Internship Report Dhairya Tiwari 190093119042 Main

/
HEAT TREATMENT AND STACKING OF PARTS OF PINAKA
A PROJECT/ INTERNSHIP REPORT
Submitted by:
Mr. Dhairya Sanjay Tiwari
(190093119042)
In partial fulfilment for the award of the degree of

Bachelor of Engineering
in
Mechanical Engineering
C.K. PITHAWALA COLLEGE OF ENGINEERING

&TECHNOLOGY, SURAT
GUJARAT TECHNOLOGICAL UNIVERSITY

Chandkheda, Ahmedabad Affiliated
APRIL 2022
Project ID-
C.K. Pithawala College of Engineering and Technology,

Near Malvan mandir via magdalla port, Dumas Road, Surat
CERTIFICATE
Date:
This is to certify that the internship report submitted along with the project
entitled Heat Treatment and Stacking of Parts of Pinaka has been
carried out by Mr. Dhairya Sanjay Tiwari (190093119042) under my
guidance in partial fulfilment of the degree of Bachelor of Engineering in
Mechanical (8th semester) of Gujarat Technological University,
Ahmedabad during the academic year 2021-22
DR. KALPESH D MANIYA DR. KALPESH D MANIYA

(Internal Guide) (Head of the department)
Gujarat Technological Univesity Page ii

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Gujarat Technological Univesity Page iii

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C.K. PITHAWALA COLLEGE OF ENGINEERING AND

TECHNOLOGY,
Near Malvan mandir via magdalla port, Dumas Road, Surat
DECLARATION
We hereby declare that the internship report submitted along with the internship entitled
Project Management Report submitted in partial fulfilment for the degree of Bachelor of
Engineering in Mechanical to Gujarat Technological University, Ahmedabad, is a
Bonafide record of original project work carried out by me at Larsen and Toubro
Limited Defence IC under the supervision of Mr. J. Harikrishnan and that no part of this
report has been has been directly copied from any student’s report or taken from any
other sources, without providing due reference.
Name of Student Signature of Student
Gujarat Technological Univesity Page iv

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ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of any task would be
incomplete without the mention of people whose ceaseless corporation made it possible,
whose constant guidance and encouragement grown all effort with success.
Our sincere thanks to our External Guide –J Harikrishnan, Manish Rana, Faculty Guide
-Prof. Dr. Kalpesh D Maniya and HOD – Prof. Dr. Kalpesh D Maniya for providing
valuable guidance throughout our internship. Whenever we were confused about anything,
they were always there to help us.
We are thankful to Gujarat Technological University to giving the opportunity for assigning
this Internship work.
Gujarat Technological Univesity Page v

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ABSTRACT
The main objective of this internship was to get clear overview and experience of
Industrial work and safety protocol used in Industries. And I have gained
knowledge of parts of Pinaka launcher, design of stacking of Underframe
(part of Pinaka) and Heat treatment process for all the parts structure. Also
gained Knowledge about basic welding and Robotic welding.
Gujarat Technological Univesity Page vi

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List of Figures
Figure 1.1 Armoured system complex.............................................20
Figure 2.1 ISO 9001:2015.................................................................21
Figure 2.2 ISO 14001:2015..............................................................22
Figure 2.3 AS 9100D........................................................................23
Figure 2.4 OHSAS 45001:2018........................................................24
Figure 3.1 Report safety concern.....................................................25
Figure 3.2 Safety Shoes...................................................................26
Figure 3.3 safety Helmet..................................................................26
Figure 3.4 safety goggles...................................................................26
Figure 3.5 Boiler suit........................................................................26
Figure 3.6 Full body harness...........................................................27
Figure 3.7 gloves...............................................................................27
Figure 3.8 hearing protection..........................................................27
Figure 5.1 Pinaka missile.................................................................28
Figure 5.2 Cradle structure..............................................................29
Figure 6.1 Fabrication shop.............................................................31
Figure 6.2 Machining shop...............................................................31
Figure 6.3 Wielding shop..................................................................32
Figure 6.4 Heat Treatment Shop.....................................................32

Gujarat Technological Univesity Page 1
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Figure 6.5 Quality Control................................................................33
Figure 6.6 Testing Lab.....................................................................33
Figure 6.7 blasting shop....................................................................34
Figure 6.9 integration shop...............................................................34
Figure 6.10 finance and accounting.................................................35
Figure 6.11 store................................................................................35
Figure 7.1 Bill of material.................................................................36
Figure 8.1 SA516-GR70...................................................................37
Figure 8.2 A333GR6.........................................................................38
Figure 8.3 A106GRB........................................................................38
Figure 8.4 SA350LF2CL1...................................................................................................39
Figure 9.1.1 Visual Testing..............................................................41
Figure 9.1.2 Magnetic Particle Test.................................................42
Figure 9.1.3 Liquid Penetrant Test...................................................43
Figure 9.1.4 Radiographic Test.........................................................44
Figure 9.1.5 Ultrasonic Test.............................................................45
Figure 9.2.1 Impact Test...................................................................46
Figure 9.2.2 Bending Test...............................................................47
Figure 9.2.3 Ultimate Tensile Strength.............................................48
Figure 10.1 Nesting..........................................................................49

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Figure 11.1 Laser Cutting.................................................................51
Figure 11.2 Waterjet Cutting............................................................53
Figure 12 Plate Cutting Layout.........................................................58
Figure 13.1 Mig Welding...................................................................60
Figure 13.2 Tig Welding...................................................................62
Figure 13.3 Arc Welding...................................................................64
Figure 13.4 Spot Welding..................................................................66
Figure 14.6 Time Temperature Graph..............................................71
Figure 14.7 Thermocouple................................................................74
Figure 15 Heat Treatment Request..................................................75
Figure 16.1 Drilling Machine.............................................................76
Figure 16.2 Drilling.............................................................................78
Figure 16.3 Reaming.......................................................................79
Figure 17.1 Sand Blasting Machine.................................................80
Figure 18 Coating.............................................................................83
Figure 19 Painting............................................................................86
Figure 20 Packaging........................................................................88
Figure 21 Stacking............................................................................89

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List Of Tables
Table 5.1 Specifications of Pinaka Launcher..............................................29
Table 8.1 SA516-GR70....................................................................................37
Table 8.2 IS2062..............................................................................................37
Table 8.3 A333 GR6.........................................................................................38
Table 8.4 A106 GRB.......................................................................................38
Table 8.5 IS4923...............................................................................................39
Table 8.6 SA350LF2CL1..........................................................................................................................39
Table 8.7 Procedure for Project Management Group.................................40
Table 9.1 Various Material Testing Methods................................................41
Table 12 Plate Cutting Layout (PCL)............................................................57
Table 13 Welding...............................................................................................58
Table 14.3 PWHT cycle...................................................................................67
Table 14.8 K type Thermocouples..................................................................69

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Contents
ACKNOWLEDGEMENT................................................................................................................................5
ABSTRACT.......................................................................................................................................................5
List of Figures....................................................................................................................................................6
1 ABOUT COMPANY 17
1.1 About history of Larsen and Toubro limited........................................................................................17
1.2 About L & T services...............................................................................................................................18
1.3 About L & T Hazira................................................................................................................................19
1.4 About L & T Defence...............................................................................................................................19
1.5 Hazira location advantages.....................................................................................................................20
2.ISO Achievements 2.1 ISO 9001:2015........................................................................................................20
FIG 2.1 ISO 9001 2015....................................................................................................................................21
2.2 ISO 14001:2015..........................................................................................................................................21
2.3 AS 9100.......................................................................................................................................................22
2.4 OHSAS 45001:2018...................................................................................................................................23
3.Safety Training.............................................................................................................................................25
3.2 Basic safety rules and regulations:.........................................................................................................25
3.3 RSC (Report safety concern)..................................................................................................................25
3.4 Importance of PPE (PERSONAL PROTECTIVE EQUIPMENTS)..................................................25
3.5 Various PPE’S..........................................................................................................................................26
4.Roles and responsibilities.............................................................................................................................27

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5.About PINAKA.............................................................................................................................................28
5.1 Specifications of PINAK A LAUNCHER...............................................................................................29
5.3 Parts of PINAKA LAUNCHER are as listed below:............................................................................30
6. Various shops and departments. 31
6.1 Fabrication Shop......................................................................................................................................31
6.7 Blasting Shop............................................................................................................................................33
6.10 Finance and Accounting.........................................................................................................................34
8. Standard of materials: and its properties 37
8.1 SA516-GR70...............................................................................................................................................37
8.3 A333 GR6...................................................................................................................................................37
8.4 A106 GR B.................................................................................................................................................38
8.5 IS 4923........................................................................................................................................................39
8.6 SA 350 LF2 CL1........................................................................................................................................39
9. Various material testing methods 40
9.1.1 Visual testing: Definition:....................................................................................................................41
9.1.2 Magnetic particle test..........................................................................................................................42
FIG 9.1.2 MAGNETIC PARTICLE TEST...................................................................................................42
Description:......................................................................................................................................................42
Procedure:........................................................................................................................................................42
9.1.3 Liquid penetrant test...........................................................................................................................43
FIG 9.1.3 LIQUID PENETRATION TEST..................................................................................................43
Description:......................................................................................................................................................43
Procedure:........................................................................................................................................................43
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9.1.4 RADIOGRAPHIC TEST....................................................................................................................44
Description:......................................................................................................................................................44
9.1.5 Ultrasonic test.......................................................................................................................................45
FIG 9.1.5 ULTRASONIC TEST....................................................................................................................45
Procedure:........................................................................................................................................................45
9.2 Destructive test.........................................................................................................................................46
Definition:.........................................................................................................................................................46
9.2.2 BENDING TEST..................................................................................................................................47
9.2.3 Ultimate tensile strength......................................................................................................................48
10.2 Considerations..........................................................................................................................................50
11. About various cutting machines 50
 LASER CUTTING.......................................................................................................................................51
11.1 Laser cutting 51
11.1.1 Method..............................................................................................................................................52
11.1.2 Vaporization cutting........................................................................................................................52
11.1.3 Melt and blow...................................................................................................................................52
11.1.4 Thermal stress cracking..................................................................................................................52
11.1.5 Stealth dicing of silicon wafers........................................................................................................52
 Reactive cutting........................................................................................................................................53
11.2 Waterjet cutting 53
11.2.1 Operation..........................................................................................................................................54
11.2.2 PROCESS.........................................................................................................................................54

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11.3 Gas cutting 55
11.3.1 Process 55
11.3.2 Conditions 55
12. Plate cutting layout(PCL) 57
13. Welding 58
● Procedure:.....................................................................................................................................................59
13.2 Tig welding...............................................................................................................................................61
Procedure-........................................................................................................................................................61
13.3 Arc welding...............................................................................................................................................62
Operation.........................................................................................................................................................62
 Arc Weld Disadvantages..............................................................................................................................63
Advantages:......................................................................................................................................................63
Disadvantages:.................................................................................................................................................64
Objective-.........................................................................................................................................................65
Procedure.........................................................................................................................................................65
14. ABOUT POST WELD HEAT TREATMENT 67
14.1 Scope..........................................................................................................................................................67
14.2 Material of construction..........................................................................................................................67
14.3 Following cycle shall be followed for PWHT........................................................................................67
14.4 Equipment................................................................................................................................................68
14.5 Thermocouple location............................................................................................................................68
14.6 Time-Temperature recording.................................................................................................................68

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14.7 Component................................................................................................................................................69
14.8 K type thermocouples..........................................................................................................................69
14.9 What is a Thermocouple?.......................................................................................................................69
How Do Thermocouples Work?.....................................................................................................................70
What Are K Thermocouples Used for?.........................................................................................................70
14.10 CAPACITOR DICHARGE WELDING............................................................................................71

WHAT IS STUD WELDING?.....................................................................................................................71
TYPES OF STUD WELDING.......................................................................................................................71
INTRODUCTION TO CAPACITOR DISCHARGE STUD WELDING.................................................72
14.11 ADVANTAGES OF CAPACITOR DISCHARGE STUD WELDING..........................................72
CD Stud Welding is used in the following products.................................................................................72
15. Various documents for heat treatment 75
● HTR (Heat Treatment Request).................................................................................................................75
 MTR (Material Transfer Request).........................................................................................................75
16. VARIOUS MACHINING PROCESS 75
1. Radial Drilling Machine.............................................................................................................................76
Working Principle of Radial Drilling Machine:...........................................................................................77
Construction of Radial Drilling Machine:....................................................................................................77
 16.2 DRILLING.......................................................................................................................................78
 16.3 REAMING........................................................................................................................................78
17. SAND BLASTING 80
17.1 Definition: 80
17.2 Description:..............................................................................................................................................80

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Procedure:........................................................................................................................................................80
18. COATING 82
Definition: 82
19. PAINTING 84
19.1 Description: 84
19.2 Procedure:................................................................................................................................................84
20. STACKING & PACKAGING 86
21. General Stacking Points 87
22. PACKAGING 88
Definition 88
23. STACKING 89
Definition 89

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1 ABOUT COMPANY
1.1 About history of Larsen and Toubro limited
What began in 1938 with two Danish engineers and a dream is today India’s largest multi–
dimensional engineering and Construction Company.
In 1938, Henning Holck Larsen and Soren K. Toubro set up a partnership in a small office in
downtown Mumbai (then Bombay). The company began as a representative of Danish
manufacturers of dairy and allied equipment’s.
A year later, when World War II broke out, the fledging Company’s genius for innovation
came to the floor. It began to make the products it used to import.
In 1945, L&T appointed dealer of Caterpillar, the American earthmoving machinery giant.
In 1946, the firm became a limited company, and soon a nationwide network of office was
set up. The wheels of growth, which would propel the company to its position of distinction,
had been set into motion, and long before mission statements became industry buzzwords,
L&T had set out a charter for itself, the company would meet the needs of India’s emerging
core sector. Side by side, the business philosophy laid emphasis on customer service.
‘In Service Life Success’ was enshrined as a corporate motto. L&T steadily climbed the list
of the top 200 Indian companies – from 72 in 1966 to 25 in 1973. By then, it had developed
a vast repertoire of skills and a reputation for high quality goods and services.
Over the years, this partnership firm started growing, driven by the vision of its founders. It
converted into a private limited company in 1946 and later acquired the status of a ‘limited’
company in 1950

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1.2 About L & T services
● Power generation
● Infrastructure
● Construction
● Heavy Industry
● IT Services
● Financial Services
● Shipbuilding
● Real Estate
● Defence
L&T distribution and service outreach underlines its strong customer orientation. The network
extends to virtually in the country. Business activities organized under four self-reliant
Strategic Business Units (SBU’s), each specializing in the different products lines. They meet
the needs of vital industries: chemical, petrochemical, refinery, fertilizer, oil and gas, power,
steel and manmade fiber. Plant and equipment designed and manufactured to customers’
specifications and various international codes.
As of 2020, L&T group comprises 118 subsidiaries, 6 associates, 25 joint venture and 35 joint
operations companies, operating across basic and heavy engineering, construction,
manufacturing of capital goods, information technology and financial services.

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1.3 About L & T Hazira
L&T’s Hazira campus is a multi-facility campus that covers a Modular Fabrication Facility
(MFF), as well as Heavy Engineering, Defence & Shipbuilding, and Power equipment
manufacturing facilities. This modern, coastal complex is situated on a vast plot near Surat in
Gujarat. The factory buildings cover over 34,500 sq. m. and the complex has a load-out quay
on the banks of the river Tapi close to the Arabian Sea.
Hazira campus is equipped to manufacture extra-large and very heavy equipment for power
projects, chemical, refinery, petrochemical & fertilizer industries, which can be shipped out via
waterways.
The Modular Fabrication Facility (MFF) at Hazira, one of the largest of its kind in South Asia,
is capable of manufacturing several large modules simultaneously with an annual fabrication
capacity of 50,000 MT.
In addition, L&T’s Hazira complex has one of the world’s largest Forging facilities, large scale
Material handling capabilities, a roll-on-roll-off slipway, and a Shipbuilding facility for high-
tech vessels.
1.4 About L & T Defence
The latest addition in the Hazira Manufacturing Complex is the Armored Systems Complex
(ASC) which is a 50 acre, green-field state-of-the-art manufacturing facility created to
manufacture, integrate and test advanced Military Armoured Platforms such as Self-propelled
Howitzers, Air-defence Systems, Infantry Combat Vehicles, Future-ready Combat Vehicles and
Battle Tanks.
This newly established & ultra-modern complex comprises of 320-meter-long workshops with
30 meter and 15-meter bays with in-house advanced Robotic Welding Systems, CNC
Machining, System Assembly & Integration facilities, Latest digital solutions for project
monitoring, Integrated store management systems, Advanced metrology and a Special Purpose
Mobility Test Track facility to roll out fully integrated Armoured systems from ‘plate-to-
platform’ basis under a single roof of the complex.
The full-fledged mobility test track, specially designed for rigorous testing, acceptance and
qualification of armoured systems, ensures that every equipment delivered meets the most
stringent quality standard and is battle worthy across terrains.
ASC has successfully executed an order for supply of 100 Nos. K9 Vajra-T 155 mm 52 calibre
Tracked Self Propelled Howitzers for the Indian Armed forces and delivered them well ahead
of contractual deliveries.

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L&T Defence Unit at Hazira also manufactures Underwater Platforms, Bridging Systems,
Missile Launching Systems and various other equipment for Land & Naval
1.5 Hazira location advantages
 Water front access for shipment of large & heavy products.

 Global network by V-SAT, facilitating exchange of information.
 295KM North of Mumbai, 21KM from Surat on the right bank of river Tapti.
Unimpeded passage to Arabian Sea, 8KM away.
 Proximity to Surat - a prominent city, well connected by rail and road to all partsof
the country.
 Rail - Broad gauge railway siding 5Km away.
 Road - located on state highway. National highway 26Km away.
 Infrastructure advantage due to rapid industrialization of Hazira belt.

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2. ISO Achievements
2.1 ISO 9001:2015
● Description:
ISO 9001:2015 is an international standard dedicated to Quality Management Systems

(QMS). It outlines a framework for improving quality and a vocabulary of understanding
for any organization looking to provide products and services that consistently meet the
requirements and expectations of customers and other relevant interested parties in the most
efficient manner possible. I The QMS is the aggregate of all the processes, resources,
assets, and cultural values that support the goal of customer satisfaction and organizational
efficiency.
FIG 2.1 ISO 9001 2015

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2.2 ISO 14001:2015
Description:
ISO 14001 is the international standard that specifies requirements for an effective
environmental management system (EMS). It provides a framework that an organization can
follow, rather than establishing environmental performance requirements.
Part of the ISO 14000 family of standards on environmental management, ISO 14001 is a
voluntary standard that organizations can certify to.
The International Organization for Standardization (ISO) defines an environmental

management system as “part of the management system used to manage environmental aspects,
fulfill compliance obligations, and address risks and opportunities.” The framework in the ISO
14001 standard can be used within a plan-do-check-act (PDCA) approach to continuous
improvement.
FIG 2.2 ISO 14001 2015

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2.3 AS 9100
● Description:
AS9100 is a widely adopted and standardized quality management system for the aerospace
industry. It was released in October, 1999, by the Society of Automotive Engineers and the
European Association of Aerospace Industries.
AS9100 replaces the earlier AS9000 and fully incorporates the entirety of the current version of
ISO 9001, while adding requirements relating to quality and safety. Major aerospace
manufacturers and suppliers worldwide require compliance and/or registration to AS9100 as a
condition of doing business with them.
Figure 2.3 AS 9100D

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2.4 OHSAS 45001:2018
● Description:
ISO 45001:2018 specifies requirements for an occupational health and safety (OH&S)
management system, and gives guidance for its use, to enable organizations to provide safe and
healthy workplaces by preventing work-related injury and ill health, as well as by proactively
improving its OH&S performance.
ISO 45001:2018 is applicable to any organization that wishes to establish, implement and
maintain an OH&S management system to improve occupational health and safety, eliminate
hazards and minimize OH&S risks (including system deficiencies), take advantage of OH&S
opportunities, and address OH&S management system nonconformities associated with its
activities. ISO 45001:2018 helps an organization to achieve the intended outcomes of its OH&S
management system. Consistent with the organization's OH&S policy, the intended outcomes
of an OH&S management system include:
a) continual improvement of OH&S performance;
b) fulfilment of legal requirements and other requirements;
c) achievement of OH&S objectives.
FIG 2.4 OHSAS 45001 2018

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3. Safety Training
3.1 Basic Training
3.2 Basic safety rules and regulations:
Stay alert
Wear the right clothes
Use the right tools
Clean and organize your workplace
Never take shortcuts
3.3 RSC (Report safety concern)
Figure 3.1 Report safety concern
3.4 Importance of PPE (PERSONAL PROTECTIVE EQUIPMENTS)
Personal Protective Equipment (PPE) is essential if you work in an industrial or factory

environment, and employers have a duty of care to provide the correct equipment for
their staff. PPE protects against health and safety risks within the workplace and can
include items such as steel toe cap boots, helmets, high-visibility gear, safety eyewear,
hearing protection, full body harness, boiler suit.

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3.5 Various PPE’S
3.2 Safety Shoes 3.3 Safety Helmet
3.4 Safety Goggles 3.5 Boiler Suit

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3.6 Full Body Harness 3.7 Gloves
3.8 Hearing Protection

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4. Roles and responsibilities
Project : PINAKA LAUNCHER

Department: PROJECT MANAGEMENT GROUP
5. About PINAKA
• Pinaka is a multiple rocket launcher system produced in India and developed by

the Defence Research and Development Organization (DRDO) for the Indian Army.
• As of 2014, about 5,000 missiles are being produced every year while an advanced
variant is under development with enhanced range and accuracy.
• As of 2019, an upgraded guided missile version of the system has been test-fired, with
a range of over 90 km.
fig 5.1 Pinaka Missile

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Fig 5.2 Cradle Structure
5.1 Specifications of PINAK A LAUNCHER
Rocket Weight 277.4 kg (612 pounds)
Rate of fire Approximately 44 seconds.
Accuracy ≤ 1.5% range
Guidance Free flight
Range 37.5 km (23.3 mi)
Rocket Diamete0072 214 mm (8.4 in)
Launching pod 2 detachable pods, each carrying 6

rockets

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5.2 Mission of project management group
Fabrication of Pinaka launcher its planning, organizing, and directing the completion of
project for an organization while ensuring these projects are on time, on budget, and
within scope.
The project management processes are a part of those project management knowledge areas.
Where all of these project management processes belong to five major project management
process groups. These project management process groups are called:
 Initiating
 Planning
 Executing
 Monitoring and Controlling
 Closing
5.3 Parts of PINAKA LAUNCHER are as listed below:
 UNDERFRAME
 CRADLE
 ROTATING BASE BODY (RBB)

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6. Various shops and departments

6.1 Fabrication Shop
FIG 6.1 FABRICATION SHOP
6.2 Machining Shop
FIG 6.2 MACHINING SHOP

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6.3 WELDING SHOP
FIG 6.3 WELDING SHOP
6.4 HEAT TREATMENT SHOP
FIG 6.4 HEAT TREATMENT SHOP

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6.5 QUALITY CONTROL
FIG 6.5 QUALITY CONTROL
6.6 TESTING LAB

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6.7 Blasting Shop
FIG 6.7 BLASTING SHOP
6.9 INTEGRATION SHOP
FIG 6.9 INTEGRATION SHOP

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6.10 Finance and Accounting
FIG 6.10 FINANCE AND ACCOUNTING
6.11 STORE
FIG 6.11 STORE

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7 BILL OF MATERIAL
FIG 7 BILL OF MATERIAL

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8. Standard of materials: and its properties

8.1 SA516-GR70
Material %
Carbon 0.27-0.31
Manganese 0.79-1.30
Silicon 0.13-1.30
Phosphorus 0.035
sulphur 0.035
FIG 8.1 SA516 GR70
8.2 IS2062
Material %
Carbon 0.23
Manganese 1.5
Silicon 0.4
Phosphorus 0.05
sulphur 0.05

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8.3 A333 GR6
Material %
Carbon 0.30
Manganese 0.29
Silicon
Phosphorus 0.025
sulphur 0.025
FIG 8.3 A333 GR6
8.4 A106 GR B
Material %
Carbon 0.25
Manganese 0.27-0.93
Silicon 0.1
Phosphorus 0.035
sulphur 0.035
FIG 8.4 A106 GR B

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8.5 IS 4923
Material %
Carbon 0.12
Manganese 0.50
Silicon 0.03-0.08
Phosphorus 0.05 max
sulphur 0.05 max
8.6 SA 350 LF2 CL1
Material %
Carbon 0.30
Manganese 0.6-1.35
Silicon 0.15
Phosphorus 0.035
sulphur 0.040
PROJECT CONTROL (
FIG 8.6 SA350LF2CL1

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8.7 PROCEDURE FOR PROJECT MANAGEMENT GROUP
PROJECT CONTROL (MKT}
MAIN BILL OF MATERIAL (DEC)
ENGINEERING BOM (PMG)
BOUGHT OUT MANUFACTURING ITEM
FITTINGS, ROUND BAR, ETC PLATE PARTS

PMG
PURCHASE ORDER (SCG)
INSPECTION AND TESTING (QC)
RECIEPT (INWARD)
IMR (INWARD MATERIAL RECIEPT)
QC (RECIEPT, INSPECTION)
CLEAR

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9. Various material testing methods
Testing
NON-DESTRUCTIVE TEST DESTRUCTIVE TEST
VISUAL TESTING IMPACT TEST

MAGNETIC PARTICLE TEST BENDING TEST
LIQUID PENETRANT TEST ULTIMATE TENSILE STRENGTH
RADIOGRAPHIC TEST CHARPY TEST
ULTRASONIC TEST
 9.1 Nondestructive test:
Definition:
Non-destructive testing (NDT) is a testing and analysis technique used by industry to

evaluate the properties of a material, component, structure or system for characteristic
differences or welding defects and discontinuities without causing damage to the original
part
9.1.1 Visual testing:
Definition:
Visual Inspection, used in maintenance

of facilities, mean inspection of equipment
and structures using naked eye and/or
any non-specialized inspection equipment
FIG 9.1.1 VISUAL TESTING

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Tools: include fiberscopes, borescopes, magnifying glasses and mirrors
Portable video inspection unit with zoom allows inspection of large tanks and vessels,
railroad tank cars, sewer lines.
Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors,
pipelines
9.1.2 Magnetic particle test
Definition:
Magnetic Particle Testing (MPT) is a non-destructive testing (NDT) process for

detecting surface and low subsurface discontinuities in ferromagnetic materials such
as iron, nickel, cobalt, and some of their alloys.
FIG 9.1.2 MAGNETIC PARTICLE TEST
Description:
Magnetic particle inspection is one of the simple, fast and traditional non-
destructive testing methods widely used because of its convenience and low cost.
This method uses magnetic fields and small magnetic particles, such as iron filings
to detect flaws in components. The only requirement from an inspect ability
standpoint is that the component being inspected must be made of a ferromagnetic
material such iron, nickel, cobalt, or some of their alloys, since these materials are
materials that can be magnetized to a level that will allow the inspection to be
effective. On the other hand, an enormous volume of structural steels used in
engineering is magnetic.

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Procedure:
In this experiment, commercially available magnetic powder manufactured for NDT
inspection will be used. A strong U shape magnet will be used to provide the
necessary magnetic field at the inspected area. The following steps are applied
during the experiment; 1. The surface of the specimen will be roughly cleaned
wiping with a piece of textile. 2. The fluorescent magnetic spray will be applied on
the surface being inspected. 3. Magnetic field will be applied with a strong magnet
to the location of interest. 4. The spots where the fluorescent magnetic particles
accumulated will be inspected under UV light.
9.1.3 Liquid penetrant test
Definition:
Liquid penetrant testing is a nondestructive material examination procedure used to
check for deficiencies such as cracks by spreading a thin liquid dye onto the
material's surface, followed by the application of a developer
FIG 9.1.3 LIQUID PENETRATION TEST
Description:
In this method the surfaces to be inspected should be free from any coatings, paint,
grease. dirt, dust, etc., therefore, should be cleaned with an appropriate way. Special
care should be taken not to give additional damage to the surface to be inspected
during the cleaning process Surface cleaning can be performed with alcohol. Special
chemicals like cleaner-remover can also be applied if needed. Subsequent to surface
cleaning, the surface is let to dry for 2 minutes.

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Procedure:
Steps used in the experiment:
1. Clean the surface with alcohol and let surface dry for 5 min.
2. Apply the liquid penetrant spray (red can) to the surface and brush for,
further penetration. Then, wait for 20 min.
3. Wipe the surface with a clean textile and subsequently apply remover spray (blue
can) to remove excess residues on the surface and wait for a few min.
4. Apply the developer spray (yellow can). The developer will absorb the penetrant
that infiltrated to the surface features such as cracks, splits, etc., and then reacted
with it to form a geometric shape which is the negative of the geometry of the
surface features from which the penetrant is sucked.
5. The polymerized material may be collected on a sticky paper for future evaluation
and related documentation, if needed.
9.1.4 RADIOGRAPHIC TEST
Definition:
Radiographic testing (or famously known as R.T.) is a process where
penetrating radiation beam passes through a test object. The transmitted
radiation is then collected by a form of sensor that is capable of measuring the
relative intensities of the penetrating radiations imposing upon it.
FIG 9.1.4 RADIOGRAPHIC TEST

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Description:
Radiography provides a permanent reference for the internal soundness of the
object that is radiographed. The x-ray emitted from a source has an ability to
penetrate metals as a function of the accelerating voltage in the x-ray emitting
tube. If a void present in the object being radiographed, more x-rays will pass in
that area and the film under the part in turn will have more exposure than in the
non-void areas. The sensitivity of x-rays is nominally 2% of the materials
thickness. Thus for a piece of steel with a 25mm thickness, the smallest void
that could be detected would be 0.5mm in dimension. For this reason, parts are
often radiographed in different planes. A thin crack does not show up unless the
x-rays ran parallel to the plane 0 the crack. Gamma radiography is identical to
x-ray radiography in function. The difference is the source of the penetrating
electromagnetic radiation which is a radioactive material such m Co 60.
However this method is less popular because of the hazards of handling
radioactive materials.
9.1.5 Ultrasonic test
Definition:
Ultrasonic testing or in short UT refers to a variety of non-destructive testing (NDT)
techniques that use ultrasonic waves to pass through a substance or object.
Ultrasonic waves are high-frequency waves that are passed through different
substances to find flaws or detecting variations in them.
FIG 9.1.5 ULTRASONIC TEST
Procedure:
1. The couplant should be applied on the inspected area.
2. For the circular test specimen, the prop will be placed in the corresponding space
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in the supporting fitting tool. Enough couplant should be used between the probe
and tool. For the flat specimen, no tool is needed, couplant only applied between
the inspected surface and the probe.
3. Special attention should be paid on the location where possible cracks exist.
4. A discontinuity like a crack produces a peak on the screen.
5. Attention should also be given to the movement of the possible peak caused by
the cracks on the specimen.
9.2 Destructive test
9.2.1 Impact test
Definition:
Impact testing is also known as ASTM E23. The impact test is a method for
evaluating the toughness, impact strength and notch sensitivity of engineering
materials. Engineers test the ability of a material to withstand impact to predict its
behavior under actual conditions.
FIG 9.2.1 IMPACT TEST

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Procedure:

1.A Charpy V-notch specimen is placed across parallel jaws in the impact-testing
machine.
2. The pointer is set up to its maximum value (300 J).
3. The hammer is released from the initial height downward towards the sample.
4.Observations and the energy absorbed are recorded and tabulated.

5.Steps 1-3 are repeated for another specimen.
9.2.2 BENDING TEST

Definition:
A bend test is a method for measuring stiffness and yield properties of certain
materials. Bend tests for ductility provide a simple way to evaluate the quality of
materials by their ability to resist cracking or other surface irregularities during one
continuous bend.
FIG 9.2.2 BENDING TEST

1. Take a test specimen of the steel rod.
2. Measure the diameter of the steel rod. Take at least 3 readings and calculate the
mean.

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3. Now place the test specimen in the bending table specimen should be kept in the
bending table in such a way that the plane
4. Intersecting the longitudinal ribs is parallel to the axis of the pin.
5.Select suitable rang of scale.
6. Start the machine and start applying load continuously and uniformly
throughout the bending.
7. As the load is applied on the rod it will start bending. Discontinue the application of load
when the range of bend specified in the material specimen has been achieved before
rebound
8. Take out the specimen and examine the tension surface of the tension surface of
the specimen for cracking.
9.2.3 Ultimate tensile strength

Definition:
The ultimate tensile strength is the maximum on the engineering stress- strain
curve. This corresponds to the maximum stress that can be sustained by a structure
in tension. Ultimate tensile strength is often shortened to “tensile strength”
FIG 9.2.3 ULTIMATE TENSILE STRENGTH

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10.. Nesting
Nesting refers to the process of laying out cutting patterns to minimize the raw
material waste. Examples include manufacturing parts from flat raw material
such as sheet metal.
Such efforts can also be applied to additive manufacturing, such as 3D printing.
Here the advantages which can include minimizing tool movement that is not
producing product, or maximizing how many pieces can be fabricated in one build
session. One difference from nesting of cut pieces is that 3D parts often have a cross
section that changes with height, which can cause interference between adjacent
parts as they are built up.
Fig 10.1 SIMPLE RECTANGULAR NESTING
Fig 10.1 IMPROVED NESTING WITH R
10.1PROCESS
To minimize the amount of scrap raw material produced during cutting; companies
use nesting software. The software analyses the parts (shapes) to be produced at a
particular time. Using algorithms, it then determines how to lay these parts out in
such a way as to produce the required quantities of parts, while minimizing the
amount of raw material wasted.

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Off-the-shelf nesting software packages address the optimization needs. While some
cater only to rectangular nesting, others offer profile or shape nesting where the
parts required can be any odd shape.
These irregular parts can be created using popular computer-aided design (CAD)
tools. Most of the profile nesting software can read IGES or DXF profile files
automatically, a few of them work with built-in converters. An important
consideration in shape nesting is to verify that the software in question actually
performs true profile nesting and not just block nesting.
In block nesting an imaginary rectangle is drawn around the shape and then the
rectangles are laid side-by side which actually is not profile nesting. There remains
scope for waste reduction.
10.2 Considerations
Nesting software must take into account the limitations and features of the
machining technology in use, such as:
10.2.1 Machining cannot take place where the raw material is clamped into place;
10.2.2 Some machines can access only half of the material at a particular time;
the machine automatically flips the sheet over to allow the remaining half to be
accessed;
10.2.3 When punching, the width of the punch tool must be considered;
10.2.4 Shearing may be permitted only in certain areas of the sheet due to limitations
of the machinery;
10.2.5 Nesting software may also have to take into account material characteristics,
such as
10.2.6 Defects on material that must be discarded;
10.2.7 Different quality areas that must match corresponding quality levels required
for different parts;
10.2.8 Direction constraints, that may come from a printed pattern or from
fiber direction;
10.2.9 Many machine manufacturers offer their own custom nesting software designed
to offer ease of use and take full advantage of the features of their specific machines.

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11. About various cutting machines
 LASER CUTTING
 WATERJET CUTTING
 GAS CUTTING
11.1 Laser cutting
FIG 11.1 LASER CUTTING
● DESCRIPTION
Laser cutting is a technology that uses a laser to vaporize materials, resulting in a
cut edge. While typically used for industrial manufacturing applications, it is now
used by schools, small businesses, architecture, and hobbyists. Laser cutting works
by directing the output of a high-power laser most commonly through optics. The
laser optics and CNC (Computer numerical control) are used to direct the material
or the laser beam generated. A commercial laser for cutting materials uses a motion
control system to follow a CNC or G-code of the pattern to be cut onto the
material. The focused laser beam is directed at the material, which then either
melts, burns, vaporizes away, or is blown away by a jet of gas, leaving an edge
with a high-quality surface finish.
 Process
Generation of the laser beam involves stimulating a lasing material by
electrical discharges or lamps within a closed container. As the lasing
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material is stimulated, the beam is reflected internally by means of a partial

mirror, until it achieves sufficient energy to escape as a stream of
monochromatic coherent light. Mirrors or fiber optics are typically used to
direct the coherent light to a lens, which focuses the light at the work zone.
In order to be able to start cutting from somewhere other than the edge, a pierce
is done before every cut. Piercing usually involves a high-power pulsed laser
beam which slowly makes a hole in the material.
Advantages of laser cutting over mechanical cutting include easier Work holding
and reduced contamination of work piece (since there is no cutting edge which can
become contaminated by the material or contaminate the material). Precision may
be better, since the laser beam does not wear during the process. There is also a
reduced chance of warping the material that is being cut, as laser systems have a
small heat-affected zone. Some materials are also very difficult or impossible to
cut by more traditional means.
11.1.1 Method
11.1.2 Vaporization cutting
In vaporization cutting the focused beam heats the surface of the material to flashpoint point
and generates a keyhole. The keyhole leads to a sudden increase in absorptivity quickly
deepening the hole. As the hole deepens and the material boils, vapor generated erodes the
molten walls blowing eject out and further enlarging the hole. Non melting material such as
wood, carbon and thermoset plastics are usually cut by this method.
11.1.3 Melt and blow

Melt and blow or fusion cutting uses high-pressure gas to blow molten material from the
cutting area, greatly decreasing the power requirement. First the material is heated to melting
point then a gas jet blows the molten material out of the kerf avoiding the need to raise the
temperature of the material any further. Materials cut with this process are usually metals.
11.1.4 Thermal stress cracking

Brittle materials are particularly sensitive to thermal fracture, a feature exploited in thermal
stress cracking. A beam is focused on the surface causing localized heating and thermal
expansion. This results in a crack that can then be guided by moving the beam. The crack can
be moved in order of m/s. It is usually used in cutting of glass.
11.1.5 Stealth dicing of silicon wafers

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The separation of microelectronic chips as prepared in semiconductor device fabrication

from silicon wafers may be performed by the so-called stealth dicing process, which
operates with a pulsed Nd:YAG laser, the wavelength of which (1064 nm) is well adapted
to the electronic band gap of silicon (1.11 eV or 1117 nm).
 Reactive cutting
Also called "burning stabilized laser gas cutting", "flame cutting". Reactive cutting is like
oxygen torch cutting but with a laser beam as the ignition source. Mostly used for cutting
carbon steel in thicknesses over 1 mm. This process can be used to cut very thick steel plates
with relatively little laser power.
11.2 Waterjet cutting
FIG 11.2 WATERJET CUTTING
Cutting with a water jet is a method of engineering for cutting objects using the
energy from high speed, high density, ultra-high-pressure water. The water is
pressurized to a maximum 392 MPa (approximately 4,000 atmospheres) and
projected from a small-bore nozzle (Φ0.1 mm).
Water that has been pressurized by an ultrahigh-pressure pump reaches a speed
approximately three times the speed of sound, producing a water jet with destructive
force.

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Its applications are widespread, with some of its more familiar uses including
cutting roof materials, dashboards and bumpers for automobiles. Cutting and
demolition of concrete structures. It is also used in cutting aircraft fuselages that use
new materials.
11.2.1 Operation
All waterjets follow the same principle of using high pressure water focused into a
beam by a nozzle. Most machines accomplish this by first running the water through
a high-pressure pump. There are two types of pumps used to create this high
pressure; an intensifier pump and a direct drive or crankshaft pump. A direct drive
pump works much like a car engine, forcing water through high pressure tubing
using plungers attached to a crankshaft. An intensifier pump creates pressure by
using hydraulic oil to move a piston forcing the water through a tiny hole. The water
then travels along the high-pressure tubing to the nozzle of the waterjet. In the
nozzle, the water is focused into a thin beam by a jewel orifice. This beam of water
is ejected from the nozzle, cutting through the material by spraying it with the jet of
speed on the order of Mach 3, around 2,500 ft/s (760 m/s). The process is the same
for abrasive waterjets until the water reaches the nozzle. Here abrasives such as
garnet and aluminum oxide, are fed into the nozzle via an abrasive inlet. The
abrasive then mixes with the water in a mixing tube and is forced out the end at high
pressure.
11.2.2 PROCESS
There are six main process characteristics to water jet cutting:
Uses a high velocity stream of ultra-high-pressure water 30,000–90,000 psi (210–
620 MPa) which is produced by a high-pressure pump with possible abrasive
particles suspended in the stream.
Is used for machining a large array of materials, including heat-sensitive, delicate or
very hard materials.
Produces no heat damage to workpiece surface or edges.
Nozzles are typically made of sintered boride or composite tungsten carbide.
Produces a taper of less than 1 degree on most cuts, which can be reduced or
eliminated entirely by slowing down the cut process or tilting the jet.
Distance of nozzle from workpiece affects the size of the kerf and the removal rate
of material. Typical distance is .125 in (3.2 mm).
Temperature is not as much of a factor.

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11.3 Gas cutting

Oxy-fuel cutting (commonly called gas cutting in the United States) is the process
that use fuel gases (or liquid fuels such as gasoline or petrol, diesel, bio diesel,
kerosene etc.) and oxygen to weld or cut metals. Pure oxygen, instead of air, is used
to increase the flame temperature to allow localized melting of the workpiece
material (e.g., steel) in a room environment.
In gas cutting, a torch is used to heat metal to its kindling temperature. A stream of
oxygen is then trained on the metal, burning it into a metal oxide that flows out of
the kerf as dross.
Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are
not considered oxy-fuel torches and can typically be identified by a single tank
(oxy-fuel cutting requires two isolated supplies, fuel and oxygen). Most metals
cannot be melted with a single-tank torch. Consequently, single-tank torches are
typically suitable for soldering and brazing but not for welding.
The five most commonly used fuel gases are acetylene, propane, MAPP
(methylacetylene-propidine), propylene and natural gas. The relative performance of
the fuel gases in terms of pierce time, cutting speed and cut edge quality, is
determined by the flame temperature and heat distribution within the inner and out
flame cones.
11.3.1 Process
Basically, a mixture of oxygen and the fuel gas is used to preheat the metal to its
'ignition' temperature which, for steel, is 700°C - 900°C (bright red heat) but well
below its melting point. A jet of pure oxygen is then directed into the preheated area
instigating a vigorous exothermic chemical reaction between the oxygen and the
metal to form iron oxide or slag. The oxygen jet blows away the slag enabling the
jet to pierce through the material and continue to cut through the material.
11.3.2 Conditions
The ignition temperature of the material must be lower than its melting point
otherwise the material would melt and flow away before cutting could take place
the oxide melting point must be lower than that of the surrounding material so that it
can be mechanically blown away by the oxygen jet
the oxidation reaction between the oxygen jet and the metal must be sufficient to
maintain the ignition temperature
a minimum of gaseous reaction products should be produced so as not to dilute the
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cutting oxygen
As stainless steel, cast iron and non-ferrous metals form refractory oxides i.e.,
the oxide melting point is higher than the material, powder must be injected into
the flame to form a low melting point, fluid slag.

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12. Plate cutting layout(PCL)
PCL created and confirmed by PMG
Approved by QA/QC (1st stage)
Shop floor conformation (PMG)
Plate issued by store
To vendor by SCG
Plate marked by vendor
Plate cut by vendor
Approved by QC (2nd Stage)
Plate to be return (Return balancing by PMG)
PCL closed

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FIG 12 PLATE CUTTING LAYOUT

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13. Welding
Manual Welding Robotic Welding
MIG KUKA
TIG CLOOS
Arc welding
Spot welding
13.1 Mig welding (METAL INERT GAS WELDING)
Aim-To provide delegates with the necessary skills, knowledge and safe working
practices to enable them to produce a range of welded joints in mild steel using the
metal inert gas shielded welding process.
● Procedure:
GMAW's basic technique is uncomplicated, with most individuals able to achieve

reasonable proficiency in a few weeks, assuming proper training and sufficient practice.
As much of the process is automated, GMAW relieves the welder (operator) of the
burden of maintaining a precise arc length, as well as feeding filler metal into the weld
puddle, coordinated operations that are required in other manual welding processes,
such as shielded metal arc. GMAW requires only that the welder guide the gun with
proper position and orientation along the area being welded, as well as periodically
clean the gun's gas nozzle to remove spatter build-up. Additional skill includes knowing
how to adjust the welder so the voltage, wire feed rate and gas flow rate are correct for
the materials being welded and the wire size being employed.
Maintaining a relatively constant contact tip-to-work distance (the stick-out distance) is

important. Excessive stick-out distance may cause the wire electrode to prematurely
melt, causing a sputtering arc, and may also cause the shielding gas to rapidly disperse,
degrading the quality of the weld. In contrast, insufficient stick-out may increase the
rate at which spatter builds up inside the gun's nozzle and in extreme cases, may cause
damage to the gun's contact tip. Stick-out distance varies for different GMAW weld

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processes and applications.

The orientation of the gun relative to the weldment is also important. It should be held
so as to bisect the angle between the workpiece; that is, at 45 degrees for a fillet weld
and 90 degrees for welding a flat surface. The travel angle, or lead angle, is the angle of
the gun with respect to the direction of travel, and it should generally remain
approximately vertical. However, the desirable angle changes somewhat depending on
the type of shielding gas used—with pure inert gases, the bottom of the torch is often
slightly in front of the upper section, while the opposite is true when the welding
atmosphere is carbon dioxide.
Position welding, that is, welding vertical or overhead joints, may require the use of a
weaving technique to assure proper weld deposition and penetration. In position
welding, gravity tends to cause molten metal to run out of the puddle, resulting in
cratering and undercutting, two conditions that produce a weak weld. Weaving
constantly moves the fusion zone around so as to limit the amount of metal deposited at
any one point. Surface tension then assists in keeping the molten metal in the puddle
until it is able to solidify. Development of position welding skill takes some experience,
but is usually soon mastered.
MIG/MAG is widely used in most industry sectors and accounts for more than 50% of
all weld metal deposited. Compared to MMA, MIG/MAG has the advantage in terms of
flexibility, deposition rates and suitability for mechanization. However, it should be
noted that while MIG/MAG is ideal for 'squirting' metal, a high degree of manipulative
skill is demanded of the MIG welder.
FIG 13.1 MIG WELDING

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13.2 Tig welding
Aim- Tungsten Inert Gas (TIG) welding uses the heat generated by an electric arc
struck between a non-consumable tungsten electrode and the workpiece to fuse
metal in the joint area and produce a molten weld pool. The arc area is shrouded in
an inert or reducing gas shield to protect the weld pool and the non-consumable
electrode.
Procedure-
Manual gas tungsten arc welding is a relatively difficult welding method, due to the
coordination required by the welder. Similar to torch welding, GTAW normally
requires two hands, since most applications require that the welder manually feed a
filler metal into the weld area with one hand while manipulating the welding torch
in the other. Maintaining a short arc length, while preventing contact between the
electrode and the workpiece, is also important.
To strike the welding arc, a high-frequency generator (similar to a Tesla coil)

provides an electric spark. This spark is a conductive path for the welding current
through the shielding gas and allows the arc to be initiated while the electrode and
the workpiece are separated, typically about 1.5–3 mm (0.06–0.12 in) apart.
Once the arc is struck, the welder moves the torch in a small circle to create a
welding pool, the size of which depends on the size of the electrode and the amount
of current. While maintaining a constant separation between the electrode and the
workpiece, the operator then moves the torch back slightly and tilts it backward
about 10–15 degrees from vertical. Filler metal is added manually to the front end of
the weld pool as it is needed.
Welders often develop a technique of rapidly alternating between moving the torch
forward (to advance the weld pool) and adding filler metal. The filler rod is
withdrawn from the weld pool each time the electrode advances, but it is always
kept inside the gas shield to prevent oxidation of its surface and contamination of
the weld. Filler rods composed of metals with a low melting temperature, such as
aluminum, require that the operator maintain some distance from the arc while
staying inside the gas shield. If held too close to the arc, the filler rod can melt
before it makes contact with the weld puddle. As the weld nears completion, the arc
current is often gradually reduced to allow the weld crater to solidify and prevent
the formation of crater cracks at the end of the weld.
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FIG 13.2 TIG WELDING
13.3 Arc welding
Objective-Arc welding is a welding process that is used to join metal to metal by

using electricity to create enough heat to melt metal, and the melted metals, when
cool, result in a binding of the metals.
Operation
Arc welding is a fusion welding process used to join metals. An electric arc from an
AC or DC power supply creates an intense heat of around 6500°F which melts the
metal at the join between two work pieces. The arc can be either manually or
mechanically guided along the line of the join, while the electrode either simply
carries the current or conducts the current and melts into the weld pool at the same
time to supply filler metal to the join.
Because the metals react chemically to oxygen and nitrogen in the air when heated
to high temperatures by the arc, a protective shielding gas or slag is used to
minimize the contact of the molten metal with the air. Once cooled, the molten
metals solidify to form a metallurgical bond.

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Arc welding provides a plethora of advantages compared to other types of welding.

These advantages include:
Low cost. This is an affordable technique because the cost of equipment is low. It
also requires less equipment due to the lack of gas.
Portability. The materials in this technique are easy to transport.
Used on unclean metals. Arc welding can be performed on dirty metals.
Work in any environment. A lot of arc processes use shielding gas so work can only
be done in one place. With arc welding, there is no need for shielding gas so work
can happen regardless of weather conditions.
 Arc Weld Disadvantages

While there are many great benefits to arc welding, there are also some
shortcomings. These disadvantages include:
Cost. While cost is considered an advantage, it is also a disadvantage because it

produces more metal waste than other methods, resulting in higher project costs.
Requires a high level of skill and training. Not all operators have a high level of
training and skills.
Thin metal. Arc welding does not work well on certain thin metals.
Advantages:
It provide higher deposition rate.
It is faster comparing to arc welding because it supply filler material continuously.
It produce clean weld with better quality.
There is no slag formation.
Minimize weld defects.
This welding produces very little slag.
It can be used to make deep groove weld.
It can be easily automated.

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Disadvantages:
It cannot be used for welding in difficult to reach portions.
Higher initial or setup cost.
It cannot be used for outdoor work because wind can cause damage of gas shield.
It required high skilled labor.
FIG 13.3 ARC WELDING

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13.4 Spot welding
Objective-
Spot welding (also known as resistance spot welding) is a resistance welding
process. This welding process is used primarily for welding two or more metal
sheets together by applying pressure and heat from an electric current to the weld
area.
Procedure
Spot welding involves three stages; the first of which involves the electrodes being
brought to the surface of the metal and applying a slight amount of pressure. The
current from the electrodes is then applied briefly after which the current is removed
but the electrodes remain in place for the material to cool. Weld times range from
0.01 sec to 0.63 sec depending on the thickness of the metal, the electrode force and
the diameter of the electrodes themselves. [citation needed]
The equipment used in the spot-welding process consists of tool holders and
electrodes. The tool holders function as a mechanism to hold the electrodes firmly in
place and also support optional water hoses that cool the electrodes during welding.
Tool holding methods include a paddle-type, light duty, universal, and regular
offset. The electrodes generally are made of a low resistance alloy, usually copper,
and are designed in many different shapes and sizes depending on the application
needed.
The two materials being welded together are known as the workpiece and must
conduct electricity. The width of the workpiece is limited by the throat length of the
welding apparatus and ranges typically from 5 to 50 inches (13 to 130 cm).
Workpiece thickness can range from 0.008 to 1.25 inches (0.20 to 32 mm.
After the current is removed from the workpiece, it is cooled via the coolant holes in
the center of the electrodes. Both water and a brine solution may be used as coolants
in spot welding mechanisms.
In the case of resistance spot welding, there are two main parts of the tooling
system, the features of which fundamentally influence the whole process: the gun
and its type, and the size and shape of the electrode. In such application, where the
gun layout should be as rigid as possible due to the high applying forces (e.g.
welding of thick materials), the C-type gun is widely used. As well as the high
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resulting rigidity, this arrangement leads to a high tooling flexibility, as the motion
of the electrodes is collinear. Unlike the C-type, the so-called X-type arrangement
provides less rigidity, although the reachable workspace is far larger than with the
C-type, thus this layout is very common, where thin and flat objects are being
processed (e.g. manufacturing of floor pan or roof panel). However, it offers less
flexibility in terms of tooling, because the paths of the moving electrodes are not
collinear (like the tips of a scissor), so a dome-shaped electrode tip should be used.
Electrodes used in spot welding can vary greatly with different applications. Each
tool style has a different purpose. Radius style electrodes are used for high heat
applications, electrodes with a truncated tip for high pressure, eccentric electrodes
for welding corners, offset eccentric tips for reaching into corners and small spaces,
and finally offset truncated for reaching into the workpiece itself.
FIG 13.4 SPOT WELDING

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14. ABOUT POST WELD HEAT TREATMENT
14.1 Scope
This procedure covers the requirement pf Post Weld Heat Treatment (PWHT) of
PINAKA STRUCTURES like Underframe, Rotating Base Body & Cradle.
14.2 Material of construction
SA516 Gr 70, IS 2062, A 333 Gr 6, A 106 Gr B, SA 350 LF2 CL1, IS4923,

Requirement for operation of Post Weld Heat Treatment
PWHT shall be carried out in gas fired/electric furnace.

Prior to the PWHT, components shall be checked to ensure that all restraints are
removed and the component is free to expand and with minimal fixture.
Component/assembly shall be supported in a manner preventing any distortions and
damage during heat treatment. Use roller wherever required for longitudinal
expansion. Job should be at least 300mm above furnace floor and 500mm away from
furnace wall for gas fired and 300 mm away from furnace wall for Electric furnace.
14.3 Following cycle shall be followed for PWHT.
Parameter Values
Loading Temperature (°C) max 400
Rate of Heating (*C/Hour) max 100
Soaking Temperature (°G) 600 > 630
Soaking Time (Hour: Minutes) min 01:00
Rate of Cooling (*C/Hour) max 100
Unloading Temperature (°C) max Furnace

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Capacitor Discharge thermocouple shall not be tacked on items having thickness less
than 3 mm. The soaking time is the time elapsed since the last thermocouple entered
the soaking range until the first thermocouple leaves the soaking range.
During the heating and cooling period, there shall not be more than 80"C variation
between any two thermocouples throughout section.
During the soaking period (Holding period), temperature variation between any two
thermocouples shall not be more than difference between minimum and maximum
soaking temperature as per range.
Care shall be taken to avoid direct flame impingement on any part of the component
Component shall be kept at a suitable height to avoid direct flame impingement on
the component (in case of gas fired). The furnace atmosphere shall be so controlled
as to avoid excessive oxidation of the surface of the component.
Surface of the component subjected to a heat treatment shall be dry and free of any
Trace of oil, grease, paint.
14.4 Equipment
Calibrated -type thermocouples and temperature recorders shall be used for heat
Treatment
14.5 Thermocouple location
Thermocouples shall be placed as per Annexure-2.

During heat treatment the thermocouples shall be in contact with the metal surface.
This is accomplished by Capacitor Discharge welding method,
14.6 Time-Temperature recording
continuous time-temperature recording of all heat treatment shall be made using

Calibrated recorders with proper date and time of heat treatment. This chart shall
Contain the information as per annexure 1
. Each thermocouple on the time-temperature chart shall be identified with the
Corresponding thermocouple number and its location on component by any one or
More of the following methods;
A line sketch of the component in a log book indicating the number and location
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Of attached thermocouples representing the channel / curves on the recorder.

Color-coding of curves representing thermocouples at different locations on
14.7 Component
The original time-temperature chart shall be reviewed by L&T and then preserved in
Final document.
Thermocouple extension cable

Thermocouple will be connected to the temperature recorder via compensating cables.
14.8 K type thermocouples
14.9 What is a Thermocouple?
Thermocouples are electronic sensors, used for temperature monitoring. Thermocouples

come in different grades or types. The two most common are the J-type thermocouple
and K-type thermocouple. There are however several others. Type T, N, E, B, R, and S.
J, K, T, and E types are known as “base metal thermocouples” and are more common.
R, S, and B are made from Noble Metals. They are used in very high-temperature
applications. The below table illustrates the different Thermocouple types, their
composition, and temperature ranges.

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How Do Thermocouples Work?

A thermocouple converts temperature to a small DC Voltage. As you can see from the
above table, they consist of two dissimilar metal wires that meet in two or more places.
The output voltage changes in a linear manner with the temperature difference between
the two junctions. When the temperature is high, the greater the DC Voltage output. It is
a good practice to protect your thermocouple with a suitable coating or tube. Typically,
a metal coating or a ceramic tube is used to protect the thermocouple wires from
damage.
What is a K Type Thermocouple?

The K-type thermocouple is probably the most common type. Its low cost and relatively
good accuracy together with a wide temperature range make it a versatile sensor. They
are suitable for continuous exposure to temperatures around 1,100°C, with a max temp
of 1,372°C (-328°F to 2,501°F).
Different thermocouple types utilize various metals for their positive and negative
wires. K-type thermocouples are nickel-based, and therefore also have good resistance
to corrosion. This makes them suitable for use in oxidizing atmospheres. K-type
thermocouples utilize Chromel, Nickel-Chromium (10% chromium) for the Positive
leg. The Negative leg is Alumel, Nickel-Aluminum (5% aluminum). The accuracy of a
K-type Thermocouple is typically a maximum of +/- 2.2°C or +/- 0.75%, whichever is
greater. However, there can be differences between different thermocouples, ven
coming from the same production batch due to deviations in the alloys. It is therefore
recommended that thermocouples undergo individual calibration.
K-type thermocouples are found in use for many industries such as water, chemical and
gas, and food industries. They are one of the more inexpensive thermocouples with
good resistance to oxidization, good linearity of measurement, and stability.
What Are K Thermocouples Used for?
They’re generally employed in applications when the temperature is above 550°C and
the thermocouple’s maximum operating pressure is reached.
 They are used in many industries like Steel & Iron to monitor temperature &
chemistry throughout the steelmaking process
 Used for testing temperatures associated with process plants e.g.,
chemical production and petroleum refineries
 Used for Testing heating appliance safety
 Type K is commonly used in nuclear applications because of its relative radiation
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hardness.
Type thermocouples are inexpensive, small, dependable, and have fast reaction times.
They can measure a wide range of temperatures from -270°C to 1,372°C with a small
degree of error. Typically, K-type thermocouples are used in temperatures above
540°C and in oxidizing atmospheres.
FIG 14.6 TIME TEMPERATURE GRAPH
14.10 CAPACITOR DICHARGE WELDING
WHAT IS STUD WELDING?
Stud Welding is an economical & fast method of welding studs. It can weld studs of
different diameters & shapes onto the parent material. Unlike other forms of joining
that require operations such as tapping and drilling, Stud Welding is done onto the
parent material without creating holes. The portability of stud welding machines, easy
operation, and cost-effectiveness are a few biggest reasons it is one of the widely
preferred welding options worldwide.
TYPES OF STUD WELDING

Stud Welding is categorized into two major types- Capacitor Discharge (CD), Welding
& Drawn Arc (DA) Welding. Wondering which one is better? Well, both are equally
important types of Stud Welding. Choosing the suitable process involves a careful
decision based on the parent material, required weld strength, the diameter of the stud,

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the thickness of the parent material, and required welding aesthetics. Drawn Arc (DA)
Welding is majorly used for heavy parent materials & high diameter studs. In contrast,
CD Welding is used for thin parent materials.
INTRODUCTION TO CAPACITOR DISCHARGE STUD

WELDING
Capacitor Discharge Stud Welding is an affordable, fast type of welding. Using

lightweight, portable capacitor discharge welding machines like the ones at Artech are
highly beneficial for industries & enterprises. CD stud welding eliminates processes
such as drilling, punching, tapping, riveting, screwing, and more. It is highly beneficial
when the parent material is thin. CD welding does not need flux. The weld time is
shorter, and it enables the weld to bond with minor oxidation; In this welding method, a
small projection/pip at the end of the stud comes in contact with the workpiece. The
energy from the charged capacitors gets discharged across the point of contact resulting
in stud projection melting and creating a molten pool in the parent material. During the
process, the stud is pushed into the workpiece under controlled pressure to complete the
weld. The best part, it all happens really quick!
14.11 ADVANTAGES OF CAPACITOR DISCHARGE STUD

WELDING
CD Stud Welding is perfect for flawlessly welding studs.

It is ideal for applications where minimal or no marking on the backside is desirable.
The Capacitor Discharge Welding Machines are portable. It is considered lightweight
welding equipment.
The weld cycles are short and work under low temperatures. Weld time is between 1
and 6 milliseconds.
CD Stud Welding can be used on thin parent material.
The process is time-saving and cost-effective.
No additional material necessary, such as flux, inert gas, etc.
APPLICATIONS OF CAPACITOR DISCHARGE STUD
WELDING

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CD Stud Welding is used in the following products.
Control Panels
Elevator Control
Panels
Stainless Steel Cookware
Stainless Steel Kitchenware
Insulation Fixing
Electrical Control Panels
Electrostatic Precipitators
Being in the Welding Machine Industry for years, Artech Welders understand how
important it is to have robust yet lightweight CD welding machines for rapid welding
actions, flexible options, minimal operator fatigue, and more. We offer CD Stud
Welding machines that are designed to join small-diameter studs to thin base metals.
Our machines can weld studs of diameter < 10 mm, weld dissimilar metals, etc.
Artech’s machines are a leading way to drive product innovations through advanced
welding technology. Make your welding process bliss with Artech’s welding
machines. Get in touch to order now.

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FIG 14.7 THERMOCOUPLE

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15. Various documents for heat treatment
● HTR (Heat Treatment Request)

● MTR (Material Transfer Request)
 MTR (Material Transfer Request)
● D’note & E-way bill
FIG 15 HEAT TREATMENT REQUEST

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16. VARIOUS MACHINING PROCESS
FIG 16.1 DRILLING MACHINE
Types of Drilling Machines:
1. Radial drilling machine

2. Upright drilling machine
3. Automatic drilling machine
4. Multiple Spindle drilling machine
5. Deep hole drilling machine
6. Sensitive drilling machine
7. Portable drilling machine
8. Gang drilling machine
1. Radial Drilling Machine
Drilling Machine is to make circular holes on the components with the help of Drill bits.
But, the purpose of the Radial Drilling Machine is used to drill the holes in the given
radial distance and this will be used, when the component size is large in terms of
height.
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When the component is large, it cannot fit its structure in the Machine vice. Therefore,
the component has to be placed on the ground and the Radial arm of the drilling
machine has to be rotated w.r.t the component to do the operation.
The Angle of a Drill bit is 118 Degrees.
Working Principle of Radial Drilling Machine:
When the power supply is given, the spindle rotates which was in conjunction with the
motor. The Radial arm is adjusted w.r.t the type of operation and height of the
workpiece. The spindle is connected to the chuck and the drill bit is placed in between
the jaws of the chuck. The Drill head is adjusted on to the workpiece and a suitable feed
is given. Then the drill bit drives into the workpiece very easily. Drive Mechanism:
Rack and Pinion Mechanism
When the hand wheel is rotated, then the Pinion which is attached to the rack also
rotates which can convert the rotary motion to the linear motion and the driving
mechanism is called as Rack and Pinion mechanism.
Construction of Radial Drilling Machine:
The setup essentially consists of

Base
Column
Radial Arm
Motor for elevating the arm
Elevating screw
Guideways
Motor for driving drill spindle
Drill head
Drill spindle
Table
Base: It is made up of Cast Iron which possesses high compressive strength and good
wear resistance. The base is used to support the assembly of parts on it and also absorbs
the vibrations induced by the machine parts.
Column: It is exactly placed at one end of a bed which can act as a support for rotating
the radial arm in 360 degrees.

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Radial Arm: It is the arm which is connected to Column. The Drill head is slided from
one end to another end by the guideways.
Motor: It is placed on the drill head for driving the work unit (Spindle of the Drill bit)
Table: The machine vice is connected to a swivel table which can hold the workpiece
for further operation.
Flywheel or Hand wheel: It is connected to the spindle arrangement which is used to

move up and down w.r.t. the workpiece.
Drive Head: It generally consists of two levers which by varying can increase or
decrease the speed of chuck.
Chuck: One end of the chuck is connected to the spindle arrangement and another end is
connected to the drill bit(tool).
Tool-Drill bit: The drill bit is used to drill the holes on the specimens.
 Workpiece: It has to be fixed in the machine vice provided on the table.
 16.2 DRILLING
Drilling operation removes the material from the inside of a workpiece. The result of
drilling is a hole with a diameter equal to the size of the utilized drill bit. Drill bits are
usually positioned either on a tailstock or a lathe tool holder.
FIG 16.2 DRILLING

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 16.3 REAMING
Reaming is a sizing operation that enlarges the hole in the workpiece. In reaming
operations, reamer enters the workpiece axially through the end and expands an existing
hole to the diameter of the tool. Reaming removes a minimal amount of material and is
often performed after drilling to obtain both a more accurate diameter and a smoother
internal finish.
FIG 16.3 REAMING

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17. SAND BLASTING
17.1 Definition:
Sandblasting, where an abrasive is fed into a high air flow directed to a surface at a
pressure of a few bars, is a common method to clean or increase the surface roughness in
many industrial applications.
17.2 Description:
Sandblasting is process of smoothing and cleaning a hard surface by forcing solid particles
across that surface at high speeds using compressed air. There are two kinds of
sandblasters: “Suction” / “Siphon”” & “Pressure” Blast Systems. There are two basic kinds
of sand blasters: Blast Cabinets & Portable Blasters. Our project used the suction/siphon
system in a blast cabinet.
FIG 17.1 SAND BLASTING MACHINE
A sandblasting system includes four basic components: the air source, the sandblasting
cabinet, the dust collector, and the blasting media. The air source is usually bottle gas or an
air compressor. The sandblasting cabinet holds the object being blasted, while the dust
collector removes dust from the cabinet. The materials used in sandblasting, whether sand
or not, are referred to as blast media.
Procedure:

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Sandblasting can remove paint, rust, and residue from oxidation from materials quickly and
efficiently. Sandblasting can also be used to change the condition of a metal’s surface, such
as through removing scratches or casting marks. Sandblasting as a cleaning method has
been widely used for over a hundred years.
Materials Used, Pros and Cons Sandblasting is also known as abrasive blasting. Basically,
it is the operation of forcibly propelling a stream of abrasive material against a surface.
The
sandblasting operation is done under high pressure to smooth a rough surface, roughen a
smooth/Shape the surface to remove its contaminants. There are several variants of
sandblasting process like bead blasting, Soda blasting and shot blasting. Before
sandblasting, it is mandatory to know about its materials and the pros and cons. If your job
profile is related to sandblasting or you owned a company that involved in the same
process, you need to stay with us. In this article, we will discuss sand blasting machines
materials and its pros and cons. But before it, let me also clear some of the details of its
operation.

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18. COATING
Definition:
A coating is a covering that is applied to the surface of an object, usually referred to as the
substrate. The purpose of applying the coating may be decorative, functional, or both.
Procedure and description

Paints and lacquers are coatings that mostly have dual uses of protecting the substrate and
being decorative, although some artist’s paints are only for decoration, and the paint on
large industrial pipes is for preventing corrosion and identification e.g., blue for process
water, red for fire-fighting control etc.
Functional coatings may be applied to change the surface properties of the substrate, such
as adhesion, wettability, corrosion resistance, or wear resistance. In other cases, e.g.,
semiconductor device fabrication (where the substrate is a wafer), the coating adds a
completely new property, such as a magnetic response or electrical conductivity, and forms
an essential part of the finished product.
A major consideration for most coating processes is that the coating is to be applied at a
controlled thickness, and a number of different processes are in use to achieve this control,
ranging from a simple brush for painting a wall, to some very expensive machinery
applying coatings in the electronics industry. A further consideration for ‘non-all-over’
coatings is that control is needed as to where the coating is to be applied. A number of these
non-all-over coating processes are printing processes.
Many industrial coating processes involve the application of a thin film of functional
material to a substrate, such as paper, fabric, film, foil, or sheet stock. If the substrate starts
and ends the process wound up in a roll, the process may be termed “roll-to-roll” or “web-
based” coating. A roll of substrate, when wound through the coating machine, is typically
called a web.
Coatings may be applied as liquids, gases or solids e.g., Powder coatings.

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FIG 18 COATING

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19. PAINTING
Painting is defined as the process of applying paint, or another medium, to a solid surface
– usually a canvas. Paints or other forms of color are commonly applied to using a
paintbrush.
19.1 Description:
Painting is the act or process of using paint. The paint can create an artwork known as
a painting, or it can be used more practically as a protective coating or form of
decoration. Paintings are a form of visual art that captures the expression of ideas and
emotions on a two-dimensional surface.
19.2 Procedure:
Instructions
1. Remove Old Paint and Rust
Use a wire brush to remove any loose or flaking paint and as much surface rust as
possible. If a handheld wire brush is ineffective, consider using a wire brush attachment
for your drill for highly degraded surfaces. If the rust has penetrated deep into the
surface, soak the object in an appropriate rust remover and follow all steps as specified
by the manufacturer. Wipe the surface with a damp cloth to clean any dust, debris, or
rust that’s leftover. Remove remaining grease by wiping the metal with a shop rag
dipped in acetone. Allow the acetone to dry.
2. Scuff Up the Metal
If the metal doesn’t have paint on it or it’s smooth, take a scuffing pad and rub it along
the metal. These pads will lightly etch the surface of the metal, which will allow the
primer to stick more effectively.
3. Prime the Metal
If you couldn’t get rid of all the rust in the previous step, coat the metal with a zinc
chromate primer that’s formulated for coating rust. After you have coated the area with
this special primer, then apply a coat of self-etching primer. This primer should be
specifically designated for metal, including a self-etching component. Read the label to
verify that metals are an intended surface. The last consideration for primer is to be sure
the primer is compatible with the paint you want to use since a primer can be either oil-
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based or water-based.
Closely follow the instructions on the primer label since they have different drying and
cure times. If the metal is going outdoors, consider adding a second layer of primer to
help prolong metal oxidation.
4. Apply Paint
If you’re debating whether to use spray paint or a paintbrush, the easiest way to paint
metal is to use a can of spray paint. It is faster, but it does not create as hard of a finish.
Here’s how to use spray paint:
Shake the can several times to mix the paint.

Hold the can 6 to 12 inches away from the metal, which will prevent the paint from
pooling. Spray the object using long, sweeping motions (don’t hold it in one spot). If
you notice excessive dripping, wipe clean, back up, and start the process again.
For best results, apply up to three thin coats of spray paint and allow the paint to dry
before applying an additional layer.
If you want a longer-lasting finish, brush on the paint using oil-based paint. By painting
the metal object with a brush, you can create a thick surface that will be more durable.
Painting metal using a paintbrush:
Mix the paint according to the manufacturer’s specifications. If the paint feels too thick,
it might need to be cut with some mineral spirits.
Once the paint is a desirable consistency, use a high-quality natural bristle brush to paint
on a thin layer.
5. Allow the Paint to Cure
The metal needs to cure for 36 to 48 hours before moving it. Ensure the object is in an
area that won’t be affected by extreme temperatures or direct sunlight when drying.

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FIG 19 PAINTING

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20. STACKING & PACKAGING

Plastic wrap, cling film, Saran wrap, cling wrap, is a thin plastic film typically used for
sealing items in to keep them over a longer period of time.
Material Stacking
Practicing safe stacking and racking avoids serious injuries caused by stockpile
collapses or by retrieving materials from improperly collected stacks. Safe stacking
reduces injury and fire risks, enhancing the efficiency of site paths of traffic.
21. General Stacking Points
Prioritize the use of machines, tools, and equipment to reduce manual and stacking of
materials.
While material is being lowered by machine, keep hands clear of load and use other
means (e.g., taglines or rigid poles) to direct materials.
Wear appropriate work gloves and safety boots when manually moving and stacking
sharp edges, burrs, splinters, or heavy loads.
Only stack material in designated areas. Never stack near doorways, access ways or fire
escape routes.
Never make stacks higher than 3 times the minimum base width, or angle of the repose,
which is lower.
Step back material as you stack to promote stability and always stack on a level surface.
Load the stack with consideration of the order in which the materials will be unloaded.
Stage materials close to work area to reduce amount of handling.
Bricks, Blocks and Palletized Material
Always try and ensure base of stack is level.
Ensure upper pack is loaded squarely on to a lower one.
If banding or packing is damaged, or materials are shifting or leaking out, do not stack
other materials on top.
Leave sufficient aisle way space between pallets, bales, etc. for safe removal.
Store pallets laying down flat Pipes and Tubes Where pipes are small in diameter, stack
in racks.
If large in diameter, securely chock, or secure, against rolling.
Don’t stack loosely or unsecured in pyramids as they can become unstable.
Laying large concrete rings flat

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22. PACKAGING
Definition
Plastic wrap, cling film, Saran wrap, cling wrap, is a thin plastic film typically used for
sealing items in to keep them over a longer period of time.
FIG 22 PACKAGING

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23. STACKING
Definition
Practicing safe stacking and racking avoids serious injuries caused by stockpile
collapses or by retrieving materials from improperly collected stacks. Safe stacking
reduces injury and fire risks, enhancing the efficiency of site paths of traffic.
FIG 23 STACKING

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24. CONCLUSION
After the internship was over I have learned about heat treatment process of parts of
Pinaka launcher and the main thing I have learned from internship is that they have
given me a task to reduce transportation cost of mobility of underframe structure
that is a part of Pinaka launcher and the problem was that only one underframe can
be load on a trailer and to load another underframe was not possible so that is when
I gave a solution about “stacking of underframe structure “ and that is to put another
underframe on each other with the help of wooden block in between so that the floor
space area required is less and the trailer can now load three underframe structures
at a time so the transportation cost is reduced and also learned knowledge of various
cutting operations and nondestructive testing methods .

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25.REFERENCE
i. www.larsentoubro.com
ii. www.wikipidia.com
iii. ISO 9001
iv. ISO 14001
v. ISO 9100
vi. OHSAS 45001
vii. https://www.alro.com/divsteel/metals_gridpt.aspx?gp=0045#:~:text=ASTM%20A516%20Grade
%2070%20Plate,improved%20notch%20toughness%20is%20required.
viii. https://www.aspirinox.com/is-2062-gr-a-b-c-sheets-plates-supplier-exporter/
ix. https://www.navstarsteel.com/astm-a333-grade-6-pipe.html
x. https://www.twi-global.com/technical-knowledge/faqs/what-is-non-destructive-testing
xi. https://www.flyability.com/ndt
xii. https://turntechprecision.com/clueless-machinist/2020/8/25/10-machining-operations-performed-on-a-
lathe?format=amp
Reference For Figures

1. Fig 1.1 www.larsentoubro.com
2. Fig 3.2 https://images.app.goo.gl/UnZk4pTBmCne2tNC6
3. Fig 3.3 https://images.app.goo.gl/tVNBWrzjvrVrSUDZ8
4. Fig 3.4 https://images.app.goo.gl/MQfQ55QQJeqN6wgZA
5. Fig 3.5 https://images.app.goo.gl/Pty23oNU4te5UEzW6
6. Fig 3.6 https://images.app.goo.gl/SvH9Txv2y3J1npDt8
7. Fig 3.7 https://images.app.goo.gl/xY8L3kYAvdQxWHof9

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8. Fig 3.8 https://images.app.goo.gl/76YYBsdRmvMDk3K69

9. Fig 5.1 https://images.app.goo.gl/4e5RVkHneSo5ayEf8
10. Fig 5.2 https://images.app.goo.gl/u6Db2VeMGPFmr7oC7
11. Fig 6.1 https://images.app.goo.gl/2nQ8NKr8s4xz51MH9
12. Fig 6.2 https://images.app.goo.gl/bm4fxTy4AXpmUweBA
13. Fig 6.3 https://images.app.goo.gl/fwQjRT7DmLVNro3p8
14. Fig 6.4 https://images.app.goo.gl/oVMhBmv9nmy3vDHy6
15. Fig 6.5 https://images.app.goo.gl/cregaty2vadozfG17
16. Fig 6.6 https://images.app.goo.gl/NkR3Fk1SavFPwYCS9
17. Fig 6.7 https://images.app.goo.gl/TJsxiemz1RM5HmVQ6
18. Fig 6.9 https://images.app.goo.gl/meo8vXDfCtkaYPut9
19. Fig 6.10 https://images.app.goo.gl/JcKZx4DeY8nzhfCMA
20. Fig 6.11 https://images.app.goo.gl/ymHZrNAoPzyafgya6
21. Fig 7 www.larsentoubro.com
22. Fig 8.1 https://images.app.goo.gl/4nsrfBJqdJtfQsUF7
23. Fig 8.3 https://images.app.goo.gl/GsF9JvxrCgLPUHHN9
24. Fig 8.4 https://images.app.goo.gl/nADazKqukktqCfg28
25. Fig 8.6 https://images.app.goo.gl/M1J5yTixbQdbfsjM8
26. Fig 9.1.1 https://images.app.goo.gl/79sEoriz3NhNhmQJ6
27. Fig 9.1.2 https://images.app.goo.gl/HxdiXw2BW7VmGGaC9
28. Fig 9.1.3 https://images.app.goo.gl/G3QWv24sidG37RfQ9
29. Fig 9.1.4 https://images.app.goo.gl/2PuXWu9yikEUWncXA
30. Fig 9.1.5 https://images.app.goo.gl/nTpa9G9PCRHcjrSJ7
31. Fig 9.2.1 https://images.app.goo.gl/P3KL4K89S87E69Ys9
32. Fig 9.2.2 https://images.app.goo.gl/jn1ne1UP6KRqTtGY9
33. Fig 9.2.3 https://images.app.goo.gl/UMNxPgR8PcaCDCVr7
34. Fig 10.1 https://images.app.goo.gl/7XFUzrJyiAEoFnzm8
35. Fig 11.1 https://images.app.goo.gl/A8rdyCNQ5nzY6kks8
36. Fig 11.2 https://images.app.goo.gl/9oMDkDpMgEF2Vfm3A
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37. Fig 13.1 https://images.app.goo.gl/juPYCSRmzovpiuWP8

38. Fig 13.2 https://images.app.goo.gl/QK69z6v23P3jY8eR7
39. Fig 13.3 https://images.app.goo.gl/p47AeT34JGr3Weph6
40. Fig 13.4 https://images.app.goo.gl/rbmz1b2HB5PynaGW8
41. Fig 16.1 https://images.app.goo.gl/SyU7LH9r4aKtVAnq8
42. Fig16.2https://images.squarespace-cdn.com/content/v1/5af3a1255cfd795b7630a981/1598420020730-
BQ7VZYBW9Y8257U4KX47/drill.png?format=1000w
43. Fig 17.1 https://images.app.goo.gl/FJWqLLS3uNjXb2WM9
44. Fig 17.1 https://images.app.goo.gl/L5vnMrj7vwQS2MeL9
45. Fig 18 https://images.app.goo.gl/xrpYv5CMzHz1DttCA
46. Fig 18 https://images.app.goo.gl/JFeqagQmTLx3iEiSA
47. Fig 19 https://images.app.goo.gl/oR2nnSmAtUpKX2Xu5

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HEAT TREATMENT AND STACKING OF PARTS OF PINAKA

A PROJECT/ INTERNSHIP REPORT

In partial fulfilment for the award of the degree of

C.K. PITHAWALA COLLEGE OF ENGINEERING

GUJARAT TECHNOLOGICAL UNIVERSITY

C.K. Pithawala College of Engineering and Technology,

DR. KALPESH D MANIYA DR. KALPESH D MANIYA

Gujarat Technological Univesity Page ii

Gujarat Technological Univesity Page iii

C.K. PITHAWALA COLLEGE OF ENGINEERING AND

Name of Student Signature of Student

Gujarat Technological Univesity Page iv

Gujarat Technological Univesity Page v

Gujarat Technological Univesity Page vi

Figure 2.1 ISO 9001:2015.................................................................21

Figure 2.2 ISO 14001:2015..............................................................22

Figure 2.3 AS 9100D........................................................................23

Figure 2.4 OHSAS 45001:2018........................................................24

Figure 3.1 Report safety concern.....................................................25

Figure 3.2 Safety Shoes...................................................................26

Figure 3.3 safety Helmet..................................................................26

Figure 3.4 safety goggles...................................................................26

Figure 3.5 Boiler suit........................................................................26

Figure 3.6 Full body harness...........................................................27

Figure 3.7 gloves...............................................................................27

Figure 3.8 hearing protection..........................................................27

Figure 5.1 Pinaka missile.................................................................28

Figure 5.2 Cradle structure..............................................................29

Figure 6.1 Fabrication shop.............................................................31

Figure 6.2 Machining shop...............................................................31

Figure 6.3 Wielding shop..................................................................32

Figure 6.4 Heat Treatment Shop.....................................................32

Figure 6.5 Quality Control................................................................33

Figure 6.6 Testing Lab.....................................................................33

Figure 6.7 blasting shop....................................................................34

Figure 6.9 integration shop...............................................................34

Figure 6.10 finance and accounting.................................................35

Figure 6.11 store................................................................................35

Figure 7.1 Bill of material.................................................................36

Figure 8.1 SA516-GR70...................................................................37

Figure 8.2 A333GR6.........................................................................38

Figure 8.3 A106GRB........................................................................38

Figure 8.4 SA350LF2CL1...................................................................................................39

Figure 9.1.1 Visual Testing..............................................................41

Figure 9.1.2 Magnetic Particle Test.................................................42

Figure 9.1.3 Liquid Penetrant Test...................................................43

Figure 9.1.4 Radiographic Test.........................................................44

Figure 9.1.5 Ultrasonic Test.............................................................45

Figure 9.2.1 Impact Test...................................................................46

Figure 9.2.2 Bending Test...............................................................47

Figure 9.2.3 Ultimate Tensile Strength.............................................48

Figure 10.1 Nesting..........................................................................49

Figure 11.1 Laser Cutting.................................................................51

Figure 11.2 Waterjet Cutting............................................................53

Figure 12 Plate Cutting Layout.........................................................58

Figure 13.1 Mig Welding...................................................................60