Synthesis & Fabrication
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
Arc Discharge Set-up
Model / Make
Custom-Made Russia
Specifications
- Electric Power (DC power) : 40-50 Kw
- Voltage : 60 Volts
- Current : 500 - 800 Amperes
- Volume of chamber : ~ 150 liters
- Max. number of graphite rods : 7 Nos.
- Vacuum of the chamber : 10-2 Pa
Details
Creates CNTs through arc-vaporization of two carbon rods placed end to end, separated by few mm, in an enclosure that is usually filled with inert gas (Helium) at low pressure. A direct current of order of few hundreds Ampere (based on Graphite Current Density), driven by a potential difference of approximately 20 - 50 V, creates a high temperature discharge between the two electrodes. The discharge vaporizes the surface of one of the carbon electrodes, and forms a small rod-shaped deposit on the other electrode. High yield of CNTs depends on the uniformity of the plasma arc, and the temperature of the deposit forming on the carbon electrode.
Centre
Centre for Carbon Materials
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
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
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
Chemical Vapour Deposition (CVD)
Three types of CVD are available at ARCI
A. Laboratory Set-Up CVD
Model / Make
Custom-made Russia
Specifications
- Power of furnace :4 KW
- Number of Zones: 3
- Temperature range: up to 1050oC
- Temperature control : 0.10oC
- Pressure range: 10-5 - 1.5 bar
- Synthesis time: 2 hours
Details
Chemical vapor deposition of hydrocarbons over a metal catalyst is a classical method that has been used to produce various carbon materials such as carbon fibers and filaments. Used at ARCI for synthesis of Carbon Nanotubes
Centre
Centre for Carbon Materials
B. CVD Unit
Model & Make
MPA Industrie, France
Specifications
CVD has four parts: a) reactor where in the reaction takes place at desired temperatures and pressures b) a gas control panel for the precise control and flow of gases c) scrubber for chemically treating the un-reacted gases d) control panel for process control
- with a maximum temperature up to 1500oC
- Chamber dimensions : 500 mm dia x 700 mm height
- Deposition rate: 50-500 microns/min
- Employs a gaseous phase reaction of the material constituents at optimized conditions of pressure, temperature and gas flow.
Details
The Chemical Vapour Deposition unit is employed for the deposition of thin and thick film coatings by a chemical reaction of the precursors. The deposition is allowed to take place on suitably designed substrates at controlled deposition rates of 50-150 microns/minute. Self standing monoliths could be prepared by carefully removing the deposits from the substrates.
Centre
Centre for Ceramic Processing
C. CVD System
Model & Make
1675, Advanced Vacuum System
Specifications
- Max. Operating Temperature of CVD : 2200oC
- Process Temperature : 1600oC
- Ultimate Vacuum : 1x10-2 Torr
- Process Pressure : 150 Torr
- Type of Vacuum Pumps : Two numbers of Liquid Vacuum Pumps
- Number of Scrubbers : 2 Nos.
- Number of Vaporizers : 4 Nos.
- Number of Gas Injectors: 5 on the Top and 4 at Sides
- Reactor Dimension : 1800 mm ht. x 1400 mm dia
- Turn-table Speed : 1-10 rpm
Details
Used for depositing SiC coating on the SiC substrate and also to make CVD-SiC stand alone parts. The CVD-SiC made has the density close to theoretical value with very high purity. The surface finish achieved on the CVD coated SiC substrate is 3-4 nm. Maximum 1 m dia. Component can be coated and SiC coating uniformity can be achieved within 10-15%.
Centre
Centre for Non-Oxide Ceramics
Clean Room Facility
Details
A Class 10000 clean room of area 130 m2 has been set up for carrying out coating, curing and drying processes in a highly controlled environment when the applications demands so. A Class 1000 clean area of 8 m2 has been set up inside the Class 10000 clean room for even more critical coating operations.
Specifications
Curing and Densification
The following units have been set-up for drying, curing and densification of coatings:
- Dense ceramic bodies
- Coatings/thin films
- Aerogels
- Monoliths and
- Ceramic fibres
Centre
Centre for Sol-Gel 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
Cross Hatch Cutter
Details
Used to analyze the adhesion of simple and multilayer coatings on substrates, as well as between multilayer coatings according to ASTM D 3359. The cross hatch cutter or the cutting tool, has one to six special blades with a separation of 1 or 2 mm, is scanned on the coatings to form a grid. A 75 mm length of a 25 mm wide semitransparent pressure sensitive tape is placed with its centre on the grid such that no creases are formed so as to ensure good contact between the surfaces. The tape is removed within 90 Â 30 seconds of application by seizing the free end and rapidly pulled back upon itself without jerks at as close an angle of 180o as possible. The grid area is inspected for the removal of coating from the substrate.
Centre
Centre for Sol-Gel 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
Feeding Machine
Model and Make
- TOB-RK60, China
Specifications
- The machine has provision for top and bottom cylinder to feed the cylindrical cell case at the bottom and the laser welded jelly roll with top cap and O-ring from the top.
- The machine operates with pneumatic control.
- Parameters: Suitable to feed cell cases with 60 mm diameter, Height: 50-150 mm.
- Capacity of feeding: 1 cell/minute
- Compressed air supply: 0.5 to 0.8 MPa
Details
The cell feeding machine is used to press the laser welded jelly roll with guide plates and top cap with O-ring into the 60mm dia. cylindrical cell case and to fasten the O-ring sealing inside the cell case.
Centre
Centre for Nanomaterials
Fluidized Bed Reactor
Model & Make
Designed & Fabricated locally
Details
The process of fluidization occurs when a fluid (liquid or gas) is passed up through the granular material under specified conditions. When a carbon containing gas flow is introduced through the bottom of a bed of solid catalyst particles, it will move upwards through the bed via the empty spaces between the particles The solid substrate (the catalytic material upon which chemical species react) material in the fluidized bed reactor is typically supported by a porous plate. The fluid (hydrocarbon and carrier gases) is then forced through the distributor up through the solid material. Depending on the operating conditions and properties of solid phase various flow regimes carbon nano-materials can be synthesized. Used for continuous synthesis of carbon nano-materials.
Centre
Centre for Carbon Materials
Four-port glove box with in-built vacuum oven facility
Model and Make
- UNIlabpro sp, MBraun
Specifications
- Four port
- Two manually operated small ante-chamber
- One PLC controlled large ante-chamber
- Environment: Argon
- Attached vacuum oven
- 20-25 L volume
- 30-200 degree centigrade temperature
Details
The UNIlabpro sp, MBRAUN four-port glove box attached with vacuum oven is an inert gas (Ar) filled gas station to handle the atmosphere sensitive materials, electrode and cell fabrication. The attached vacuum oven can be used to dry electrode materials and fabricated electrode film. The four port glove box has been designed for the electrode and cell fabrication in R&D level.
Fuel Cell Fabrication
A. Wet Ball Mill
Details
The planetary ball mills are used wherever the highest degree of fineness is demanded. Apart from the classical mixing and size reduction processes the unit meets the technical requirements for colloidal grinding and also have the necessary energy input for a mechanical alloying process.
PEMFC electrode development involves preparation of diffusion layer slurry and catalyst ink slurry for which a good homogeneous mixture of the ingredients with desired particles of uniform dimension is required. The material is normally soft and the medium can be wet or dry.
This equipment can also used for R & D purpose for different applications.
Centre
Centre for Fuel Cell Technology
B. Screen Printing Machine
Details
Different types of coating like brushing, spraying and painting are used for fuel cell electrode preparation. A screen printing machine is used for fabrication of electrodes with uniform thickness. This unit can also be used for adhesive coatings in gaskets being used in fuel cell assembly . This is a semi-automated process for electrode development, increases the production rate, and reduces the harmful exposure of organic solvents compared to other techniques.
Centre
Centre for Fuel Cell Technology
C. Hydraulic Hot Press
Specifications
- 4 posts
- 7" bore cylinder
- 42" lower platen operating height
- Temperature up to 500 F
- Adjustable daylight of 8-15"
- PID controller
- Pressure compensated hydraulic pump
- Water coolant,
- Heat exchanger
- Switch over from Manual to motorized operation.
Details
This equipment is used for the lamination of electrodes with electrolyte which are micron thick. The high precision in the platen surface, pressure and water supply makes the unit ideal for making MEAs with less interfacial resistance, thereby improve the catalytic activity.
Centre
Centre for Fuel Cell Technology
D. Ultrasonic Processor
Details
Ultrasonic processor with sonotrode(s) of different sizes are used in preparation of large volume of carbon and catalyst slurries used in fuel cell electrode fabrication.
Centre
Centre for Fuel Cell Technology
E. Ultrasonicator Bath
Details
This unit is selected for use during the process of making fuel cell electrodes when the catalyst ink and carbon ink have to be kept agitated and the particles are expected to be in the suspended state rather than settling down at the bottom.
Centre
Centre for Fuel Cell Technology
F. Vacuum Ovens and Sintering Ovens
Specifications
Operating temperature: upto 400oC
Details
Vacuum ovens and sintering ovens operating at different temperatures have been installed which are used at various stages in the processes of making electrodes. The sintering processes can be carried out at reduced pressure or nitrogen atmosphere which are required to avoid catalyst particles sintering, oxidation and ignition.
Centre
Centre for Fuel Cell Technology
Glovebox (2 ports)
Model & Make
IL-2GB, Innovative Technologies, USA
Specifications
- Ports: 2 nos
- Gas: Argon
- Oxygen: <1 ppm
- Moisture: <1 ppm
- Transfer Chamber: 2
Details
Instrument used for storing and synthesis of materials under inert condition and coin cell fabrication.
Centre
Centre for Nanomaterials
Grooving Machine
Model and Make
- TOB-GCFK60, China
Specifications
- Grooving parameters: Suitable to groove with cell cases with 60 mm diameter, Height: 50-150 mm.
- Grooving height accuracy: ± 0.05 mm
- Grooving depth accuracy: ± 0.02 mm
- Capacity: Grooving minimum of 1 cell case/minute.
- Working conditions: 20-30°C, RH of 70-100%.
- The cylinder case will not rebound due to compression resistance, and provides uniform grooving.
Details
The grooving machine is used to groove cylindrical cell cases with the electrode jelly roll. It is essential for proper fitting of the jelly roll inside the cell case.
Centre
Centre for Nanomaterials
Hazemeter
Specifications
- System sample port - 21 mm
- Measurement area - 16.5 mm
- Measurement ranges of haze and transmittance are 0-100% with a measurement time from 0-6 sec.
Details
Used for measurement of Haze and transmittance of coatings on transparent substrates. According to ASTM 1003, haze is the percentage of light that deviates from the incident beam by more than 2.5o on average. Particles or surface irregularities like scratches act as light scatterers and results in a hazy appearance of the material. Mainly, the unit is being used for evaluation of Haze and transmittance of transparent coatings on transparent substrates like glass or plastics.
Centre
Centre for Sol-Gel Coatings
Hot powder extrusion facility
Model & Make
- In-house developed facility
Specifications
- Maximum load: 1150 MPa
- Billet size; 50 mm
- Extrusion ratios: 4 to 30
- Maximum temperature: 1150°C
Details
- Alloy powders are extruded into various-sized solid rods depending on the materials.
Jelly Roll Core Flattening Machine
Model and Make
- India
Specifications
- Provided with cutting, curling and flattening function.
- The machine operates with pneumatic control.
- Operates with pneumatic supply.
- Operate jelly rolls with a min dia. of 56-58 mm
- Operates jelly rolls length ranging from 60-150 mm with weight approx. 130 g.
Details
The flattening machine used for flattening both ends of jelly roll simultaneously with three operations in series using 3 different tools. The jelly roll made by winding aluminium foils of 20 micron thick coated with 100-micron carbon on each side of foil. The flattening of jelly roll on both sides is required for laser welding of guide plates to either side of jelly roll.
Centre
Centre for Nanomaterials
LEVITATIONAL GAS INFLOW UNIT
Model and Make:
Sourced from High Energy Physics Laboratory, Moscow.
Specifications
- Synthesize of nanopowder for Cu, Ag, Ni, Fe, Al, Co
- Synthesize of Fe-Cu, Fe-Co, Fe-Ni, Ag-Cu, Cu-Ni alloy nanopowders
- Particle size range -10 nm to 100 nm
- Production Capacity – 1-5 g/h
Details
- The levitational gas condensation nanopowder synthesizing unit works on the principle of Gen-Miller condensation.
- Suitable to produce all kinds of metals and alloy with a melting point between 600 to 1900°C and density between 5-9 g/cm3.
- In-situ encapsulation of nano-powder surface.
- Controlled passivation
- Suitable for synthesizing oxide nano-powder of Al2O3, Fe-oxide from metals.
Centre
Centre for Automotive Energy Materials
Magnetron Sputtering System
Model & Make
Excel India, Mumbai
Details
Sputtering is a vacuum evaporation process which physically removes portions of a coating material called the target, and deposits thin, firmly bonded onto an adjacent surface called the substrate.
The process occurs by bombarding the surface of the sputtering target with gaseous ions under high voltage acceleration. As these ions collide with the target, atoms or occasionally entire molecules of the target material are ejected and propelled against the substrate, where they form a very tight bond. The resulting coating is held firmly to the surface by mechanical forces, although, in some cases, and alloy or chemical bond may result. Since the coating material is passed into the vapor phase by a mechanical rather than a chemical or thermal process, virtually any material can be deposited. Direct current is used to sputter conductive materials.
DC magnetron sputtering system can deposit catalyst particles like Iron, Nickel, Cobalt etc on substrate materials for the growth of carbon nanotubes.
Centre
Centre for Carbon Materials
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
Nabertherm Box Furnace
Model
LC082X003
Make
Bahnhofstr. 20, Germany
Specifications
- Chamber volume: 8 litre
- Continuous operating temperature: 1450 C
- Maximum temperature: 1500 C
- Heating time to Tmax: 50 min
- Inner chamber dimensions: w170 x d290 x h170mm
- Outer dimensions of furnace: W450 x D620 x H570 mm
- Heating capacity: 13 kW
- Voltage: 400 V Ac / 50 Hz / 3 – phase
- Weight: 40 kg
Details
To anneal samples at high temperatures.
Centre
Centre for Automotive Energy Materials
Nabertherm Muffle Furnace
Model
LT 9/ 11
Make
Bahnhofstr. 20, Germany
Specifications
- Chamber volume: 9 litre
- Continuous operating temperature: 1100 C
- Maximum temperature: 1300 C
- Heating time to Tmax: 75 min
- Chamber dimensions (inches): w9 x d913/64 x h611/16
- Overall dimensions of furnace (inches): W18 x D221/2 x H21
- Heater wattage: 3000
Details
To anneal samples at high temperatures.
Centre
Centre for Automotive Energy Materials
Pilot Plant for the Large Scale Synthesis of Sols
Details
A pilot plant for the synthesis of inorganic and organic-inorganic hybrid sols has been set up. It consists of three reactors of capacities 100 l, 20 l and 10 l with storage vessels of various capacities (from 30 l up to 200 l) attached to the respective reactors. Known quantities of the precursors or reactants can be transferred from the storage vessels into the reactors. Small additions of chemicals can be precisely controlled through suitable dosing systems, provided. The reactors can be operated in the temperature range -5oC to 150oC. The plant is equipped with sophisticated process controls and safety mechanisms for efficiently producing large volumes of sols. The prepared sols can be collected in receivers and transported for coating, curing and densification.Centre
Centre for Sol-Gel Coatings
Planetary Ball Mill
Model & Make
PM 100 CM, RETSCH, Germany
Specifications
- Size reduction principle: Impact, friction
- Material feed size*:< 10 mm
- Final fineness*:< 1 µm, for colloidal grinding < 0.1 µm
- No. of grinding stations:1
- Speed ratio: 1:-1
- Sun wheel speed:100 - 650 min-1
- Effective sun wheel diameter:141 mm
- Grinding jar sizes:12 ml / 25 ml / 50 ml / 80 ml / 125 ml / 250 ml / 500 ml
- Setting of grinding time: 00:00:01 to 99:59:59
Details
Pulverizing, mixing, homogenizing, colloidal milling, mechanical alloying of soft, hard, brittle, fibrous materials (dry or wet)
Centre
Centre for Automotive Energy Materials
Planetary vacuum mixer
Model and Make
- Dual shaft planetary mixer, Gelon LIB Co Ltd. China.
Specifications
- Rotary Speed: 0-800 rpm
- Mixing Container: 150 ml, 500 ml
- Mixing blades: Biaxial planetary stirring
Details
The slurry for lithium-ion battery/supercapacitor electrode coating is prepared by mixing active electrode material, conductive carbon black and a polymer binder in a planetary vacuum mixer to achieve viscous homogenous slurry.
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
Roll-to-Roll Coating Machine
Model and Make
- TOB-SY300J, China
Specifications
- Method: Comma coating method, the machine should be capable of single face continuous and intermittent coating
- Coating line speed: Adjustable upto 2 m/min
- Dryer temperature: RT-150 oC
- Drying method: Hot air circulation with upper and lower double-sided blowing for electrode drying.
- Maximum coating width: 260 mm
- Maximum coating thickness: 400 micron
Details
The roll-to-roll coating machine will be used for coating viscous slurry to make homogenous thickness electrode foils for cell fabrication.
Centre
Centre for Nanomaterials
Scratch Hardness Tester
Details
Used for evaluating the scratch resistance of coatings. Pencil hardness test is an easy and fast method to determine the scratch hardness of coatings on substrates by means of drawing pencil leads of known hardness varying from 9H to 9B at a constant applied mass across the coated surface and is measured according to ASTM norm D 3363-05. The testing unit comprises the body which is the pencil tester, a set of 20 pencils of varying hardness and a special pencil sharpener.
Centre
Centre for Sol-Gel Coatings
Sealing Machine
Model and Make
- TOB-MFK60, China
Specifications
- Sealing parameters: Suitable to seal with cell cases with 60 mm diameter, Height:50-150 mm.
- Capacitor height accuracy after sealing: ±0.05 mm.
- Sealing shell accuracy after sealing: ±0.03 mm
- Capacity: Sealing minimum of 1 cell case/minute
- The sealing result in airtight sealing of the case to prevent electrolyte leakage.
- It provides with a booster cylinder control mould for parallel sealing of the upper and lower moulds to easily form an automation.
Details
The sealing machine is used to seal cylindrical cell cases after grooving with the electrode jelly roll. It is essential for proper sealing of the cell for final testing and usage.
Centre
Centre for Nanomaterials
Semi-Automatic Winding Machine
Model and Make
- TOB-15060YZ, China
Specifications
- Winding unit: cylindrical type
- Needle or Mandrel diameter: 6 mm-60 mm.
- Needle length: 80 mm.
- Automatic winding, automatic needle change, automatic separator cut off, stick termination of tape and blanking is provided.
- Line tension (variable): 0.1 N to 0.7 MPa
- Production rate: 1-2 jelly roles /minute
- Control system: PLC and HMI, servo and stepper motor
Details
This machine will be used for making electrode jelly rolls for making cylindrical type Supercapacitor cells
Centre
Centre for Nanomaterials
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
Spray Pyrolysis System
Model & Make
SM Scientech 2005, Kolkata
Specifications
Water evaporation capability is 20 litres/ hr.
Details
Aqueous solutions (various molarities) of metal nitrate salts along with pre determined quantities of additives is fed via a peristaltic pump and atomized at a particular pressure of compressed clean/dry air is allowed to enter in to a hot zone to under go pyrolysis. The temperature is again a predetermined one for a given composition with the help of thermal analysis.Required temperature in pyrolysing chamber is generated by blowing hot air to have the advantage of cyclonic classification possible for the product powders as a function of their size. Operating parameters for each composition can be stabilized by studying the effect of (solution) feed rate & molarity, pyrolysis temperature and atomizing pressure to achieve the highest yield. Nano powders such as doped/pure ZnO, ZrO2, YSZ, Lanthanum Strontium Manganate-LSM in bulk (kg level) can be synthesized
Centre
Centre for Ceramic Processing
Substrate Cleaning/Pretreatment Facilities
Details
To obtain high quality coatings, high quality substrates that are prepared and cleaned well are the most essential requirements. Presence of dust or grease can adversely affect the uniformity of coatings and their adhesion to the substrates. Defects once introduced during the coating stage are seldom removed by post treatment techniques like curing or annealing. In view of this, the Centre for Sol-Gel Coatings has procured state-of-the-art cleaning equipment suitable for a variety of substrates. EPG, based on prior experience, had made recommendations for upgraded versions of some of the equipment, making this facility at ARCI better than the one at EPG's location at Saarbrucken, Germany.
The cleaning facilities established at the Centre are the following:
Flat glass cleaner
A flat glass cleaner is available for cleaning of glass substrates of varying dimensions. The equipment has a working width of 1300 mm. Typically, the substrate size can vary from 1000 mm long and 1000 mm wide to 300 m long and 250 mm wide. The thickness can be between 1-8 mm and the conveyor speed can be varied from 2-5 m/min. The machine uses demineralized water for cleaning.
Pre-treatment System
Sword Brush Cleaner
This is for cleaning glass, metal or plastic substrates by removal of the fine layer of dust that forms on substrates. The machine can handle substrates with maximum dimensions 1500 mm in length and 1500 mm in width. Minimum dimensions that can be handled are 250 mm x 250 mm and thickness can vary between 2 mm and 50 mm. The conveyor speed can be from 2-7 m/min.
Flat spray unit
Plasma Pre-treatment System
A fully programmable plasma pretreatment unit has been set up for activation of the substrate surfaces. The manipulation of substrate position and substrate handling is made possible by a 6-axis robot. Depending on the nature of the substrate and coating, this technique can be used to improve the adhesion properties of the coating on the substrate. The plasma temperature is approximately 300oC and the substrates can be glasses, metals or plastics. Samples can range from 100-300 mm in length and 100-300 mm in width, depending on the nature and mass of the substrate. Working distance can be varied between 6 and 20 mm.
Ultrasonic Cleaners
Ultrasonic cleaners of capacities 110 and 210 litres have been installed for removal of grease and accumulated dust on the surface of the substrates. Maximum weight of the substrates for the two units are 20 and 40 kg, respectively.
Centre
Centre for Sol-Gel Coatings
Taber Abrasion Tester
Model & Make
Taber Dual Rotary Platform Abrasion Tester model 5155
Specifications
- Abrading wheels- CS-10 calibrase wheels
- Operating loads : either 250 or 500 g
- Speed of the wheels: between 60 and 72 cycles/minute
Details
Used for measuring the abrasion resistance of prepared coatings according to ASTM norm D 4060 - 01. The abrading wheels are resilient wheels that offer a mild-medium abrading action like that of normal handling, cleaning, and polishing. The wheels are refaced periodically with a refacing disc. The abrasion resistance of the coating is quantified by periodically measuring the mass (volume) loss of the coatings or determined qualitatively by the visual end point method.
Centre
Centre for Sol-Gel Coatings
Thermal Evaporation & Deposition System
Model & Make
VR Technologies, Bengaluru
Specifications
- Current : 0-10 A (primary), 0-200A (secondary)
- No. of sources : 2
- Vacuum : 10-6mbar
- Source Materials : Mo, W
Details
For thin film deposition of Metals and Alloys. Equipped with digital thickness monitor, substrate heater and plasma cleaning attachment
Centre
Centre for Automotive Energy Materials
Three-Dimensional (3D) Mixer
Make
- Hexagon Product Development Private Limited, Vadodara, Gujarat.
Model
- ALPHIE-10
Specifications
- Power Supply: 0.5 HP, 220 V
- Gross volume capacity: 10 Litre
- Cage Speed: 10 to 70 rpm adjustable
- Clamping device: Nonmetallic crown with rubber strings
- Speed and time change facility, forward reverse cycle speed provision
- Plug, program and operate hassle-free.
Use
- To thoroughly mix metal, ceramic and alloy powders.
- Inert atmosphere may be used in the cans if required.
Vaccum Filling Machine:
Model and Make
- TOB-ZY60B, China
Specifications
- Parameters: Suitable to seal with cell cases with 60 mm diameter, Height: 50-150 mm.
- Provides two filling stations to fill 2 cells at a time.
- Electrolyte filling capacity: 20 ml-250 ml with automatic injection mechanism.
- Vacuum during electrolyte Injection: 10-3 to 10-4 Kpa.
- The machine is pneumatically controlled.
- The machine is able to work in temperature of 20-30 °C inside a glove box under inert atmosphere.
- The size of electrolyte filling machine provided with a dimension of 1200 mm length, 780 mm depth and 920 mm height inside the glove box.
Details
The vacuum filling machine is used to inject electrolyte into the cylindrical cell cases after sealing and should be operated inside a glove box or in a dry room with less than 1 percentage relative humidity.
Centre
Centre for Nanomaterials