Aerospace
Ultrafine Aluminum Powder for Propellant Applications
Overview
Ultrafine aluminum powder (UFAP) is commonly used in a wide variety of applications like rocket propellant additives, thermite mixtures, paints and hydrogen generation, etc due to its reduced ignition delay and temperature thus leading to complete combustion of particles. Though UFAP can be synthesized by a number of techniques, radio frequency induction plasma (RFIP) offers inherent advantages over other techniques. The purity of the powder is ensured since RFIP setup has no electrodes. The productivity is also reasonably high ~0.5-1 kg/hr, depending upon the material and its feed rate. The precursor powder carried by a carrier gas passes through the injection probe and gets delivered into the plasma chamber. The vaporized precursor is then subjected to a drastic quench as it comes out of plasma chamber.
Key Features
- Ultra fine Al increases burning rates; required for solid or liquid propellant
- Import embargo
- ARCI has got capability to make Al nano powder in kg levels
- Ability to tailor the particle size and its distribution
- Metallic aluminium content as high as 90%
- Predominantly displays an exothermic peak compared to micron sized Al powder
Potential Applications
- Propellant additives for both solid as well as liquid propellants
- Sintering additives
- Coating applications
- Thermite welding applications
- Hydrogen generation
Intellectual Property Development Indices (IPDI) 
- Synthesis of powder at kg levels was demonstrated
- One kg of powder delivered to SF Complex, Jagdalpur, DRDO for field trials
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents
Major Publications
- P.Sai Karthik, S.B. Chandrasekhar, D. Chakravarty, PVV Sriniuvas, VSK. Chakravadhanula, TN Rao, Propellant grade ultrafine aluminium by RF induction plasma, Advanced Powder Technoilogy, 29, 804-12, 2018
Sintered silicon carbide (SiC) components
Overview
Silicon carbide (SiC) is one of the most attractive ceramic materials because of its excellent mechanical properties such as high strength, moderate toughness, and high wear and oxidation resistance, and strength retention at elevated temperature. ARCI has the expertise to manufacture SiC parts with various size and shapes by pressureless sintering using solid-state or liquid phase sintering additives and also by hot pressing technique. SiC parts of complex geometry can also be manufactured through machining at the green stage using 5-axis CNC machine. Dimensional accuracy can also be achieved on sintered SiC parts by final shaping with the help of sophisticated ultrasonic machining.
Key Features
- Tuneable density and other thermo-mechanical properties.
- Flexibility in producing SiC parts incorporating solid-state or liquid phase sintering additives.
- Capable to produce SiC components up to 750 mm diameter.
- SiC parts with critical can be manufactured.
Potential Applications
- Mechanical seals particularly for corrosive environment.
- Impact and abrasion resistance parts.
- Light-weight structural parts for aerospace applications.
- Impact and wear resistant parts.
Intellectual Property Development Indices (IPDI)
- The technology has been validated for production of various size and shape SiC parts by pressureless sintering and available for technology transfer.
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents
Major Publications
- P. Barick, D. C. Jana and B.P. Saha, Load-dependent indentation behaviour of βSiAlON and αSilicon carbide, Journal of Advanced Ceramics, 2, (2013), 185192.
- S. V. A. Raj, D. C. Jana, P. Barick and B. P. Saha, Microstructure Evolution in Densification of SiC Ceramics by Aluminium Vapour Infiltration and Investigation of Mechanical Properties, Ceram. Inter., 44 (2018), 9221-9226
- D. C. Jana, P. Barick and B. P. Saha, Effect of Sintering Temperature on Density and Mechanical Properties of Solid-State Sintered Silicon Carbide Ceramics and Evaluation of Failure Origin, J. Mater. Eng. Perform., 27 (2018), 2960-2966.
- D. C. Jana, G. Sundararajan and K. Chattopadhyay, Effective activation energy for the solid-state sintering of silicon carbide ceramics, Met. Mater. Trans. A, Vol 49 A (2018), 5599-5606.
Nanocomposites electrode for hybrid supercapacitor with quick-burst energy release
Overview
For last few decades, the rapid growth in the manufacturing sector for sustainable global economy has increased the demand for energy consumption. The energy generation is mainly relying on conventional energy sources. The depletion of fossil fuels, global warming and environmental-friendly energy sources prompted the development of efficient energy storage and conversion technologies. Now a day, ultracapacitors, a category of energy storage appliance which can bridge the gap between conventional capacitor and electrochemical batteries are widely studied to serve as one of the promising candidate for next generation energy storage devices owing to their exceptional characteristics like high power density, fast charge/discharge process and long cycle life. Among all, nanocarbon materials (carbon nanotubes, graphene, carbon sphere etc) are extremely explored as electrode material due to their intriguing thermal, electrical, mechanical and chemical properties. Our technology demonstrates the development of high performance nanoelectrode for hybrid supercapcitor based on nanoscaled-carbon integrated with electroactive oxide/sulphide and conducting polymers.
Key Features
- Facile synthesis of nanoscaled-carbon with surface modification
- Activated porous graphene with tailored pore size distribution
- Shape-tailored metal oxide/sulphide with controllable surface area
- Hybridizing nanocarbon with oxide/sulphide or conducting polymer
- High power density with moderate energy density and multifunctionality
- All-solid-state supercapacitor
- Scalable preparation process
Potential Applications
- Aerospace
- Defence
- Automobiles
- Power grid system
- Consumer electronics
- Tools
Intellectual Property Development Indices (IPDI)
- Nanocomposites for electrode preparation are fabricated
- A prototype all-solid-state supercapacitor is developed
- Development of multifunctional supercapacitor is underway
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Magnetorheological finishing polishing – initiated
Overview
content will be posted soon...
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents
Major Publications
Low expanding glass ceramics – initiated
Overview
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents
Major Publications
Powders for Additive Manufacturing
Overview
Additive manufacturing (AM) is fast emerging as a key manufacturing process to produce near-net shaped metallic components, where three dimensional components are built by adding the material layer by layer. While it is universally acknowledged that the quality of final AM component depends on the quality of the metallic powder that one starts with, the specific attributes of this powder quality are not understood. Additionally, the process yields in manufacturing of metallic powders for AM are generally very low (<20%). At present nickel-based superalloy powders (IN718, IN625 and CM247LC) for AM are being produced by a few reputed companies from USA, Switzerland, Germany, Canada and UK. However, each company produces its own tailor made powders with a given process. ARCI, having the state of the art inert gas atomiser facility is in the process of developing powders for AM.
Key Features
- Ease of manufacture of near-net shaped components by AM using powders
- Powder requirements are currently being met by imports and are expensive
- At present, there are no manufacturers of gas atomized powders in general, and Ni based superalloy powders, in particular, in India.
- Make in India
Potential Applications
- Aerospace
- Defence
- Biomedica
- Automobile
Intellectual Property Development Indices (IPDI)
- Synthesis of powder (at 10 kg levels were demonstrated)
- Powders are undergoing trials on AM studies
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents
Major Publications
Functionally graded dental implants by SPS
Overview
Titanium and its alloys are the most commonly used materials for dental implants. Although the biological performance of these alloys are extremely good, there are potential immunologic and aesthetic compromises with titanium implants. The material currently explored to replace titanium alloys is yttria-stabilized zirconia (YSZ) due to its tooth-like colour, hardness, toughness, corrosion resistance and osseointegration. However, the lack of long-term stability of YSZ in presence of body fluid is a major disadvantage. Hydroxyapatite (HA) is another material having extremely good biocompatibility and osseointegration but possess extremely poor mechanical properties. To achieve the benefits of each of these materials and nullify their drawbacks, it is envisaged to develop functionally graded materials (FGM) of Ti-alloy/zirconia, zirconia-HA and HA/Ti-alloy using the spark plasma sintering (SPS) process. Their physical and mechanical properties, microstructure analysis and in-vitro biocompatibility tests will be carried out to investigate the feasibility of each of these FGMs as possible dental implants by comparing their performance with existing commercial implants.
Key Features
- A simple PM process to fabricate metal-ceramic FGMs in one step to be explored for the first time
- FGMs are difficult to fabricate due to failures at the interfaces and mismatch in physical properties of the constituent materials; SPS process is expected to overcome these fallacies
- Developing new implant materials from FGMs is a new concept
Potential Applications
- Dental implants having mechanical properties and biological performance similar to or better than existing implants
Intellectual Property Development Indices (IPDI)
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents
Major Publications
Laser Hybrid Welding of Nickel based super alloys
Overview
Research to increase the efficiency of conventional fossil power plants by increasing the steam temperature and pressure has been pursued worldwide. The need to reduce CO2 emission has recently provided an additional incentive to increase efficiency. The main enabling technology in achieving the above goals has been the development of stronger high temperature materials. Solid solution and carbide strengthened Nickel based super alloys have been identified as candidate materials for Advanced ultra-supercritical (AUSC) boilers capable of operating with 760oC, 35Mpa steam. Laser hybrid welding is one of the potential fusion joining techniques developed for these alloys. Deep penetration capability of laser and edge bridgability of arc process enables processing of defect free joints at higher speed with acceptable mechanical properties. Laser hybrid welding process is AMSE coded and validated process.
Key Features
- Demonstrated laser hybrid weldability of 10mm thick Plates and Tubes at coupon level.
- Defect free hybrid welds with minimal HAZ liquation.
- 100% joint efficiency.
Potential Applications
- Power sector
- Aerospace
- Nuclear
Intellectual Property Development Indices (IPDI)
- Performance and stability are validated at coupon level
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Laser Welding of Titanium alloy Ti-6Al-4V
Overview
Due to high reactivity of titanium, especially at elevated temperatures, it reacts strongly with most atmospheric elements like, oxygen, hydrogen, nitrogen, etc. and gets embrittled readily. Hence, elaborate shielding arrangements are required while welding and often electron beam welding is preferred as it is done in vacuum. Laser Welding with simple and effective shielding arrangement has been proven to be techno-commercially feasible joining technique as compared to Electron Beam Welding.
Key Features
- Localised inert gas shielding set up.
- Welded joint made with square and lip joint configuration on 4mm thick sheets with 100% joint efficiency.
Potential Applications
- Aerospace •
- Chemical industry
- Medical industry
Intellectual Property Development Indices (IPDI)
- Performance and stability are validated at coupon level
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Abrasion Resistant, Hydrophobic Coatings on Carbon-Epoxy Composites (CEC)
Overview
Carbon epoxy composites (CEC) have excellent advantages such as lightweight, high strength and weathering resistance when compared to aluminum alloys and high-grade steels. Moreover, body parts made of CEC when used for aerospace applications can be tailor-made with limited number of joints. But CEC are poor in abrasion and erosion resistance and degrade when contacted with hydraulic fluids such as water or any oil. Sol-gel formulations developed by ARCI when deposited on CEC were found to substantially improve scratch/abrasion resistance. Transparent or coloured abrasion resistant, hydrophobic coatings on polyurethane painted carbon-epoxy composite coupons could be generated using UV polymerizable silanes and their performance was found to be promising for aerospace applications. The developed coating technology was found to be amenable for scale-up and automation.
Key Features
- Eco-friendly
- Durability of hydrophobicity and abrasion resistance
- Amenable to coat large areas with easy automation
- Good adhesion to the substrate materials
- Can be applied as bond coat to promote adhesion with paints
- Can be made as coloured coatings
Potential Applications
- Automobile components
- Aerospace components
- Communication gadgets
Intellectual Property Development Indices (IPDI)
- Performance and stability validated at laboratory scale
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents
- An improved abrasion resistant and hydrophobic composition for coating plastic surfaces and a process for its preparation, Indian Patent application number 1278/ DEL/ 2011 dtd 02-05-11
