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NATIONAL METALLURGICAL LABORATORY

Metallurgy group is actively involved in research and development in the areas of process modeling and failure analysis apart from a variety of other testing and consultancy services.

R&D Services :

q Failure analysis of industrial components

The question such as failure analysis is vital to identify the cause of the failures. Was the failure caused by an application problem? A design problem? A process problem? A mechanical problem? Materials? A quality issue associated with component manufacturing? Or is the failure an end of life wears out mechanism?

National Metallurgical Laboratory Madras Centre provides fast, accurate and affordable failure analysis to a wide range of industries - from underground mines to advanced spacecraft. NML equipped modern state-of-the-art facility to perform failure analysis.

Our expertise includes the following areas:

POWER GENERATION COMPONENTS (BOILER TUBE ASSESSMENT) (POWER PLANT FAILURE ANALYSIS EXPERTISE)
CEMENT MANUFACTURING COMPONENTS
AEROSPACE AND COMMERICAL PRODUCTS
STRUCTURAL COMPONENTS
MARINE PRODUCTS
PETROLEUM/OIL INDUSTRY HARDWARE
CASTINGS, FORGINGS, EXTRUSIONS, AND MACHINED PRODUCTS
HEAT TREATED AND SURFACE COATED PRODUCTS
WELDED PRODUCTS
ROTATING OR RECIPROCATING COMPONENTS
COMPOSITE & MEDICAL DEVICES

The possible failure mechanisms are:

- Corrosion	- Liquid Metal Embrittlement
- Ductile and Brittle Fractures	- Marine Corrosion
- Ductile and Brittle Fractures	- Pitting Corrosion
- Fatigue	- Stress Corrosion Cracking
- Galvanic Corrosion	- Uniform Corrosion
- Hydrogen Embrittlement	- Wear Fractures
- Intergranular Corrosion

List of recent projects completed :

Sl. No	DESCRIPTION
1	Report on the Analysis of Fireside Corrosion of Boiler Tubes In The Waste Heat Recovery Boiler At NTPC, Dadri
2	Failure Analysis of a Waterwall Tube From Tuticorin Thermal Power Station
3	Test Report on Failed Pieces of B1 Type H.T.Bolt of En19 Grade
4	Analysis of Frequent Failures of Platform Hangers
5	Analysis of Tube Failure in A Thermic Fluid Heater
6	Analysis of Frequent Failures of ERW Steel Pipes While Thread Rolling
7	Failure Analysis of Carbon Spring Steel Platform Hangers
8	Failure Analysis of Economizer And Primary Super Heater Tubes
9	Failure analysis of final superheater boiler tubes and turbine blades
10	Failure Analysis of LP Rotor Turbine Blades of Stage 3A From 60MW Ennore Thermal Power Station
11	Failure Analysis of Boiler Water Tubes Of 1�63 MW Tuticorin Thermal Power Plant
12	Failure Analysis on High Pressure Heater Tube of Unit 12�210 MW Neyveli Lignite Power Station
13	Failure Analysis on Condenser Tube of Thirumakottai Gas Turbine Power Station
14	Failure analysis of economizer tubes from coal based Thermal Power Plant
15	Analysis of failure of an underground water pipeline at TIDEL Software Park, Chennai
16	Failure analysis of tie rods and screw conveyor in a failed injection moulding machine sponsored
17	Mitigation of fireside corrosion of air pre-heater tubes at SLPP, Gujarat
18	Failure of an idle air control valve in a gasoline-fuelled automobile

LIST OF CLIENTS CASE STUDIES IN FAILURE ANALYSIS

Prevention:
Our Scientists can, not only establish failure mechanism, but also suggest prevention measures to reduce the probability of a recurrence of the failure. Scientific failure analysis methods, including traditional tools such as root cause analysis are adopted.

Testing Service :

Testing hardness of materials on Vickers, Brinell and Rockwell scales

Micro and macro hardness testing of metals and alloys

Microscopic characterization of materials

Assistance to Dept. of Customs and Directorate of Revenue Intelligence in providing technical evaluation and standardization of materials on metallurgical import consignments at the ports of Chennai, Pondicherry, Mumbai and Tuticorin etc.

Calibration Services :

On site verification of hardness testing machines

Major facilities :

Leica DMLM Metallurgical Microscope with MPS 30 PHOTO AUTOMAT
Leica Qwin Image Analyzer
Leica VMHTMOT Microhardness tester
Digital Rockwell test machine (INDENTEC 2002, UK)
Digital Vickers test machine (INDENTEC 2002, UK)
Epstein Tester for core loss measurement
Complete range of metallographic sample preparation equipment
Modular compact Rheometer-MCR 101 (Anton Paar, Germany)
High Temperature Chamber Furnace-HT 1800 (Linn High Therm GmbH, Germany)
High mass-high volume Thermogravimetric Analyser (Thermo Cahn, USA)

TILE TESTING :

The tiles testing section of NML-MC has the facilities for testing and evaluation of cement tiles, ceramic tiles, concrete pavement blocks, concrete cubes, granites, marbles etc. as per Indian Standards
	Testing Services Abrasion resistance Water absorption Flexural strength Compressive strength Flatness Bulk density Apparent porosity Apparent specific gravity
Major Facilities Automatic Compression Testing Machine (2000 KN) Manual compression testing machine (1000 KN) Automatic Flexural Testing Machine (100 KN) Manual flexural testing machine (100 KN) Abrasion Testing Machine Digital sieve shaker (wet and dry) Tiles making machine Portable skid resistance meter Fade-O-Meter � light fastener tester
*Tests:* a. Water absorption b. Compressive strength (upto 2000 kN) c. Abrasion/wear resistance (0.01 to 25 mm) d. Flexural / Wet transverse strength (upto 100 kN) e. Flatness f. Bulk density g. Apparent porosity h. Apparent specific gravity o Above tests are done as per IS standards o No. of specimens/sample per test required:6 nos. Minimum specimen tile/block size for flexural strength/wet transverse strength: 250 mm x 250 mm x 10 mm.

BACK

Contact us
Dr. S. Srikanth Director NATIONAL METALLURGICAL LABORATORY (Council of Scientific & Industrial Research) JAMESHEDPUR 831 007 Phone: (0657) 2271715, 2270092, 2271709-14 (PBX) Fax: (0657) 2270527, 2271251, 2271159 Email: director[at]nmlindia[dot]org, Website: www[dot]nmlindia[dot]org	Dr. G. Bhaskar Raju Scientist-In-Charge NML Madras Centre, CSIR Madras Complex Taramani, CHENNAI 600 113 Ph: 044 2254 2077, 2254 2529, 2254 2523, Fax: 044 2254 1027 Email: sicnml[at]csircmc[dot]res[dot]in Working hours: 9.00 am to 5.30 pm (Monday to Friday, except Govt. holidays)

Analysis of failure of an underground water pipeline at TIDEL Software Park, Chennai