Indian Metallurgy: The Platinum Years (Indian Institute of Metals Series)

Series Editor’s Preface
Preface
Growth of IIM and Metallurgy in India During the Last 75 Years
Current Series Information
Contents
Editors and Contributors
Part I Industry
1 Research and Development in Tata steel—The Past, the Present and the Future
	1.1 Introduction
	1.2 The Inception
	1.3 The Formative Years
	1.4 From Howrah Bridge to ‘Tatanagars’
	1.5 Overcoming Challenges in Iron Making
	1.6 Perfecting Steelmaking
	1.7 Quest for New Products
	1.8 Pursuing Intellectual Property
	1.9 A Leap into the Future
	1.10 Conclusion
	References
2 WIL’s Contribution in Development of Welding for Exotic Materials
	2.1 Walchandnagar Industries Ltd: Feather in Our Nation’s Cap with a Benchmark for Engineering Excellence
	2.2 Birth of the Organisation
		2.2.1 Early Years
	2.3 Walchandnagar Industries Ltd
	2.4 Achievements of WIL at a Glance
		2.4.1 First Ever
		2.4.2 First to Manufacture
	2.5 Welding Development in ESR Modified 15CDV6 Material [2-3]
		2.5.1 Optimization of HT Procedure for 15CDV6 Material
	2.6 Metallurgical Study of Aluminium Bronze (Non-ferrous Overlay) on Low Alloy Steel
		2.6.1 Metallurgical Analysis
		2.6.2 Hardness Traverse Analysis
		2.6.3 Conclusion
	2.7 Welding Technology for Stainless Steel Containing 1.2% Boron Content [1]
	References
3 Mukand—Quality Leadership in Stainless Steel, and Special and Alloy Steel Long Products
	3.1 Introduction
	3.2 The Foundry
	3.3 The Steel Plant
	3.4 Pioneering Spirit
	3.5 Development of Stainless Steel at Mukand
	3.6 Specialised Alloy Steel Development at Mukand
	3.7 Increase in Production as Markets Mature
	3.8 Research and Development (R&D)
	3.9 Total Quality Management
	3.10 Awards and Recognitions
	3.11 Gearing Up for the Millennium
	References
4 History of Indian Rare Earths Limited
	4.1 Genesis
	4.2 Operation
	4.3 Market Outreach
	4.4 Current Projects
		4.4.1 Projects in the Value Chain of Rare Earths and Minerals
		4.4.2 Pilot plant for Titanium Dioxide and Zirconium Oxy-Chloride
		4.4.3 Titanium Slag
	4.5 Mineral Projects
		4.5.1 Capacity expansion of OSCOM
		4.5.2 Hrushikulya-BajrakotBrahmapur Deposit (BSM), Odisha
		4.5.3 Bramhagiri Mineral Sands Deposit (BSM), Odisha
		4.5.4 Inayam-Midalam Deposit (BSM), Tamil Nadu
		4.5.5 Kudiraimuzhi Deposit (BSM) in Tamil Nadu
		4.5.6 Donkuru-Boruva (BSM) Deposit in Andhra Pradesh
		4.5.7 BoruvaBendi (BSM) Deposit in Andhra Pradesh
	4.6 RE Source Augmentation
		4.6.1 Ambadongar Deposit
		4.6.2 Bramhagiri RE Plant
	4.7 Summary
5 The DASTUR Story
	5.1 The Making of a Visionary
		5.1.1 A Firm Believer in the Concept of ‘Atmanirbhar Bharat’
	5.2 Giving Shape to a Vision
	5.3 Dreams Take Wings
	5.4 Distinguishing Features of DASTUR
	5.5 Professional Integrity and Conviction
	5.6 Catering to Evolving Market Requirements
	5.7 Vision for the Future
	5.8 DASTUR’s Association with The Indian Institute of Metals (IIM)
	5.9 DASTUR—The Consistent Pursuit of Excellence and Innovation
6 Hindalco’s Journey Over a Period of Six Decades: Making the World Greener-Stronger-Smarter
	6.1 Introduction
	6.2 Hindalco’s Journey
		6.2.1  The Beginnings
		6.2.2 Brownfield Expansion and Technology Upgradation
		6.2.3 Greenfield Expansions and Acquisitions
		6.2.4 Securing Raw Materials
	6.3 Technological Challenges and Innovations
		6.3.1 Development of Specialty Alumina and Hydrates
		6.3.2 Bauxite Residue use Towards Circular Economy
		6.3.3 Development of Energy Efficient Aluminium Smelting Technology
		6.3.4  Downstream Application Developments
	6.4 Going Global
	6.5 We have set out clear strategic priorities for ourselves as we embark on the next phase of our growth journey:
		6.5.1 Focus on Value Added Products
		6.5.2 Strong Environment Social and Governance (ESG) Commitment
	6.6 Concluding Remarks
	References
7 MECON's Journey of Six Decades—A Saga of Engineering Excellence in Iron and Steel
	7.1 Genesis and Profile
	7.2 Achievements
		7.2.1 Projects in Strategic Sectors
		7.2.2 Oil and Gas
		7.2.3 Power
		7.2.4 Infrastructure
		7.2.5 Overseas Operations
		7.2.6 Alignment with National Priorities
	7.3 Atmanirbhar Bharat
	7.4 Service Portfolio
	7.5 Summing Up and Future Vision/Outlook
8 BALCO’s Journey: A Story of Growth, Determination, and Transformation
	8.1 Laying the Foundation Stone
	8.2 The Story of Success
	8.3 Making India Self-reliant
	8.4 Stride Towards Excellence
	8.5 Milestones over Four Decades and Journey or Rolled Products
	8.6 Towards the Betterment of Society
	8.7 Environmental, Social, and Governance (ESG) Initiatives
	8.8 Summary
9 JSW Steel—Journey with Speed and Innovation
	9.1 Introduction
	9.2 Introducing New Technologies and Unique Initiatives
	9.3 Human Resources and Corporate Social Responsibility
	9.4 Summary
Part II Research and Development Organisation
10 Seven Decades of Metallurgical Excellence—CSIR-NML
	10.1 Introduction
	10.2 Legacy Achievements
		10.2.1 Ferroalloys Production (Circa 1960–65)
		10.2.2 Pioneering Sponge Iron Production in India (Circa 1970–75)
		10.2.3 Pioneering Magnesium Production in India and Related Developments (Circa 1970–1987)
		10.2.4 Establishment of the Largest Creep Testing Laboratory (Circa 1970)
	10.3 Recent Scientific and Technological Achievements
		10.3.1 Steel
		10.3.2 Coal
		10.3.3 Strategic Metals
		10.3.4 Industrial Wastes Valorisations and Effluents Treatment
		10.3.5 Devices and Equipment Development
		10.3.6 Functional Materials
		10.3.7 Structural Health Monitoring
	10.4 Working for the Society
		10.4.1 Assisting Artisans
		10.4.2 CSIR Integrated Skill Initiative
		10.4.3 Interactions with Students and Schools
	10.5 Epilogue
11 Molten Salt Electrowinning of Metals and Materials: Opportunities and Challenges
	11.1 Introduction
	11.2 Principles of Metal Extraction Processes and Electrometallurgy
	11.3 Molten Salt Electrolysis
		11.3.1 Important Parameters in Designing Efficient Molten Salt Systems
	11.4 Extraction of Alkali and Alkaline Earth Metals Through Molten Salt Electrolysis
		11.4.1 Electrowinning of Sodium Metal Through Molten Salt Electrolysis
		11.4.2 Electrowinning of Lithium Metal Through Molten Salt Electrolysis
		11.4.3 Calcium Metal Production Through Molten Salt Electrolysis
		11.4.4 Production of Magnesium Metal Through Molten Salt Electrolysis
	11.5 Molten Salt Electrowinning of Refractory Metals
	11.6 Rare Earth Metals
		11.6.1 Electrochemistry of Rare Earths
		11.6.2 Electrowinning of Rare Earths
		11.6.3 Electrowinning of Rare Earths at CSIR-CECRI
	11.7 Challenges in Molten Salt Electrolysis
	11.8 Scope for Molten Salt Metallurgy
	11.9 Author Contributions
	References
12 Contribution of Bhabha Atomic Research Centre to the “Metals Journey of India”
	12.1 Introduction
	12.2 Technologies Developed at BARC
		12.2.1 Zirconium, Hafnium and Titanium, and Their Alloys and Applications
		12.2.2 Materials for Fuel: Uranium, Plutonium and Thorium
		12.2.3 Refractory Metals: Niobium, Tantalum, Vanadium, Molybdenum and Tungsten
		12.2.4 Cobalt
		12.2.5 Rare Earth Metals
		12.2.6 Alkali Metals: Lithium, Magnesium and Calcium
		12.2.7 Light Elements: Beryllium and Boron
		12.2.8 Ferroalloys
	12.3 Alloy Development Programme: Evaluation of Physical, Mechanical and Corrosion Properties
	12.4 Future Perspectives
	References
13 Galvanizing Industry in India—Past, Present & Future
	13.1 Introduction
	13.2 Global and Indian Scenarios
	13.3 Why Galvanize?
	13.4 Hot Dip Galvanizing
	13.5 Galvanizing—Past
	13.6 Galvanizing—Present
	13.7 Galvanizing—Future
	13.8 Conclusion
14 Lead Recycling in India—Imperative Need for Affirmative Actions
	14.1 Introduction
	14.2 Evolution
	14.3 Summary
15 Defence Metallurgical Research Laboratory: Relentless Journey Towards Materials Galore
	15.1 Introduction
	15.2 Core Competence
	15.3 Protective Armour Technologies
	15.4 Ammunition Technologies
	15.5 Shaped Charge Warhead Liner Technology
	15.6 Technologies for Naval Steels
	15.7 Investment Casting Technologies for Superalloys
	15.8 Life Prediction Technologies for Aero-Engine Components
	15.9 Extraction of Reactive and Refractory Metals
		15.9.1 Titanium Sponge
		15.9.2 Magnesium
		15.9.3 Tungsten
	15.10 Titanium Alloys for Aircraft Components
	15.11 Powder Processing Technologies
	15.12 Materials for Hypersonic Vehicles
	15.13 Liquid Silicon Infiltration (LSI) Technologies
		15.13.1 Reaction Bonded Silicon Carbide (RBSC)
		15.13.2 Cf-C-SiC Jet Vanes
	15.14 Near Net Shape Technologies
	15.15 Electronic Materials
	15.16 Metal Foam Technologies
	15.17 Advanced Magnetic Materials Technology
	15.18 Advanced Metal Joining Technologies
	15.19 Tribological Technologies
	15.20 Additive Manufacturing
	15.21 Outlook for the Future
	15.22 Summary
16 Metallic Materials R&D in Vikram Sarabhai Space Centre: Past, Present and Future
	16.1 Introduction
	16.2 Genesis of Metallic Materials Research at Thumba
	16.3 History of Development of Maraging Steel for Solid Rocket Boosters
	16.4 On-Demand Materials for Rocket Science
		16.4.1 High Strength Aluminium Alloys
		16.4.2 Titanium Alloys
		16.4.3 Magnesium Alloys
		16.4.4 Steels for Cryogenic Applications
		16.4.5 Materials for High Temperature Applications
		16.4.6 Investment Castings for Cryo/semi-Cryogenic Engines
		16.4.7 Special Purpose Materials
	16.5 Welding Metallurgy
		16.5.1 Friction Stir Welding of Aluminium Alloy Propellant Tanks
	16.6 Developments in Non-destructive Testing of Materials
	16.7 Facilities for Material Processing and Characterisation
	16.8 Materials Research Activities at Liquid Propulsion Systems Centre
	16.9 Fifty Years of Materials Development Activities in ISRO and Future Goals
		16.9.1 Additive Manufacturing
		16.9.2 Indigenisation of Flow Forming Alloys
	16.10 Conclusion
	References
17 Nuclear Fuel Complex—A Five Decade Success Story of Indian Nuclear Power Program
	17.1 Relevance of Nuclear Power
	17.2 Dr. Homi J. Bhabha—Father of the Three-Stage Nuclear Power Program in India
	17.3 Birth of Nuclear Fuel Complex
	17.4 Timeline of Milestones
	17.5 Production Activities in NFC
	17.6 Contributors to the Success of NFC
		17.6.1 Nuclear Fuel Manufacturing Plants
		17.6.2 Reactor Grade Zirconium Metal Production Plant
		17.6.3 Fuel Cladding and Assembly Components Production Plants
		17.6.4 Nuclear Reactor Core Component Production Plants
		17.6.5 Stainless Steel and Special Alloy Tubes Production Plants
		17.6.6 Special Materials Plant
		17.6.7 Quality Assurance Group
		17.6.8 Safety Engineering Division
		17.6.9 Environment Protection
		17.6.10 Zirconium Complex, Tamil Nadu (a Unit of NFC, Hyderabad)
		17.6.11 NFC-Kota, Rawatbhata, Rajasthan
	17.7 Experiences in Indigenous PHWR Fuel Manufacturing
		17.7.1 Innovative Technologies/Technological Breakthroughs in Fuel Manufacturing
		17.7.2 ‘Atmanirbharta’—A Make in India Initiative
	17.8 Association with NPCIL
		17.8.1 Role of NFC in First Criticality of KAPP
	17.9 Summary
18 RDCIS-SAIL: A Perspective of Five Decades of Relentless Excellence in Ferrous Research and Innovation
	18.1 Genesis and Formative Phase
		18.1.1 Inception History
		18.1.2 Formulation of Plans and Programmes
		18.1.3 Initial Collaborative Efforts
		18.1.4 Project Categorisation/Verticals
	18.2 Innovations and Applications in Steel Plants
		18.2.1 Process and Design Research
		18.2.2 Development of Niche Steel Products and Superior Refractories
	18.3 Unique Systems and Procedures
		18.3.1 ISO 9001 Accreditation
		18.3.2 Certified Annual Benefit (CAB)
		18.3.3 Customer Satisfaction Index (CSI)
	18.4 National/International Accolades and Recognitions
		18.4.1 Corporate and Individual Awards
		18.4.2 Publications and Intellectual Property Rights (IPR)
		18.4.3 Strengthening of Collaborative Efforts
		18.4.4 Priority for R&D Outlay in Steel Research in India
	18.5 In Summary
	References
19 Applications of Plasma in Metallurgy and Vice-Versa: Indian Context
	19.1 Introduction
	19.2 About IPR
	19.3 Introduction to Plasma
	19.4 International Scenario
	19.5 National Scenario
	19.6 Plasma Technologies Developed at IPR
		19.6.1 Plasma Surface Modification Technologies
		19.6.2 Thermal Plasma Applications
		19.6.3 Development of Materials for Blanket Technology
	19.7 Development of Materials and Joining Techniques for Plasma Facing Components
		19.7.1 Mono-block PFC Development
		19.7.2 Dome PFC Development
		19.7.3 Tungsten Coated PFC Development
		19.7.4 Plasma Facing Materials Development
		19.7.5 Helium Cooled PFCs
		19.7.6 Liquid PFC R and D
	19.8 Fusion Magnets and Conductor Development at IPR
	19.9 Conclusion
	References
20 Evolution of “International Advanced Research Center for Powder Metallurgy and New Materials (ARCI)”, a Unique Centre for Translating Materials Research to Technology
	20.1 Genesis
	20.2 The Mandate
	20.3 Thrust Areas
		20.3.1 Powder Metallurgy and Nanomaterials
		20.3.2 Surface Engineering
		20.3.3 Ceramic Processing
		20.3.4 Laser Processing of Materials
		20.3.5 Fuel Cell
		20.3.6 Nanocomposite Coatings
		20.3.7 Solar Energy Materials
		20.3.8 Automotive Energy Materials
		20.3.9 Materials Characterization and Testing
		20.3.10 Technology Transfer Models
		20.3.11 Setting-Up of National Centres
	20.4 Conclusion
Part III Institutes
21 Historical Development and Current Status of Metallurgy Education in Banaras Hindu University
	21.1 Introduction
	21.2 Progressive Growth of the Department
	21.3 Undergraduate and Postgraduate Programs
	21.4 Research Highlights
	21.5 Linkages with Industry and R&D Organizations
	21.6 Awards and Distinctions
	21.7 Co-professional Activities
	21.8 Concluding Remarks
22 Platinum Years of Metallurgical and Materials Education and Research—The IISc Saga
	22.1 Conception and the Formative Years
	22.2 Consolidation of the Undergraduate Programme and Nascent Research Projects of Strategic Importance
	22.3 Introduction of M.E. and Ph.D. Degree Programmes
	22.4 Silver Jubilee of the Department and Strengthening of Research
	22.5 Special Assistance Programme of the University Grants Commission and Transformation of the 3 Year B.E. Degree to a 4 Year Integrated M.E. Course
	22.6 Recognition as a Centre of Advanced Study and March to the Golden Era
	22.7 Millennial Initiatives and Rechristening of the Department
	22.8 From Diamond to Platinum—In Pursuit of Excellence
	22.9 Accomplishments
	22.10 IIM-IISc Linkage
	References
23 Metallurgical Education in India: College of Engineering Pune’s (COEP) Contribution
	23.1 College of Engineering Pune (COEP)
	23.2 Department of Metallurgy and Material Science
	23.3 Professional Societies Activities
	23.4 Industrial Collaborations
	23.5 Way Ahead
24 Metallurgy at PSG-Coimbatore: An Overview
	24.1 Introduction
	24.2 Commencement of Metallurgical Engineering @ PSG Tech
	24.3 Faculty and Visiting Professors, the Vigour of the Department
	24.4 Research Advancements
	24.5 Industry—Institute Interaction
	24.6 Alumni of the Department
	24.7 The IIM Coimbatore Chapter
	24.8 Summary
25 Sixty Years of Metallurgy at IIT Madras
	25.1 Introduction
	25.2 Professor E. G. Ramachandran (EGR)
	25.3 Professor K. A. Padmanabhan
	25.4 Professor P. Venugopal
	25.5 Professor Vasudevan
	25.6 Conclusions and Outlook
	References
26 The Journey of the Department of Metallurgical and Materials Engineering, NIT Durgapur, Towards Achieving Academic Excellence
	26.1 Introduction
	26.2 Brief History of the Department and the Institute
	26.3 Vision and Mission of the Department
		26.3.1 Vision
		26.3.2 Mission
	26.4 Journey Towards Academic Excellence Over the years
		26.4.1 Academic Programmes
		26.4.2 Teaching and Research Activities
		26.4.3 Sponsored Research Projects
		26.4.4 Collaborative Research
	26.5 Areas of Research at a Glance
	26.6 Research Facilities
	26.7 Notable Contributions and Achievements Since the Past Decade
		26.7.1 Faculties’ Awards and Achievements
		26.7.2 Research Publications and Patents
	26.8 Distinguished Alumni of the Department
	26.9 Summary
27 Metallurgical and Materials Engineering at the National Institute of Technology Karnataka: A Historical Overview
	27.1 Introduction
	27.2 Historical Notes
	27.3 Research, Projects and Events
	27.4 Recognition of Students and Faculty
	27.5 Summary
28 Metallurgy at the National Institute of Technology Rourkela—a Polished FileRef="512880_1_En_28_Figb_HTML.png" Format="PNG" Color="BlackWhite" Type="LinedrawHalftone" Rendition="HTML" Resolution="300" Width="106" Height="44"
	28.1 Introduction
	28.2 The Journey of Struggle to Triumph: The REC Era
	28.3 The Change Over Period: The NIT Era
	28.4 Concluding Remarks
	References
Part IV Individuals
29 Six Decades of Academic Research in Materials Engineering: A Personal Perspective
	29.1 Introduction
	29.2 The Early Decades
	29.3 The Period of Consolidation
	29.4 Current Century
	29.5 Some Critical Issues from Personal Perspectives
	29.6 Epilogue
30 Accelerated Discovery, Development, Manufacturing, and Deployment of New Materials Using Integrated Computational Materials Engineering (ICME) Tools and Digital Platforms
	30.1 Introduction
	30.2 ICME for Industrial Problem Solving
		30.2.1 Traditional Process of Alloy Design to Production
		30.2.2 Acceleration Through ICME Methodologies
	30.3 Digital Platforms to Enable Industrialisation of ICME
		30.3.1 Need for Digital Platforms for ICME
		30.3.2 TCS PREMAP—Platform for Realisation of Engineered Materials and Products
	30.4 An Illustration—Design and Development of a Dual Phase Steel Sheet
	30.5 Concluding Remarks
	References
31 A Glimpse of the Growth of Mechanical Metallurgy Over the Past 50 years
	31.1 Introduction
	31.2 Factors Influencing the Growth and Development
		31.2.1 Manpower
		31.2.2 Physical Capital
		31.2.3 Technology and Investment
		31.2.4 Other Miscellaneous Factors
	31.3 Formative Years in the Development of Mechanical Metallurgy in India
	31.4 Growth and Development in Pre-2000
	31.5 Growth and Development in Post-2000
	31.6 Mechanics of Materials
	31.7 Perspective for Future Research in Mechanics of Materials
	31.8 Summary
	References
32 Texture Research in the Past 75 Years: Historical Perspective and a Personal Journey
	32.1 Introduction
	32.2 Texture: Definition Measurement and Representation
	32.3 Historical Perspective: The International Scene
	32.4 My Tryst with Texture: The Indian Perspective
	32.5 Conclusions
	Reference