VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI-590018, KARNATAKA

A Technical Seminar Report on

“CONFORMA CLAD”

Submitted in partial fulfilment of the requirements for awarding the degree of

Bachelor of Engineering in Mechanical Engineering
In the academic year 2021-2022

Submitted by

AMRUTHESH V GURIKAR

(1RN19ME401)

Under the guidance of

Mr. Mahesh Kumar N
Assistant Professor

Department of Mechanical Engineering

RNS INSTITUTE OF TECHNOLOGY
(AICTE Approved, VTU Affiliated & NAAC ‘A’ Grade Accredited)
UG Programs - CSE, ECE, ISE, EIE and EEE have been Accredited by NBA for the
Academic years 2018-19, 2019-20 and 2020-2021
Dr. Vishnuvardhan Road, Raja Rajeshwari Nagar, Channasandra, Bengaluru-560098
2021 - 2022
 RNS INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
BANGALORE - 560098

CERTIFICATE

This is to certify that the Technical Seminar on “CONFORMA CLAD” has been
successfully completed by AMRUTHESH V GURIKAR (1RN19ME401), Bonafede
student of RNS Institute of Technology in partial fulfilment of the requirements for
Bachelor of Mechanical Engineering in Visvesvaraya Technological University, Belagavi
during academic year 2021-2022. It is certified that all corrections/suggestions indicated for
Assessment have been incorporated in the report deposited in the departmental library. The
design project report has been approved as it satisfies the academic requirements in respect
of Assessment of said course.

Signature of Guide Signature of HOD

Mr. Mahesh Kumar N Dr. Mukesh Patil

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 DECLARATION

I, AMRUTHESH V GURIKAR (1RN19ME401), student of VIII semester B.E., Mechanical

Engineering, RNS Institute of Technology, Bengaluru, hereby declare that the Technical
Seminar on “CONFORMA CLAD” has been carried out by me and submitted in partial
fulfilment of the requirement for Bachelor of Engineering in Mechanical Engineering of
Visvesvaraya Technological University, Belagavi, during academic year 2021-2022.

Date: 10/06/2022 Amruthesh V Gurikar

1RN19ME401

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 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task would be
incomplete without the mention of the people who made it possible, whose constant guidance
and encouragement crowned the efforts with success.

I would like to thank the Management of RNS Institute of Technology for providing such a
healthy environment for the successful completion of this seminar.

I would like to express my thanks to the Principal Dr. M K Venkatesha for their
encouragement that motivated us to successfully complete the Seminar.

It gives me immense pleasure to thank Dr. Mukesh Patil, Professor and Head of Department,
Mechanical Engineering for his constant support and encouragement.

I wish to express my deepest sense of gratitude to my project guide Mr. Mahesh Kumar N,
Assistant Professor, Department of Mechanical Engineering, for his constant support and
guidance throughout the project.

Last, but not the least, I would like to hereby acknowledge and thank my parents who have
been a source of inspiration and also instrumental in the successful completion of my seminar.

Amruthesh V Gurikar

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 CONTENTS

ACKNOWLEDGEMENT.…..………………………………………………….4
INTRODUCTION…………………………………………………………………………6
o Conforma Clad

LITERATURE SURVEY……………………………………………………….8
o Cladding
o Infiltration Brazing
o Wear
o GD & T
o Surface Finish
PRODUCT……………………………………………………………………..12
o Shaft Sleeve
o Slurry Pump
PROCESS……………………………………………………………………...14
QUALITY CONTROL………………………………………………………...15
o Control Plan
o Quality Assurance Plan
ADVANTAGES OF CONFORMA CLAD…………………………………...20
FURTHER EXPLANATION FOR VARIOUS APPLICATIONS……………21
CONCLUSION………………………………………………………………...23
REFERENCES

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 INTRODUCTION
CONFORMA CLAD
As pioneers in the field of infiltration brazed tungsten carbide cladding, Kennametal
Conforma Clad™ spent four decades developing and refining high end wear solutions for
industry. We utilize three standard tungsten carbide cladding formulas - WC200, WC210,
WC219- that provide superior wear protection for a wide range of operating conditions and
wear modes. In addition to the standard tungsten carbide cladding formulas, we also offer
custom formulations to fit specific customer requirements.

The Conforma Clad process produces claddings with densely loaded particles of tungsten
carbide, resulting in exceptional resistance to abrasion and erosion relative to other hardfacing
solutions such as chrome carbide weld overlay and thermal sprays.

How it Works

1. Powder Mixing 2. Cloth Formation

Selected Powders and organic binders are Material rolled to predetermined thickness
mixed. and density.

3. Cloth Cutting 4. Furnace Brazing

Cloth cut to shape and applied to metal Clad component is place in furnace and
components with low temperature heated. The molten alloy wicks down into
adhesive. a layer of tungsten, carbide particles,
metallurgically bonding the hard particles

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7
 LITERATURE SURVEY

CLADDING
Cladding is the bonding together of dissimilar metals. It is different from
fusion welding or gluing as a method to fasten the metals together. Cladding is often achieved
by extruding two metals through a die as well as pressing or rolling sheets together under
high pressure. It is a weld overlay process yielding an entirely new surface that can be used
with a large variety of overlay materials in different forms such as powder, wire, or a cloth
form.

INFILTRATION BRAZING
Vacuum Brazing is a process that creates high quality joints under temperatures from
about 800°C to 1150°C in a vacuum atmosphere. This also allows for the joining of different
materials like for example carbide to steel.
Basically, brazing is a process that combines elements with the use of a brazing material.
Prepared elements with applied brazing material are placed in a vacuum furnace and heated up
to brazing temperature (from 800 to 1150°C) which is higher than the liquidus temperature. At
this temperature, the parts are held for a short time (10 min) and then are slowly cooled to
solidus temperature. This also allows for the joining of different materials like for example
carbide to steel.

During the process, the appropriate level of vacuum needs to be kept. Brazing in a vacuum
furnace can also take place in a protective atmosphere, most often an argon atmosphere.

APPLICATIONS:

The most important properties of vacuum brazed connections are as follows:

• Very strong and reproducible joints. Equal to or even stronger than the basic material.
• By using precious brazing material, corrosion resistant joints are created.
• Joints can be exposed to relatively high temperatures. (< 800 ºC)
• Clean process. Products remain metallically blank.
• Brazing without flux agents. Therefore, no undesirable surface reactions.
• Very clean, hygienic gap free joint. Important for the food or medical industry.
• Vacuum tight/leak proof joints.
• Possibility of joining various materials with each other (e.g.: metal-ceramics).
• Brazing and hardening possible in a single process.
• Parts can undergo practically all hardening processes after a brazing treatment.
• High level of construction freedom; thick/thin is possible, large surfaces can be
joined.
• More than one joint can be created in a single process. The creation of complex
products is possible
• High level of dimensional stability possible, no or practically few distortions.

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WEAR

The removal of material from a solid surface as a result of mechanical action exerted by
another solid. Wear chiefly occurs as a progressive loss of material resulting from the
mechanical interaction of two sliding surfaces under load.

Wear is such a universal phenomenon that rarely do two solid bodies slide over each other or
even touch each other without a measurable material transfer or material loss. Thus, coins
become worn as a result of continued contact with fabrics and human fingers; pencils become
worn after sliding over paper; and rails become worn as a result of the continued rolling of train
wheels over them. Only living things (such as bone joints) are in some sense immune to the
permanent damage caused by wear, since they have the property of regrowth and healing.

There are four basic types of wear: adhesive, abrasive, corrosive, and surface-fatigue.

The most common type, adhesive wear, arises from the strong adhesive forces that are
generated at the interface of two solid materials. When solid surfaces are pressed
together, intimate contact is made over a number of small patches or junctions. During sliding,
these junctions continue to be made and broken, and, if a junction does not break along the
original interface, a wear particle is formed. These particles eventually break away. Adhesive
wear is undesirable for two reasons: first, the loss of material will eventually lead to a
deterioration in the performance of the mechanism; and second, the formation of large wear
particles in closely fitted sliding members may cause the mechanism to seize at an early stage
in its productive life. Adhesive wear is many times greater for unlubricated than for effectively
lubricated metal surfaces.

Abrasive wear occurs when a hard, rough surface slides over a softer one, producing grooves
on the latter. It also can be caused by loose, abrasive particles rolling between two soft sliding
surfaces or by particles embedded in one of the opposing surfaces. Abrasive fragments borne
by a stream of liquid or gas may wear down a surface if they strike the surface at high speeds.
Since abrasive wear takes place when the abrading material is rough and harder than the surface
to be abraded, it can be prevented either by eliminating the hard, rough constituent or by
making the surface to be protected harder still.

Corrosive wear occurs whenever a gas or liquid chemically attacks a surface left exposed by
the sliding process. Normally, when a surface corrodes, the products of corrosion (such as
patina) tend to stay on the surface, thus slowing down further corrosion. But, if continuous
sliding takes place, the sliding action removes the surface deposits that would otherwise protect
against further corrosion, which thus takes place more rapidly. A surface that has experienced
corrosive wear generally has a matte, relatively smooth appearance.

Surface-fatigue wear is produced by repeated high stress attendant on a rolling motion, such
as that of metal wheels on tracks or a ball bearing rolling in a machine. The stress causes
subsurface cracks to form in either the moving or the stationary component. As these cracks
grow, large particles separate from the surface and pitting ensues. Surface-fatigue wear is the
most common form of wear affecting rolling elements such as bearings or gears. For sliding
surfaces, adhesive wear usually proceeds sufficiently rapidly that there is no time for surface-
fatigue wear to occur.

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GD & T

Geometric Dimensioning and Tolerancing (GD&T) is a system for defining and

communicating engineering tolerances and relationships. It uses a symbolic
language on engineering drawings and computer-generated three-dimensional solid
models that explicitly describe nominal geometry and its allowable variation. It tells the
manufacturing staff and machines what degree of accuracy and precision is needed on each
controlled feature of the part. GD&T is used to define the nominal (theoretically perfect)
geometry of parts and assemblies, to define the allowable variation in form and possible size
of individual features, and to define the allowable variation between features.

Geometric Tolerancing Reference Chart (per ASME Y14.5 M-1982)

Type of control Geometric Characteristics Symbol

Form Straightness

Form Flatness

Form Circularity

Form Cylindricity

Profile Profile of a line

Profile Profile of a surface

Orientation Perpendicularity

Orientation Angularity

Orientation Parallelism

Location Symmetry

Location Position

Location Concentricity

Run-out Circular run-out

Run-out Total run-out

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SURFACE FINISH

Surface finish, also known as surface texture or surface topography, is the nature of a surface
as defined by the three characteristics of lay, surface roughness, and waviness. It comprises the
small, local deviations of a surface from the perfectly flat ideal (a true plane).

There are wide ranging variations in finishing and edge conditions. Listed are some of the more
common manufacturing techniques and their corresponding Ra surface finish values. See how
ISO Finishing compares to common metal manufacturing practices.

Ra, Is the Arithmetic Average of the Absolute values of roughness profile ordinates.
Most commonly used unit of surface measurement.
Statistically very stable and repeatable parameter
A good parameter where process is under control.
Not a good discriminator between peaks and valleys.
Not a good measure for sealed surface.

Rq – RMS, Root Mean Square Average of the roughness profile ordinates.

Is more sensitive to peaks and valleys then Ra
Used to control very fine surfaces in scientific measurements and statistical evaluations.

Rz, Maximum roughness height

Is more sensitive than Ra to changes in surface finish as maximum profile heights and not
averages are being examined.
Rz and Rt are used together to monitor the variations of surface finish in production process.
Similar values of Rz and Rt indicate the consistent surface finish.

ROUGHNESS

Roughness is the closely spaced irregularities on a machined surface. These

irregularities mainly consist of feed marks. Feed marks are the result of the overlapping tool
paths made by each successive cutting edge as it engages the workpiece. Consider once again
the sample profile record shown in Figure 1. Although this is the same machined surface, the
profile recorder is set to record roughness only.

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 PRODUCT

SHAFT SLEEVE
A shaft sleeve is a hollow metal tube, cylindrical in shape, which is mounted over a shaft
and shaft assembly to protect it in a corrosive environment. Shaft sleeves are commonly found
in single stage pumps. The pump shaft usually offers protection from corrosion and erosion.

Material – Steel Clad Thickness – 1.5mm

HRc – 28/36 Clad Length – 164.62mm
AISI 4140 Clad Area – 74201.43mm2
Major Dia – 146mm Clad HRc – 58-68
Minor Dia – 100mm WC 210
Length – 171mm

APPLICATIONS
• Slurry pumps
• Bottom pumps
• FCC charge pumps
• Residual oil pumps
• Coke drum charge pumps

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SLURRY PUMPS
A slurry pump is a type of pump designed for pumping liquid containing solid
particles. Slurry pumps changes in design and construction to adjust to multiple type of slurry
which varies in concentration of solids, size of solid particles, shape of solid particles, and
composition of solution. Slurry pump are more robust than liquid pumps; they have added
sacrificial material and replaceable wear parts to withstand wear due to abrasion.
Slurries are mixtures of solids and liquids, with the liquid serving as the transport mechanism
used to move the solid. The size of the particles (or solids) in slurries ranges from one micron
in diameter up to hundreds of millimetres in diameter. The particle size significantly impacts a
pump's ability to move a slurry through a process line.

All slurries share five essential characteristics:

1. More abrasive than pure liquids.

2. Thicker in consistency than pure liquids.
3. May contain a high number of solids (measured as a percentage of the total volume).
4. The solid particles usually settle out of the slurry's precipitate relatively quickly when
not in motion (depending on the particle size).
5. Slurries require more energy to move than do pure liquids.

Slurries are further classified by industry into four classes based on how aggressive they are
— Class 1 being the least aggressive and Class 4 the most aggressive. The pumping of slurries
can have the following wear impacts on both pumps and pipeline components:

• Abrasions: including gouging, high-stress grinding, and low-stress grinding (applicable

only with settling-type slurries).
• Erosion: the loss of surface materials caused by the action of the particles in the slurry
being pumped. Erosion is primarily found with the pumping of settling-type slurries.
• Corrosion: caused by the electrical galvanic action in the fluid being pumped. Certain
types of slurries (e.g., highly acidic or alkaline compounds) will have more impact on
component corrosion than will more benign slurries.

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 PROCESS

Steel Inward
Inspection

Washing

Grit Blasting Silicon Carbide

Tungsten Carbide Cloth Application Braze cloth

Furnace Charge
Preparation

Temp – 10200 C
Furnace Brazing
Pressure – 6 mBar

Stage Inspection

Welding /
Surface Finish Ra 0.8μm
Grinding

Final Inspection

Mark pack &

Dispatch 14
 QUALITY CONTROL

QUALITY
• Product fitness for use.

• The totality of the features and characteristics that bear on the products ability to satisfy
the given need
a. Performs Functional Reliably

b. Performs Function in a Designed Way

c. Performs Function for a Long Time

INSPECTION
“Measuring the dimensions what has been produced or what is being produced, whether it
complies to the specification specified”

• Post Process inspection:

Measurement made after the part has been produced.

a. High cost operation already completed

b. Difficult to identify the defects

c. Difficult to identify the responsibility for the defect

d. High cost rejection or rework.

• On process inspection:

Measurement made while part being produced.

a. Defect being identified very early stage itself and at each stage

b. Facilitate continuous improvement

c. Cost of rejection or rework reduced.

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CONTROL PLAN
A control plan is a living document that outlines the methods taken for quality control
of critical inputs to deliver outputs that meet customer requirements. It also provides a written
description of the measurements, inspections, and checks put in place to control production
parts and processes.
The document is used in a PPAP if there is a process change or if a new process is
implemented. Control plans are consistently maintained to reflect real time updates.

Control Plan Outline

1. General part and supplier information

• Part number
• Supplier name and contact information
• Approval and revision dates

2. Process Steps and Support Equipment

• Part/process number – this matches up to steps in the PFMEA and process flow
diagram.
• Process name and description – thoroughly describes what each process step
accomplishes.
• Device reference numbers – lists any special tools or machines used to carry out the
process step.

3. Product and Process Characteristics

• Characteristic number - References a unique number of each characteristic being

checked.
• Characteristic of product or process (one or the other)
o Product characteristic - If the characteristic being checked is on a product then
then the product box will be filled in with a description (i.e. screw depth).
o Process characteristic - If the characteristic being checked is of a process then
the process box will be filled in with a description (i.e. drive screw at 45 degree
angle).
• Critical to quality (CTQ) feature– box is marked with a Y for yes and N for no if the
characteristic is important to quality.

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4. Methods of Control

• Specification and tolerance – notes any unique specification and tolerance for each
product or process characteristic being checked.
• Evaluation method –describes measurement technique used to evaluate each
characteristic being checked.
• Sample (only if evaluation method involves a sample)
o Sample size – the number of part or process samples taken to check from
production (i.e. 5 parts).
o Sample frequency – the interval at which each sample is being taken (i.e. sample
checked hourly).
• Control method – specifies how control is maintained for each characteristic (i.e. error
proofed).
• Reaction plan – describes the reaction the process monitors if an unexpected condition
occurs (i.e. re-inspect all products produced after the last inspection).

Why is a control plan important?

The development of a control plan not only helps suppliers diagnose their quality
challenges, but also helps them eliminate production waste and maintain consistency. In
addition, suppliers use control plans to establish methods of process control during production
and to stop issues from snowballing into something more detrimental. Implementing control
plans help suppliers overcome critical challenges and focus on points that are most important
to their customers such as product quality, process efficiency, and expense reduction.

Types of Control Plans

• Prototype

A prototype control plan is applicable if a component is in the early phase of

development. This is inclusive of descriptions of dimension measurements, materials,
and performance tests happening during a prototype development.

• Pre-launch

A pre-launch control plan is applicable when the prototype phase is complete for a
component but full production has yet to be approved. This is inclusive of dimension
measurements, materials, and performance tests conducted after the prototype phase is
complete.

• Production

A production control plan is applicable when a component is in full production. The

plan is comprehensive of characteristics, process controls, tests, and measurements
conducted through full production.

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QUALITY ASSURANCE PLAN
A Quality Assurance Plan (QAP) is used to define the criteria and processes that will
ensure and verify that data meet specific data-quality objectives throughout the Data
Lifecycle. It is also defined as a document created by the project team, which if followed, will
ensure the finished product meets all criteria making it the best possible quality product. The
product should not only meet all customer requirements but also meet the business objectives
and targets.

Sample QAP

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QAP for Shaft Sleeve

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 ADVANTAGES OF CONFORMA CLAD
• Cladding microstructure is consistent throughout, with minimal dilution and a
tight interface between cladding and substrate. This consistency facilitates wear
monitoring while parts are in service as the cladding will wear uniformly from top
to bottom.
• Cladding has minimal porosity, typically less than 3 percent, and no
interconnected porosity.
• Cladding has a strong metallurgical bond (>70,000 psi), ensuring no unexpected
loss of protection in application such as flaking or spalling.
• Cladding can be used in operating temperatures up to approximately 1850°F and
has excellent high temperature erosion resistance in fine particle erosion streams.
• Cladding can be applied to complex geometries, inside diameters, and other non-
line-of-site surfaces that are unreachable by other methods.
• Third party testing has shown that 1/16” of Conforma Clad cladding is equivalent
to 1” of chrome carbide weld overlay or 3” of carbon steel plate in fly ash erosion
applications, making it the solution of choice when weight considerations are
paramount, such as fans.

1. Cladding - Dense Carbide Loading/Uniform Distribution

2. Bond Line - True Metallurgical Bond
3. Diffusion Zone - Minimal Dilution
4. Substrate - Retains Substrate Properties When Heat Treated

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FURTHER EXPLANATION FOR VARIOUS APPLICATIONS

Industries benefitting from Conforma Clad solutions include but are not limited
to:

• Mining
• Mineral Processing
• Cement
• Recycling
• Pulp & Paper
• General Engineering

Chute Pump Casing

Fan Blade Exhauster Pump Cover

21
Pump Impeller Shaft Sleeve

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 CONCLUSION
After thorough understanding of the process of conforma clad by observing all the various steps
in it, I focused mainly on the hands-on experience of cloth application and cataloging my report
on conforma clad. While making a report, I learnt a lot of practical aspects about a large-scale
industry.
The report contains all the major observations and conclusions regarding my work as an intern.
It also contains information on various application and advantages of conforma clad
technology.

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REFERENCES
1. https://www.kennametal.com
2. https://en.wikipedia.org/wiki/Kennametal
3. https://www.kennametal.com/in/en/products/conforma-clad-wear-resistant-
coatings/cloth-based-cladding.html
4. https://www.kennametal.com/us/en/products/conforma-clad-wear-resistant-
coatings.html
5. https://www.kennametal.com/in/en/products/conforma-clad-wear-resistant-
coatings/general-industrial.html
6. https://www.aalberts-st.com/processes/vacuum-
brazing/#:~:text=Vacuum%20Brazing%20is%20a%20process,for%20example%20ce
ramic%20to%20steel.
7. https://www.sciencedirect.com/topics/engineering/shaft-sleeve
8. https://www.gdandtbasics.com/gdt-symbols/
9. https://www.grammarly.com/blog/how-to-write-a-report/
10. https://www.csidesigns.com/blog/articles/slurry-pump

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