suspensions. In comparison with conventional radially injected plasma spray systems, the axially injected powder particles attain better momentum and greater heat transfer while travelling along the plasma plume. Therefore, the axial plasma sprayed coatings exhibit good deposition rate and efficiency and also, offer possibilities of engineering the microstructure with dense, porous and cracked features.
Fine structured coatings provide improved properties than micron-sized coatings. However, the fludized powder feeding arrangement are incapable of injecting fine particles, which necessitates the use of liquid based feeding either as suspensions or solution precursor based spraying. Additional capabilities of axial plasma spraying can be realized through efficient spraying of fine particle suspensions which otherwise are difficult with radial injection systems. Axial suspension plasma spray (ASPS) is an emerging coating technology through the use of fine-sized powder particles suspended in a suitable solvent such as water or ethanol and injected into the plasma flame to get desired microstructure. Unique features of axial suspension plasma spray are,
- Tailored microstructure – dense, porous, columnar, vertically cracked, feathery
- High spray rate
- Relatively thin coatings are possible compared to conventional thermal spray
- Better surface finish
- Wide range of materials – cermets, ceramics, metals and alloys
Prominent application areas with axial plasma spray technique include industries requiring thermal barrier, dielectric, insulation, wear, corrosion resistance and refurbishment. For example, YSZ based thermal barrier coatings applied through ASPS exhibit lower thermal conductivity and identical microstructure similar to that EBPVD process, which can be effectively exploited for cost-effective thermal barrier coatings in gas turbine components.
Centre
Centre for Engineered Coatings
Calo Tester
Model & Make
PLATIT
Details
Calo tester is used for making calo's of known diameter especially used for measuring thickness of any thin film. The Calo tester uses ball grinding mechanism employing a known diameter steel ball for making a calo on the test sample surface. The minimum thickness that can be measured depends on the dimensions of the ball used. The calo generated from the tester is then monitored using an optical microscope connected to a computer having software (based on simple trigonometry principles) for thickness calculation.
Centre
Centre for Engineered Coatings
Cathodic Arc Physical Vapour Deposition (CAPVD)
Model & Make
p300, PLATIT
Details
Cathodic Arc Physical Vapor Deposition (CAPVD) is a well known thin film deposition technique for developing very thin (~ 5 nm) to highly thick films (~ 50 µm) of any material. The CAPVD system at ARCI is unique in its kind in India with cylindrical cathodes. The cylindrical cathodes have the advantages of maximum target utilization and minimum droplet formation during the film deposition (to an extent of one order less than the conventional deposition). The state-of-art facility was established to address various surface engineering aspects in major sectors like Machining, Automotive, Aerospace, Aesthetic, Solar Energy etc. Various R&D activities currently ongoing at ARCI includes micro or nano crystalline or composite pure metals, nitrides, carbides, carbo nitrides and diamond like carbon in wide configurations such as mono / multi / gradient layer structures.
Centre
Centre for Engineered Coatings
Cold Spray Coating
Model & Make
Acquired from the Institute of Theoretical and Applied Mechanics (ITAM), Siberia and indigenized to suit Indian markets and applications with several modifications
Details
Cold Spray is a high rate material deposition process which involves spraying metallic and composite powders at supersonic velocities (800-1200 m/s) on to suitably prepared substrates. The powder particles are injected in supersonic gas jet, upstream of a De Laval nozzle wherein they attain velocities close to the gas velocity. Cold spray process consumes very less thermal energy when compared to other thermal spray techniques and hence holds the advantage of obtaining dense coatings without oxidation, grain growth and degradation. A unique advantage of cold spray technique is that it can coat nanocrystalline and amorphous powders using cold spray as it retains the powder properties in the coating
Centre
Centre for Engineered Coatings
Continuous Coating Deposition (CCD) System - MAO
Model & Make
Indigenously developed
Specifications
Thickness of thin films that can be deposited :0.25-10 microns
Details
The CCD system is capable of depositing insulating and corrosion resistant oxide thin films in the thickness range between 0.25-10 microns on thin foils and wires on continuous scale. The proof-of-concept system built at ARCI has been demonstrated to coat half-kilometer long foils. The technology is scalable to treat wider and longer foils and wires. The technology has already been patented in several countries and exploring the potential to develop novel, oil free transformer and other electrical / electronic applications in collaboration with Indian industry partners.
Centre
Centre for Engineered Coatings
Electron Beam Physical Vapour Deposition
Model & Make
Indigenously developed and integrated with the help of foreign collaborator M/s International centre for Electron beam technologies, Kiev, Ukraine
Specifications
Depending on requirements, Electron Beam Physical Vapour unit has been fitted with traditional evaporators (water-cooled crucibles with vertical shafts for displacement of evaporation ingots). The load chamber has the capability of cleaning of the job surfaces and fixing of jobs before moving into the working chamber. Electron beam guns are fitted with a two-stage system of differential high-vacuum pumping, allowing implementation of the evaporation process, it has capabilities with purging of various gases into the working chamber.
Details
A high energy electron beam physical vapour deposition (EBPVD) coating process which allows high deposition rates, precise composition and microstructural control capable of depositing thermal barrier coatings with MCrAlY as a bondcoat and high temperature oxidation resistant coatings that are used on gas turbine blades of aero-engine and power generating industries. The facility is capable of depositing coating of thickness ranging from a micron to a few mm, and also coatings with graded structure and properties.
Centre
Centre for Engineered Ceramics
High Power Impulse Magnetron Sputtering (HiPIMS) facility
Overview
Magnetron sputtering is one of the well-known Physical Vapor Deposition (PVD) technique for generating defect-free thin films at low deposition temperatures. Contrary to any other PVD techniques, magnetron sputtering is a process in which the removal of the target material (in other words like evaporation) takes place through the momentum transfer process. Since it is a momentum transfer process, literally using this technique, most of the materials deposition can be done. In similar lines, High Power Impulse Magnetron Sputtering (HiPIMS) is a process in which, the power given to the source/target will be in short pulses of very high energy. In general, the high energy ionic depositions are known for achieving good adhesion, high density and good control over reactive process. As on date, the HiPIMS facility at ARCI is a lab scale equipment with planar as well as cylindrical cathodes. The HiPIMS facility with its unique advantages can be used for developing thin films that are key to major sectors like, automobile, aerospace, manufacturing, optics, electronics, alternate energy, biomedical, sensors, etc.
Key Features
- The facility can be used to deposit any metallic or reactive depositions (Metals, Metal nitrides, metal oxides & metal carbides)
- Can be used to develop thin films on internal or external surfaces of any regular objects
Applications:
- Any metallic, nitride or oxide coatings can be deposited
- Solar selective coatings for solar thermal applications
- Diffusion barrier coatings for electronic components
- Decorative coatings for aesthetic applications
- Biocompatible coatings for biomedical applications
- Coatings for developing different sensors
Infinite focus 3D optical microscope with real 3D rotation unit
Model and Make
- Infinite focus G5, Alicona
Details
A microscope with non-contact optical data acquisition based on focus variation technology. Automatic 3D data acquisition using automated data fusion with an automatic rotary unit in combination. The standard measurement modules included are:
- Measurement tools for volumetric measurements
- Measurement tools for profile measurement (profile form, profile roughness: Ra, Rq, Rz)
- Measurement tools for surface texture (surface roughness: Sa, Sq, Sz, etc.)
- Measuring tool for edge evaluation (angle, radius, form, contour, etc.) to a level of 1 µm
- Difference measurement (to compare to 3D objects)
- Depth measurement with 3D display function (for profiling MEMS, biomedical Stent, etc.)
- Target – actual comparison of measurement data and CAD model
- Export of measured results (CSV, 2D, 3D, QDAS)
Laser Based Particle Diagnostic System
Model & Make
Spraywatch 2.0i, OSEIR, FINLAND
Specifications
Details
The particle diagnostic system is an essential device for optimizing of the coating process parameters in thermal spray coating systems like detonation spray, cold spray, high velocity oxy-fuel and plasma spray coating techniques. It is used for measuring particle velocity, temperature and size of various spray grade coating powders during coating deposition. The system is also being used for evaluating the particle velocities in abrasive blasting, erosion wear test rig etc.
Centre
Centre for Engineered Coatings
Micro Arc Oxidation (MAO)
Model & Make
Indigenously developed
Specifications
System is equipped to treat up to 12,000 sq. cm. surface area in a single batch.
Details
MAO is also known as Plasma Electrolytic Oxidation (PEO) system. MAO technology is the next generation eco-friendly process capable of depositing dense, ultra-hard (up to 1850 HV) ceramic coatings on different varieties of Al alloys. Wear and corrosion resistant coatings can be deposited on Al, Mg, Ti alloys. ARCI has got the capability to custom design the MAO systems targeted to meet application specific requirements. The technology has been patented in India and USA. The coatings were found to be very attractive in terms of service life enhancement in various fields such as Textile, Automobile, Aerospace, Petrochemical, Wiredrawing and general engineering industry.
Centre
Centre for Engineered Coatings
Micro Tensile/Fatigue Testing of miniature samples
Model
Multipurpose Micro tensile Testing Machine Type LFV 0.5 S + LFV 3S
Max. Static load ± 3000 N
Max. Dynamic load ± 2500 N (up to 30 Hz)
Make
Walter & Bai Switzerland
Year
2008
Purpose
Mechanical property evaluation of thin (< 1 mm) coatings, LASER clads
Specifications
- Max. static load ± 3000 N
- Max. dynamic load ± 2500 N (up to 30 Hz)
- Digital Control System Series EDC for closed loop control of load, displacement or deformation for static and dynamic testing up to 50 Hz
- DIONSTAT Application Software package for standard tensile, compression, bending etc. testing
- High resolution Video Extensometer type ME46 for non contact strain measurement with automatic target Recognition complete with PC and Software, gauge length: 1-10 mm
- X-Y micrometer position stage, mounted between base platen and load cell to allow ultra-precise positioning and movement of specimen
- Dynamic Extensometer for Fatigue Testing - Gauge Length:10 mm, measuring displacement: +/- 2.0 mm, Natural frequency: 100 Hz
- Miniature Extensometer Model- gauge length 3, 6, 8 and 10 mm; measuring travel ±5%, ±10%, +20/-10%,+25/-10%, +50/-5% and +100/-5% of gage length
- Small lightweight, mechanical clamp grip for forces up to 3 kN with adapters, 10 mm wide serrated faces and faces for round samples up to diameter 3 mm
- Micro Electro Mechanical Systems (MEMS) bend fixture with variable span length including adapters
Centre
Centre for Engineered Coatings
Nano mechanical testing
Model
Nanomechanics Inc, Oak Ridge, USA
Specifications
- Load range: ±50mN or ±1N (High load actuator) electromagnetic actuator
- Displacement range: ±20μm
- Displacement time constant: 20μs
- Data acquisition rate: 100kHz
- Frequency range: 1- 200Hz
Details:
- High precision and high accuracy indentation testing with continuous measurement of hardness and elastic modulus as a function of depth
- Frequency dependent viscoelastic characterization (storage modulus, loss modulus and loss factor) between 1-200Hz
- High speed mechanical property mapping for stiffness, hardness and elastic modulus mapping (Each indent takes < 1s)
- High strain rate hardness measurements as a function of indentation strain rate in the strain rate range of 10-4 1/s – 3 X 104 1/s
Centre
Centre for Engineered Coatings
Pulsed Electrodeposition (PED)
Model & Make
DPR 20-50-200; Dynatronix ,USA
Specifications
The electrodeposition facility is accompanied with a commercial pulse power generator with 20 Amps average current, 50 V with peak current rating of 200 Amps.
The deposition can be carried out on wide variety of materials and components.
Details
PED is one of the oldest techniques that has been recently applied to synthesis of nanostructures. Electroplating or electrodeposition is the method of coating the surface of a material, with the help of an electric current. This method is very useful in the production of monolayers and conducting thin films, nanocrystalline metals and alloys, and templates. The most common use of electrodeposition in the field of nanotechnology is the synthesis of nanostructured metals
Centre
Centre for Engineered Coatings
Rotating bending fatigue test machine (RBF-200)
Make
Fatigue Dynamics Inc USA
Model
RBF-200
Year
2005
Purpose
Fatigue life estimation of coated materials
Specifications
- cycle counter: 9,999,999,900 maximum counts
- adjustable speed spindle :500 to 10,000 rpm
- calibrated beam and poise system, which can apply an infinitely adjustable moment of up to 200 inch-pounds to the cantilevered end of the specimen bar.
- Collets sizes available include ¼, 3/8, and ½ inch diameters.
- Unless specified otherwise, a ½ inch pair of collets is furnished with the machine.
Details
The RBF-200 is a compact, bench-mounted machine designed to apply reversed bending loads to unthreaded, straight shank specimen bars.
Specimen design
The applicable inch-pound moment setting for the poise weight is determined on the basis of some desired bending stress level in the specimen. Generally this moment may be determined from the equation: M = SD3/32 = 0.0982 SD3 Where, M = Setting for poise weight in inch-pounds S = Desired bending stress level in specimen at minimum cross section in pounds per square inch D = Diameter of specimen at minimum cross section in inches.
Centre
Centre for Engineered Coatings
Scratch Tester (CSM)
Model & Make
Revetest Macro Scratch Tester (RST), CSM (Now Anton Paar)
Specifications
- Indenter: Rockwell C (Diamond tipped)
- Load Range: 1 mN to 200 mN
- Loading type: Constant or progressive loading
- Failure Detection: Acoustic emission or change in friction coefficient
- Sample dimensions: > 10Lx10Wx5H mm3
Details
The macro scratch tester is extensively used in the measurement of interface (substrate to coating) or cohesive (with in the coating) adhesive strength of thin films or coatings deposited on any substrate material. Further it can also be used to measure material surface mechanical properties like, fracture and deformation.
Solution Precursor Plasma Spraying (SPPS)
Details
SPPS is an innovative and rapid method to produce mostly functional oxide ceramic coatings by starting from solution precursors and directly producing inorganic coatings. This technique utilizes the molecularly mixed precursor liquids, which essentially avoids the handling and selection of powders, opening up new avenues for developing compositionally complex functional oxide coatings. Basic properties of the process are fundamentally similar to other thermal spraying processes.
The benefits of utilizing the SPPS process include
- the ability to create nanosized microstructures without any feeding problems normally associated with powder systems
- flexible, rapid exploration of novel precursor compositions and combinations
- circumvention of expensive powder feedstock preparation steps
- better control over the chemistry of the deposit
Centre
Centre for Engineered Coatings
Surface and Contour Measuring Machine
Model
ZEISS ACCRETECH SURFCOM NEX 031 SD-14
Brief Technical specifications
- Resolution-X: 0,016μm ,Z (Roughness): 0,1nm/+-3,2μm range up to 20nm/+ 500μm range ,Resolution-Z (Contour): 0,04μm
- Length deviation-X: +-(1,0 + 0,01L) μm ,Z (Contour): +-(1,5 + 2H/100) μm
- Straightness-X: 0,05 + 0,001L μm
- Touch direction 1: Touch direction above, Touch direction 2: Touch direction below, exclusively with contour stylus tip
- Measuring direction: pull/push, exclusively contour
- Temperature compensation/progressive feed: 20°C +- 5°C
ZEISS ACCRETECH SURFCOM NEX 031 capabilities
- This machine capable of hybrid, roughness, contour, surface topography and combined functions.
- The SURFCOM NEX series allows you to select detectors by application.
- Detectors can be used as a single detector or combined with others to serve as multiple sensors.
- Temperature correction system provides you the accuracy guaranteed temperature range to 20°C ± 5°C
- Quick-change arm with attachment recognition sensors.
- Z-axis measurement range expanded to 60 mm (±30 mm).
- T-shaped stylus for continuous upward/downward measurement.
- Safety mechanism against detector collision
Centre
Centre for Engineered Coatings
Table Top Nano Hardness Tester (NHT)
Model & Make
NHT, CSM Instruments
Specifications
Range of Low Loads : 5 mN to 500 mN
Details
Nano Hardness Tester is used for measuring hardness and elastic modulus of thin films and thick coatings. The conventional nano indenter systems in general requires prolonged times for attaining thermal stability while the NHT system being equipped with a reference ring around the indenter such that the thermal vibrations are balanced and the measurements could be started almost instantaneously. By means of employing low loads, it is possible to eliminate substrate effects while measuring hardness / modulus of thin samples (films). Knowing the shape of the indenter used (Vickers, Berkovich, spherical, etc.) and the depth to which the indenter has penetrated into the sample, the area of the indent is calculated and hardness is calculated. Also since load-displacement curves are measured, the elastic modulus can also be calculated. The system is equipped with a continuous stiffness measurement (CSM) module and is capable of giving the hardness / modulus as a function of penetration depth.
Centre
Centre for Material Characterization and Testing
Universal Testing Machine For Bond Strength Measurement of Thermal Spray Coatings
Model and Make
BWDT-50Y; BANBROS, INDIA
Details
Universal tensile testing machine with a load capacity of 50kN was installed and commissioned at the centre for engineered coatings. The primary objective is to measure bond strength or adhesion strength of thermal spray coatings as per C633 standard. Sample dimension needs be as per the standard i.e., 1 inch diameter with further details in the standard. The test utilises a glue/tape that has a adhesive strength of ~70 MPa.
Centre
Centre for Engineered coatings