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Nayak, Jagannath
- Microwave Sintering: An Energy Efficient Process for Sintering Aluminium Metal Powder
Authors
1 Training Division, Central Power Research Institute, Bangalore-560 080, IN
2 Department of MME, National Institute of Technology-Karnataka, Surathkal-575025, IN
Source
Power Research, Vol 12, No 2 (2016), Pagination: 381-394Abstract
Microwave sintering process is quite significant and unique in recent times for sintering material for densification because of its intrinsic advantages such as rapid heating rates, reduced processing times, uniform temperatures with minimal thermal gradients. Microwave sintering process leads to substantial energy savings with higher efficiency, improved properties, finer microstructures, environmental friendly process and with less environmental hazards. The concept of sintering metals in microwave has been attempted by many researcher. Though metals are known to reflect microwave radiation, researchers have confirmed sintering of metas in powder form through microwave. In this study, sintering of aluminium metal powder through microwave route has been attempted. The study indicated that aluminium metal powder compacts sintered through microwave process showed better physical, tribological and thermal properties compared to the ones sintered through conventional sintering methods.Keywords
Microwave, Sintering, Aluminium Powder, Sintering Ceramic, Tribological Properties
- A Study on the Mechanical Behaviour of Microwave Sintered Aluminium Cenospheres Based Syntacticfoams
Authors
1 TrainingDivision, CentralPower ResearchInstitute, Bangalore-560 080, IN
2 Department of Mechanical Engineering, RV College of Engineering, Bangalore-560 059, IN
3 Director (Retd.),Central Power Research Institute, Bangalore-560080, IN
4 Department of MME, National Institute of Technology, Karnataka, Surathkal-575025, IN
Source
Power Research, Vol 12, No 2 (2016), Pagination: 395-408Abstract
Aluminium Syntactic Foams(ASF) are metallic foam material that are of great interest to the automobile manufacturers for their light weight coupled with tailorable engineering properties. Sufficient studies have been carried out on development of aluminium cenospheres based light weight syntactic foams which are fabricated through stir casting and melt infiltration techniques but it is seen from the literature that the synthesis of Aluminium Cenospheres metal foams fabricated through Powder Metallurgy (PM) route and densification through Microwave Sintering (MWS) has been less studied.
In this context, ASFs comprising of Aluminium metal matrix embedded with fly lsh cenospheres particulates have been fabricated through Powder Metallurgy (PM) route and sintered through Microwave (MW) sintering process at a temperature of 665° C. Cenospheres ranging from 0 to 50 volume%have been incorporated in the mix. The sintered ASF has been taken up for characterization for the mechanical properties such as Compression and Flexural strength. The compression test samples have also been taken up for Finite Elemental Analysis (FEA) and the Flexural Strength tested samples have been studied for fractography using scanning Electron Microscope (SEM). There sultso btained have been compared with aluminium cenospheres foamsthatwere sintered through conventional sintering process at the same temperature in electrical resistance furnace. Microwave sintered samples have shown better mechanical properties compared to the conventionally sinteredones. The study has been conducted to assess the suitability of using these ‘Syntactic Foams’ material for applications in automotives and other engineering applications.
Keywords
Cenosphere , microwave sintering, aluminum metal matrix composite, powder metallurgy, syntactic metallic foams- Fly Ash Cenospheres – A Resourceful Material for Engineering Applications
Authors
1 Materials Technology Division, Central Power Research Institute, Bengaluru - 560080, IN
2 Department of Metallurgical and Materials Engineering, National Institute of Technology Karnataka, Surathkal - 575025, IN
Source
Power Research, Vol 11, No 1 (2015), Pagination: 207-222Abstract
In India, about 60% of the total power generation comes from thermal power stations operating on fossil fuels like coal and lignite [1]. Presently about 400 million tons of coal and lignite is consumed annually for power generation. Typically, Indian coals have an average ash content of about 45%, thereby leading to generation of around 180 million tons of ash annually as an industrial by product.
Out of the total ash generated, 70 % of this ash comprises of fly ash and the remaining are bottom ash, economizer ash, air-preheater ash, etc. Presently, dry fly ash is being utilized in a big way in value added products like bricks, blocks, pavers, etc., while bulk volumes of fly ash is consumed in blended cement manufacture, different types of concrete, construction of dams, roads, river embankments, etc.
Fly ash also contains about 1.0 % hollow particles called as ‘Cenospheres’ generated during combustion of the pulverized coal at high temperatures in the thermal power plant boilers. Cenospheres is a useful by-product of coal combustion which can be harvested from the ash ponds or by any other methods such as tribo-electric separation, slurry precipitation, pond skimming etc., from fly ash. Fly ash cenospheres are unique in the way that they possess excellent properties such as lightweight, low density, nonmetallic, high melting points. These unique properties make cenospheres a prospective raw material to produce value added products for use in engineering applications. The paper discusses the work carried out at Central Power Research Institute on cenospheres characterization and development of value added products for various applications.
Keywords
Fly Ash Cenospheres, Microspheres, Ash Pond, Alumino-silicate, Comprehensive Characterization, Engineering Applications- A Study on the Physical and Morphological Characteristics of Aluminum Cenosphere Composite Sintered at High Temperature in Microwave
Authors
1 Materials Technology Division, Central Power Research Institute, Bangalore 560 080, IN
2 Department of MME, National Institute of Technology-Karnataka, Surathkal- 575 025, IN