Atlas Copco Internship Report

Hamsini Gopalakrishna Atlas Copco, Nanjing, China Summer Internship – 2012

ATLAS COPCO, Nanjing, China

Report of

Summer Internship28th May to 26th July 2012

By

Hamsini Gopalakrishna

Purdue University

Purdue ID: 0024012407

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West Lafayette, IN – 47906, USA

CONTENTS

Certificate . . . . . . . . . . . . . . 3

About Atlas Copco . . . . . . . . . . . . 4

Summary . . . . . . . . . . . . . . 5

Detailed report . . . . . . . . . . . . . 6

Summary of samples analyzed . . . . . . . . . 8

Details of samples analyzed . . . . . . . . . . 10

Thoughts and future work . . . . . . . . . . 25

Acknowledgement . . . . . . . . . . . . 26

Travel report – Xu Zhou BUT company . . . . . . . 27

Appendix I – Manuals . . . . . . . . . . . 29

Appendix II – Photographs . . . . . . . . . . 65

Xu Zhou trip . . . . . . . . . . . . 73

Wuxi visit . . . . . . . . . . . . . 77

Appendix III – Presentation . . . . . . . . . . 81

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CERTIFICATEThis is to confirm that Hamsini Gopalakrishna has successfully completed

her industrial internship at Atlas Copco, Nanjing, China. This 8 week internship

lasted from the 28th of May till the 26th of July 2012. She worked in the

Materials and Metallurgical Group in Rocktec and was assigned the following

tasks –

1) Familiarizing, using and writing the quick reference manuals for a

microscope, a stereoscope, hardness testers, sample making machines and

the SEM. The Ultrasonic tester and the Magnetic Particle tester were also

included.

2) Measurements using all of the above equipment with samples (where

applicable).

3) Non Destructive Testing (NDT) at supplier’s factory. (Xu Zhou BUT

Construction Machinery Holding Co.Ltd.)

4) Study tour of Atlas Copco assembly plant of Nanjing and Wuxi.

5) Familiarization of welding, casting, ultrasonic testing and magnetic particle

testing standards as well as other industrial procedures.

She has completed the above tasks successfully and on time. We found

Hamsini Gopalakrishna to be efficient, industrious and to have a hunger to

learn new techniques. She is very cooperative and has good team spirit. She

will be an asset to any organization she would work with. We wish her success

in her future endeavors.

Dr. Johnny Huang Mr. Suresh Shyamsundar

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Materials and Metallurgical group leader Head of R&D center (Rocktec)

About Atlas Copco

Atlas Copco is a Swedish industrial conglomerate which manufactures

compressors, generators and industrial tools in addition to construction and

mining equipment. It was founded in the year 1873. Its headquarters is in

Stockholm, Sweden. It has production sites in 20 countries. Their single largest

market is in mainland China. It has 18 facilities in China. The plants at Wuxi,

Nanjing and Tianjin are R&D centers with state of art laboratories in addition

to having production facilities.

Atlas Copco, Nanjing is a research facility that has various divisions like

Rocktec, Surface Drilling Equipment (SDE), Underground Rock Excavation

(URE), Geotechnical Drilling Equipment (GDE) and Atlas Copco Drilling

Solutions (ADS). It also has a full assembly line on site. Approximately 400

people work in the plant at Nanjing. Rocktec supports the other divisions in the

technical aspects. Rocktec has six divisions namely Applied Mechanics,

Materials and Metallurgical group, Measurement group, Patent group, Product

Lifecycle Management (PLM) Solutions and Industrial design. The PLM

division focuses on Product Design (CAx) and Product Data Management.

Atlas Copco, Wuxi is a research facility in addition to being an assembly

plant. Approximately 600 personnel work in the plant. They produce screw

compressors. Their staff averages 110 hours of technical training per person on

the job.

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Summary

It was a very educative and hands-on experience overall. During the internship (28th May – 26th July 2012), Hamsini successfully completed the tasks outlines below.

i) Hamsini independently used the lab equipment. The lab equipment consisted of an SEM, hardness testers, microscope, stereoscope, sample making equipment and Non Destructive Testing (NDT) equipment.

ii) She prepared quick reference guides for all of the above equipmentiii) She helped write the lab regulations for safety in the labsiv)She used the Analyzed samples including

a) Failed crank shaftb) ADS shaftc) Comparison between two pistonsd) Fractured bolte) Deformed bushingf) Aluminum feed beamg) Steel exhaust pipe

v) She familiarized herself with various standards likea) EN ISO 5817:2007 – Welding – Fusion-welded joints in steel, nickel,

titanium and their alloys (beam welding excluded) – Quality levels for imperfections

b) BS EN 1290:1998 – Magnetic particle testing of weldsc) BS EN ISO 17640:2010 – Ultrasonic testingd) BS EN ISO 377:1997 – Steel and steel products – Location and

preparation of samples and test pieces for mechanical testinge) BS EN ISO 3651-2:1998 – Determination of resistance of inter-granular

corrosion of stainless steelsf) ISO 21610:2009(E) – Accelerated corrosion test for inter-granular

corrosion susceptibility of austenitic stainless steels g) en 10 9001 K – Atlas Copco Standard for Delivery requirements for Steels

and iron productsh) en 6134 K – Atlas Copco Specifications for Steel and Iron casting

requirementsvi) She studied and familiarized with case studies and reports by other engineers.vii) She accompanied the NDT Engineer, Mr. Allen Zhang and the Sourcing

Quality Engineer (SQE) Mr. Zhengzheng Xu to the BUT Construction Machinery Holding Co. Ltd. in Xu Zhou. (21st June, 2012). Welds in the frames for B-282 were to be tested for surface and sub-surface flaws using the Ultrasonic testing methods.

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viii) She toured the Wuxi Atlas Copco plant to better understand the working of the industry. Accompanied Mr. Alex Xie and Mr Charles Fu (19th July, 2012).

Detailed report

On my first day, May 26th, 2012, Hamsini Gopalakrishna was assigned to the Materials and Metallurgy team. She was introduced to the members; Dr. Johnny Huang (Dr. Huang Xing), the team leader, Mr. Allen Zhang (Mr. Zhang Guoqiang) and Mr. Charles Fu (Mr. Fu Pei). Mr. Allen is the Welding and Non Destructive Testing (NDT) engineer. Mr. Charles is the Materials Science engineer. she was able to get a clear idea of the scope and nature of work after a tour of the lab and the production facility. The materials analysis lab has been functional since March, 2012.

The equipment in the labs consisted of

a. Microscopesi. Optical Microscope

ii. Optical Stereoscopeiii. Scanning Electron Microscope (SEM)

b. Sample making equipmenti. Cutting machine

ii. Mounting machineiii. Grinding and polishing machineiv. Precision weighing scale

c. Hardness testersi. Vickers microhardness tester

ii. Universal testeriii. Brinell tester

d. Non Destructive Testing Equipment (NDT)i. Ultrasonic tester

ii. Magnetic particle tester.

Over the next few weeks, she was trained on using the above equipment by Mr. Charles and Mr. Allen. She got familiar with their usage and settings. She also used these machines with several samples and took readings (where applicable). My first task was to write short user manuals or quick reference guides for the equipment. This was because most of the manuals provided by the supplying companies were in Chinese and/or were too long. When the

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manuals were finalized, they were laminated and displayed next to the machines. She highlighted various precautions to be taken for safe usage of the lab equipment. The manuals can be found in Appendix I.

Her second task was to create a presentation. The design engineers, mechanical engineers and engineers from the sourcing department were to be given a presentation about the equipment in our labs by the Materials and Metallurgical group. The main idea was to inform the engineers about how the equipment in the labs can help analyze samples to provide useable information. She made the presentation illustrating the main uses and features of the equipment in the labs. This can be found in Manual III.

Hamsini visited the BUT Construction Machinery Holding Co. Ltd. in Xu Zhou (21st June 2012). She accompanied Mr. Allen Zhang and Mr. Zhengzheng Xu from sourcing. Some machine frames were to be tested using the Ultrasonic tester for surface and sub-surface flaws in the welds.

Mr. Alex Xie (Mr. Xie Xiaogang), a measurement engineer, and Mr. Charles Fu and Hamsini visited the Atlas Copco R&D center in Wuxi, China. It had a full product assembly line as well. We met Mr. Koen Lemmens, the R&D center Product Development Support Manager and Mr. Cheng Xiao Bo, the Materials Engineer. They also met Mr. Lin Zhi Min, the Noise and Vibration Engineer and Xu Bin Jie, the Infrastructure, Calibration and Computer Aided Testing (CAT) engineer. They took a tour around the facility. They saw various types of compressors, generators and testing equipment. After lunch, they had a discussion with the materials engineer on a broken aluminum oil separator. They were trying to find out the probable cause of failure.

There were often samples that came from the factory to be analyzed. Microstructure analysis, failure analysis and hardness test were some of the tests run on the samples. The details of the samples included the following

a. A crank shaft used in automobiles. Atlas Copco was testing the reason for failure. The pipe was induction welded. This failed during testing.

b. A comparison between an Atlas Copco and a competitor’s pistons. The Atlas Copco piston cracked while operating.

c. A fractured bolt from ADS.d. An analysis of a failed bushing from the SDE department (from the

CDM 75). The bushing had deformed.e. An aluminum feed beam from the drilling machines. The beams

supplied by a local company were being compared to imported beams.f. Drilling shaft that Atlas Copco was buying from a supplier. This failed

during testing. (ADS)

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g. A steel pipe had to be tested for corrosion resistance. She helped prepare a sample for chemical analysis. She read up on standards for a corrosion test.

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Summary of samples analyzedTable 1: Samples analyzed during the internship

Sl. No

Item Failure Details Processes Equipment used Conclusion

1 Crank shaft A crack was noticed during inspection. It was induction

welded. In induction welding, electromagnetic induction is

used to heat the piece.

Microstructure analysis

Sample making equipment (Cutting,

Mounting, Grinding

machines),Microscope

The welding was flawed. The probable cause of the crack in the weld is incorrect weld

temperature. The microstructure around the weld – ferrite and pearlite indicate that the pre-welding

pressure was up to standards.

2 Comparison between Atlas

Copco and competitor 4”

pistons

The Atlas Copco piston failed in operation. It cracked at the

striking surface.

Hardness testing and

Microstructure analysis

Sample making equipment,

microscope and Vickers hardness

tester

The raw materials were different. The competitor core is more tempered. This increased

toughness. In their carburization layer, the microstructure is finer. Their surface is less harder

than Atlas Copco’s pistons.

3 Bolt from ADS

The bolt cracked half way during assembly. This bolt and

three others in the same structural position were

analyzed for causes of failure.

Surface and failure analysis

Stereoscope The surface was harder* than the core as per requirement. Both the core and the surface

hardnesses were above the required standards. This caused the surface to be brittle and prone to

cracking. The hardness of the other bolts used in the same functional position was too low (sourced from

the warehouse). This led to fracture

* The hardness tests, microstructure analysis and chemical composition analysis were done prior to my internship.The most probable cause of failure has been bolded. In some cases the cause of failure is not evident.Table summarizing the samples analyzed during the internship – Continued

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Sl. No

Item Failure Details Processes Equipment used Conclusion

4 Deformed bushing

The bushing deformed when the feed beam moved. The assembly technician was adding oil to the cylinder when the beam moved. The pin roll had detached.

Microstructure analysis andHardness testing

Sample making equipment, microscope and Vickers hardness tester

The chemical composition, microstructure, hardness and its tensile strength meet the requirements. The microstructure around the deformed area suggests ductile failure. Material cause of failure may be ruled out

5 ADS Shaft A shaft circle welded with plates was broken at/near the Heat Affected Zone (HAZ).

Element analysis, tensile test, micro-hardness test and analysis

Tensile tester, Vickers hardness tester, sample making equipment and microscope

The high internal stress concentration near the welding area caused it to break. High weld area hardness also caused failure. Application of an external force tends to break it. It was found that the welders were not sticking to the welding protocol.

6 Aluminum feed beam for the drilling machines.

This was not a case of failure. The aluminum beams from local companies were being compared to the imported beams being used.

Hardness test Brinell hardness tester

The average hardness value was 104.36. HB. The imported feed beams are being used in the machines. Due to lack of a portable hardness tester, testing the imported beams will be postponed. This was an ongoing analysis at the time of the internship.

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Detailed analysis1) Crank Shaft

The crankshaft is the metal piece in the middle. Due to the geometry of the cut metal piece, the pieces on the sides were added for support.

Fig 2. Photomicrograph of the induction weld. Magnification 200x

Cracks were observed during inspection. It was sent to the labs for further inspection. Upon preparing the sample and examining it under a microscope, it was found that improper welding was the cause. There was a crack in the welding. The probable cause is improper weld temperature. This can be known by the fact that the microstructure around the weld is typical of proper pressure parameters.

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Fig 1. The mounted sample of the crank shaft weld piece.


2) 4” pistons – Atlas Copco vs. CompetitorThe starting material was different. The Atlas Copco piston was made of 18CrMnNi2MoA while the competitor’s piston is made of 20Cr2Ni4A.

The direction of the hardness gradient is shown

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Fig 5. AC ZJK piston

Fig 6. HJG piston

Fig 3. The ZJK (Atlas Copco) piston

Fig 4. The HJG (competitor) piston


Fig 7. ZJK2 piston surface structure, Fig 8. ZJK2 piston, core carburized case. 500x structure 500x

0 1 2 3 4 5 60.3

0.35

0.4

0.45

0.5

0.55

0.6

0.65

0.7

0.75

0.8Carbon content vs. Distance

Wt% Carbon ZJKWt% C after decarbonizationWt % Carbon HJG piston

Distance from surface (mm)

Carb

on C

onte

nt (%

)

Graph 1. Carbon content with the distance from the surface.

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Fig 9. HJG piston, surface structure, carburized case×500

Fig 10. The surface defect on sample 1, the center. 500x


0 2 4 6 8 10 12 14 16400

450

500

550

600

650

700

Hardness vs. Distance

Distance from outside to inside (mm)

Hard

ness

(HV)

Graph 2. Hardness as a function of the distance from the outside to the inside of the sample – ZJK piston

0 2 4 6 8 10 12 14 16 18 20400

450

500

550

600

650

Hardness vs. Distance

Distance from inner surfaceto outer surface (mm)

Hard

ness

(HV)

Graph 3. Hardness from the inner surface to the outer surface as a function of distance – HJG piston

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3) ADS failed bolt

Three bolts marked DB Broken, DB and ZS had the same functional position. The supplier realized that ZS didn’t meet standard requirements and replaced them with bolts marked zs. The bolt marked DB Broken failed during assembly. Two other bolts in the same functional position were also tested for comparison (DB and zs).

Fig 11. Side view – DB Broken Fig 12. Top view of the cut part DB Broken

Table 2. Bolts analyzed for their composition.

Mark C Si Mn P S Cr Mo

DB Broken 0.43 0.24 0.84 0.015 0.007 0.99 0.2

DB 0.39 0.23 0.61 0.014 0.007 0.99 0.16

zs 0.33 0.2 0.55 0.016 0.006 0.91 0.16

Hardness testing: The four bolts were tested for hardness in the core region and on the surface. Representative graphs are given below the table

Table 3. Hardness values for core and surface of the different bolts

Mark Core Hardness (HV 0.3) Surface Hardness (HV 0.3)DB Broken 448, 440, 445 430, 440, 437

DB 437, 430, 422, 412, 410, 417 448, 432, 441, 420, 438, 421ZS 369, 353, 357 229, 233, 239zs 361, 347, 333, 367, 374,

378, 299, 300, 309, 337, 328, 338, 288, 282, 287

396, 393, 391, 415, 412, 403, 469, 487, 472, 408, 405, 420, 407, 415, 422

Standard Requirements

GB/T 3098.1-2000

Minimum: 385, Maximum: 435Surface hardness shall not be more than 30 Vickers points above the measured core hardnesses. This is for HV 0.3

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15250

270

290

310

330

350

370

390

410

430

450

261

347 333

367374 378

299

300309

337328

338

288282 287

369 353 357

437 430422

412 410417

448440 445

385

435

Hardness values - Corezs

ZS

DB

DB Broken

Standard

Hard

ness

(HV

0.3)

Graph 4. Hardness of the core.

1 2 3 4 5 6 7 8 9 10 11 12 13 14200

250

300

350

400

450

500

369

393 391

415 412403

469487

472

408 405420 415 422

229 233 239

448

432

441420

438421430

440

437

385

435

Hardness Values - Surface

zs

ZS

DB

DB Broken

Standard

HArd

ness

(HV

0.3)

Graph 5. Hardness of the surface

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These photographs were taken at 500x

Fig 13. DB Broken surface: Tempered troosite Fig 14. DB Broken core: Tempered troosite

Fig 15. DB surface: Tempered troosite Fig 16. DB core: Tempered troosite

The above analysis was completed by the Materials group before I started my internship. The data has been included for the sake of completeness.

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Fig 17. Zs surface – tempered troosite and block ferrite. 50x

Figure 18. zs core tempered troosite with ferrite. 500x


Fig 19. Top view of the broken bolt Fig. 20 Side view of the broken bolt

The surface of the bolt was analysed. Along with the data from the hardness

tests, it was found that the bolt was brittle due to high hardness. This was the

cause of failure.

The hardness of the bolt exceeded the requirement of 435 HV 0.3 in the GB/T

3098.1-2000 standard.

Hardness of the zs bolt was too low.

The carbon and Mn content in the broken bolt was higher than the other bolts

tested. This is a cause for high hardness.

Ferrite observed in zs and low core hardness indicates that the heat treatment

process isn’t well controlled. The part isn’t thoroughly hardened.

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4) Deformed bushing

The bushing was cut to reveal the deformed side. This side was mounted, grinded and polished. The chemical composition matched the requirement for Q345D in GB/T 1591-2008.

Fig 21. The deformed bushing Fig 22. The deformed surface – after cutting

Fig 24. The average HV0.3 hardness values of the samples with their respective locations

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Surface to observe microstructure

DeformedSurface

Fig 23. Mounted sample of the deformed surface


Fig 25. Core. 100x Fig 26. Core. 400x

Fig 27. Deformed surface. 100x Fig 28. Deformed surface. 400x

Fig. 29. Non deformed surface. 100x Fig 30. Non deformed surface. 400x

Table 4: Chemical composition of the sample and Q345D requirement.Element C Si Mn P S

Bushing sample,% 0.15 0.21 1.06 0.013 0.007Q345D requirement,% >0.18 >0.50 >1.70 >0.030 >0.025

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Fig 31. Deformed Corner: 50x Fig 32. Deformed surface corner 400x

Table 5: Hardness values of the various surfaces

Location Core Deformed Surface

Non deformed surface

Deformed Corner

Trial 1 212 218 168 230

Trial 2 199 209 176 224

Trial 3 199 198 176 231

Trial 4 189 191 184 -

Average 200 204 176 228

Due to lack of information about heat treatment process, it is impossible to judge whether the part’s mechanical properties are suitable. The ductile nature of the deformation indicates that the failure may not be entirely due to material causes. The chemical composition matches the requirements. The ferrite and pearlite microstructure is typical. The sample hardness is around 176 – 204 HV 0.3 and the tensile strength is 560 – 625 MPa The tensile strength was obtained using a conversion chart DIN 50150: Conversion of hardness values for metallic materials.

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5) ADS Shaft

The shaft circle welded with plates was broken. Element inspection, tensile testing, micro-hardness test and microstructure analysis were done on the shaft base metal. A micro-hardness test was run on the weld.

The chemical composition matches grade 45 steel. The matrix consists of pearlite and ferrite which is typical for normalized grade 45 steel. Weld area microstructure consists of sorbite with ferrite in the grain boundaries.

Fig 33. The ADS shaftFig 34. Mounted sample of the shaft

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Fig 35. Base metal 100× Fig 36. Base metal 500×The white phase is ferrite, and the dark phase is pearlite.

Fig 37. Weld area 100× Fig 38. Weld area 500×

The dark phase is sorbite, and white phase in grain boundary is ferrite.

Table 6: Chemical composition of the shaft

Element C (%) Si Mn P S Cr Ni

Grade 45 Steel

0.42-0.50 0.17-0.37 0.50-0.80 <0.035 <0.035 <0.25 <0.3

Sample 0.43 0.22 0.58 0.025 0.017 0.05 0.02

Table 7: Mechanical properties of the shaft

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Tensile Strength (MPa) Yield Strength (MPa) % Elongation

650 259 23

The average hardness for the base metal is 198.6 HV 0.3. The average hardness value for the weld area is 360 HV 0.3.

6) Aluminum Beam

The local and imported beams were to be compared. The local beams are cheaper. If they meet the standard requirements, they would replace the imported beams. Hardness test was run on the local beam (pictured below). The imported beams are being used in the machines. The lab is not equipped with a portable hardness tester. Bringing the whole beam to the lab would be a problem as the beams are over 20 feet in height. One of the ways the imported beams can be tested is when a machine beam fails; a part of it can be cut and tested. Another way is if a beam is bought solely for testing purposes. This was an ongoing project when the internship ended.

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Fig 39. The Al feed beam

Fig 40. Front view of the beam

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Fig 41. Mounted sample Fig 42. Piece used for hardness testing

Table 8: Composition of the beam

Element Si Fe Cu Mn Mg Zn Ti Zr

Amount (%) 0.14 0.20 0.08 0.24 1.2 4.80 0.04 0.12

Table 9: Mechanical properties of the local Al beam

Tensile Strength (MPa)

Yield Strength (MPa)

Percentage elongation (%)

Reduction in area (%)

341 382 15.5 44

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The local beam qualified by meeting the standard requirements. The microstructure analysis for the Al sample was to be done as well.

Thoughts at the end of my internshipHamsini appreciates the discipline and work ethics the employees have. The

atmosphere is conducive for free exchange of ideas and thoughts. Communication is free and easy. The people are very nice and supportive. Safety is always a top concern in the labs. Some of the suggestions she has arei) The company can join hands with a local/international university for research

in to better, more efficient futuristic materials and other aspects like cutting down on environmental impacts. The venture can be like a think tank for both research and production.

ii) The team can look into alternative methods, processes and materials to enhance efficiency and cut costs.

iii) Implement methods to reduce the company’s carbon footprint on the environment.

iv) A lot of good suggestions come from the work floor. A small reward can be

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given to anyone who suggests a positive change in work methods or in any process involved in production. This was implemented in a factory she visited earlier and they had spectacular results.

v) Make the team building sessions in to an activity oriented event. Employees can be divided into groups. They will be given some tasks that they have to finish as a group.

vi) A prominent personality or an inspirational icon can be invited to give a short talk regularly.

vii) A creativity corner – room can be set where the employees can go de-stress and fuel thoughts on for improvements. It will also help employees think better. Sitting in a chair all day long is not good for one’s health. Rules can be made about how often and how long an employee can be in the creativity corner. Games like chess, Chinese checkers, etc. can be placed there.

viii)A white board can be placed near the doors. A new English word everyday can be written on it with its Chinese word and the English word’s usage in a sentence and its meaning in Chinese

ix) A technical term with its definition and Chinese term can also be written on the same board. Including the pronunciation will help a lot in the long run.

x) The company management can consider diversifying into aerospace, hydraulic systems, transportation and locomotive industries where the current knowledge of Atlas Copco is partly used.

Future workI would like to continue adding to my industrial experience by working on

failure analysis and usage of modern materials to replace existing materials. I would like to work on modern materials that involve composites. The hands on experience obtained while analyzing various samples has helped me understand the theory learnt at Purdue University. It has enhanced my knowledge.Acknowledgement

I am grateful to the management of Atlas Copco and in particular, Mr.

David Lou, the CEO of Atlas Copco, Nanjing for considering my application

for the internship and for providing me with this opportunity and financial

support.

I am thankful to Dr. Johnny Huang, PhD and head of the Metallurgical

lab for the support and guidance during the internship. I was allowed full

access to sophisticated instruments like the SEM, Hardness testers, etc which

made the learning a great experience. I would also like to thank Mr. Charles Fu,

the Materials Engineer, and Mr. Allen Zhang, the Welding and NDT Engineer,

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who supported me in the learning. I was able to work as if I was a regular staff

of Atlas Copco due to their support and words of encouragement. I would like

to thank all my colleagues who helped me.

I am thankful to Mr. Suresh Shyamsundar, the head of R&D center

(Rocktec) at Nanjing, for his assistance during the internship.

I wish to thank the heads of the production facilities at Nanjing and

Wuxi for permitting a detailed tour of the facility and interaction with the

production engineers. The staff of HR, administrative and support departments

were of great help and I acknowledge their assistance. The visit to Atlas Copco

has been a truly rich working experience in a professional organization that will

be cherished for a long time. I will be delighted at the prospect of a second

internship next summer at Atlas Copco if there is an opportunity.

Last but not least, I would like to thank the Office of Professional

Practice and in particular Dr. Yating Haller. The Office of Professional Practice,

Purdue University provided me with a travel grant to cover travel expenses for

the trip to China. It supported me in obtaining professional experience which

will go a long way in understanding the theory leaning at Purdue University.

Travel Report – Xu Zhou BUT Company visit

On June 21st, we visited BUT to perform the UT inspection on two URE ST2D frames of, as shown in Figure 1.The inspectors from BUT and SGS detected the frames separately, and they will submit an inspection report.Result:Inspectors from SGS tested 2 products and measured the length and location of the defects.We also invited the inspectors of BUT to perform the site operation of UT inspection. We also took photographs of the products.Conclusion: Basically after comparing the test reports of SGS and BUT, we found that the

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test results were similar.The inspectors’ operation skills and their attitude of responsibility were acceptable.But there are several problems affecting the welding quality and the inspection results, (Figure 2). Some improvements in the following areas should be made:1) The welding between unequal thickness plate;2) Welding Process of the complete penetration joint;

The NDT Engineer’s recommendation:1) The Visual Inspection should be performed strictly to reject the

unacceptable welds;2) Welding Process should be suitable for the Site Welding;a. There should be transition in the welding between plates of unequal

thickness. (Figure 2-a)b. The Groove Face should be decreased to maintain the joint complete

penetration. (Figure 2-b).3) Process improvement should be carried out to some part.

a. The area of unmelted steel should be treated by grinding or some other methods.(Figure 2-c)

b. The Arc start zone should be flatted using relevant methods. (Figure 2-d)c. There should be no Arc-Strike in the plate. (Figure 2-e).d. The product should be cleaned properly.

Fig 43: Inspection Products – Frames used in the machines

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Fig 44. Transition in the welding Fig 45.The groove face

Fig 46. Unmelted steel Fig 47. Arc Start Zone

Fig 48. Arc Strike

Appendix I – ManualsBelow are the manuals Hamsini drafted out for Atlas Copco after using the equipment in the lab thoroughly. The manuals are in the following order:

a. Microscopes

i. Optical Microscope

ii. Optical Stereoscope

iii. Scanning Electron Microscope (SEM)

iv. EDX. This is a program which allows for qualitative analysis of

materials in conjunction with the SEM.

b. Sample making equipment

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i. Cutting machine

ii. Mounting machine

iii. Grinding and polishing machine

iv. Precision weighing scale

c. Hardness testers

i. Vickers microhardness tester

ii. Universal tester

iii. Brinell tester

d. Non Destructive Testing Equipment (NDT)

i. Ultrasonic tester

ii. Magnetic particle tester.

MANUAL: OPTICAL MICROSCOPEThis manual illustrates how to use the optical microscope. There are two

parts – Part A and Part B. This is based on the frequency of use of the particular

tool and its operational complexity. Functions in Part A are more commonly

used.

Part A contains instructions using the microscope, adding a scale bar,

measuring lengths, areas, and angles and using the Extended Focus Integration

and merging functions.

Part B contains information on finer analysis of the specimen. This

includes grain size classification, inclusion classification, spheroidal graphite

classification (only in cast irons) and phase percentage calculation. To use

functions from part B, help from the Materials and Metallurgical group must

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be sought.

Index

Using the microscope

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 30

Adding a scale bar

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 31

Measuring lengths, areas and angles . . . . . . . . . . . . . . . . . . . . . . .32

Extended Focus Integration (EFI) . . . . . . . . . . . . . . . . . . . . . . . . .33

Merging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Percentage phase fraction calculation . . . . . . . . . . . . . . . . . . . . . .35

Inclusion, grain size and spheroidal graphite classification . . . . . 36

Using the microscope – General instructions1) Take off cover and ensure the light intensity is at the lowest setting.

2) Ensure the stage is lowered and place the sample. Choose lens with the

desired magnification.

3) Raise the stage until the sample almost touches the lens. Doing this ensures

that the stage always moves away from the lens while focusing. The sample

should never come in contact with the lens. This minimizes damage to the

lens.

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Stage control


4) Pull the lever at the side of the eyepiece to the desired option.

5) Lower the stage to focus the image. You can adjust the light intensity also

to enhance the image. The knobs below the stage can be used to move the

sample.

6) To obtain the image on the computer,

a. Switch on the camera. (Small switch on the side). Ensure that the USB

cable is connected to the microscope camera. You will see a green light.

b. On the computer, open OLYCIA Metal and click on the DP icon.

7) Click the snap button to take pictures of the specimen. You can save the

pictures.

8) To use the features of the software, the image has to be selected after the

OLYMPUS DP window is closed.

9) Turn down the light to the lowest intensity and switch off the camera and

the microscope. Lower the stage.

10) When closing the software, it will first ask you if you are sure you want to

quit. When you say yes (left button), it asks if you want to save any of the

images. Say yes (Y) or no (N). Turn off the computer.

11) Cover the microscope after the light box in the back has been cooled to

room temperature.

PART AIt is important that the magnification of the lens matches the

magnification selected in the program for all the below functions.

1) Add a scale bar

i. Open the desired picture.

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Light Intensity

The different knobs of the microscope


ii. Click on the button with a red flag

iii. If the magnification is 100x, you can double click the preset option

that shows in the pop up dialog box.

iv. For any other magnification, click and create a text box.

Specify the length of the scale bar needed. Make sure the

magnification in the program (see sentence after Part A) matches the

chosen magnification of the lens. You can adjust the scale bar to suit

your needs.

v. Click the layer button to save the updated image. Do this

whenever you modify the image to save the changes.

2) Measure lengths, areas and angles

i. Once a picture is open, click the ruler button and choose the appropriate option from the pop up box.

From left to right,TOP: Horizontal, Vertical, Oblique. These are all linear lengths.BOTTOM: Nonlinear length, Angle between two lines, Area of

selected polygon

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ii. For lengths, select the length by clicking and dragging across the picture. Right click outside the selected area. The length will be displayed. It can also be seen on the table in the dialog box.

and , andiii. For calculating angles between two features on the picture, select the

angle option. Click and drag a line. Draw a second line from the end of the first line. Once done, right click. The angle will be displayed both on the picture and in the table.

iv. For calculating an area, click and draw around the desired area. Once

the polygon is complete, right clicking will show the area covered by the selected part. When the start point and the end point are not closed, right clicking will result in them joining. Right clicking again shows the area both on the picture and in the table

v. Click the layer button to save the updated image. Do this whenever you modify the image to save the changes.

3) Extended Focus Integration and merging

Extended Focus Integration: This tool is used to obtain a

completely focused image from a specimen that has an uneven

surface

i. Using the DP, take several pictures of the same spot with different

parts in focus.

ii. Close DP and click EFI button .

iii. Choose the relevant pictures from the list

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iv. Clicking on the fifth button in the bottom loads the existing images

on to the dialog box. The first button adds an image while the second

button inserts an image. The third button deletes selected pictures

from the dialog box. The fourth button clears all the loaded pictures.

v. Click the EFI button (One below SuperEFI). The SuperEFI button is

more precise and takes longer. For a small number of pictures, using

the EFI or the SuperEFI gives the same image.

vi. Once the images are collated, the new fully focused image will pop

up. Save the image.

vii. All parts of the image should be focused in at least one picture.

Merging: To obtain a single image of bigger sections of the specimen.

i. Take several pictures with parts overlapping as shown below where the blue box is the desired image and save them.

Fig 1. Method of taking useful picture for the MIA tool

ii. Click on the MIA button

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Fig 2. Options to be changed

Fig 3. Alignment of the pictures


iii. Click the settings button

iv. A window will pop up. Change the number of columns (red) and rows (blue). You can select the horizontal and vertical overlap respectively (black)

v. Once the pictures are opened

using this button, the screen will look like this (picture to the left).

Make sure the pictures are selected in the sequential order (the top of the specimen is on the top and the bottom of the specimen is at the bottom).

vi. Go to the second tab

vii. Click on icon. The collated image will appear on the screen. Save the image once you are done.

PART B

To use any of the features below, help from the Materials and

Metallurgical group MUST be sought.

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1) Percentage phase fraction

a. Click the Phase percentage button . There will be three options

that pop up.

b. The options are automatic and manual. The third option is irrelevant.

c. A dialog box pops up once the automatic mode is selected.

d. This box is preset. There is an unchecked box in the top right part of

the dialog box. Check it and click OK.

e. Make sure all the light coloured spaces turn green once you click OK.

f. You can manually fill the unchanged parts using the paint pop up.

Once this is done, click the OK button.

g. The percentage phase fraction will show up on a report. You can use

this number.

2) Inclusion, Grain size and Spheroidal graphite

classification

Inclusion, grain size and spheroidal graphite (in cast iron) classifications

are very similar to perform.

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The light switch and intensity controller


1. Choose the classify option

2. Then choose the second option from the bottom.

3. In the pop up box, there are four drop down menus. Choose the

appropriate Standard Code, Standard Name, name of the

element/compound you want to analyze. There are different options

for the first three drop down menus depending on whether the

classification being done is inclusion, grain size or spheroidal

graphite. For the fourth menu, choose the inclusion size/grain size

and spheroidal graphite size. This is done by comparison of the

sample from the computer and the photo of the specimen.

MANUAL: OPTICAL STEREOSCOPE

This manual discusses the usage of the

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optical stereoscope. This is used to view surfaces in detail. This also helps in

determining the source and direction of propagation of fracture. More

information on its working principle and sample measurements can be found in

the library.

Using the stereoscope1) Take off the cover and lens covering.

2) Switch on the stereoscope.

3) Set the light to the lowest intensity

and switch on the light source.

4) Place the sample on the stage and focus the lights on the sample

5) There are two viewing modes that can be used: eyepiece only and eyepiece

with camera. Choose the appropriate one.

6) There are two lenses with different magnifications that can be used.

7) There is a knob on the side that

helps zoom in. (A) 8) The second knob (B) on the

right side helps focus the lens.

9) Focus the image.

10) Moving the sample is done

manually.

11) Make sure the camera USB

cable is

plugged in. The microscope and the

stereoscope share the same cable. Switch on

the camera.

The camera switch

12) To take pictures,

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The magnification and focus adjusting knobs


a. Switch on the computer and open the OLYCIA Metal software

b. Click the DP icon

c. Click the snap button once the image has been focused.

13) You can add a scale bar, measure lengths, areas and angles, use the

Extended Focus Integration and merging tools.

14) To do this, please refer to Part A of the user manual of the

microscope.

15) Once you are done examining the sample, turn off the lights and

remove the sample.

16) Cover the lens and the eyepieces.

17) Turn the stereoscope and the camera off. Switch off the computer.

MANUAL: Scanning Electron Microscope

When an optical microscope fails to show finer details, a scanning

electron microscope (SEM) is used. A scanning electron microscope (SEM)

uses back scattered electrons to provide a very precise and highly magnified

picture of the samples. The surface need not be polished or etched but it must

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be conductive. A thin metallic surface coating must be present while viewing

nonconductive materials. SEM’s are useful in the range of 10-7m and 10-3m.

The minimum magnification with this SEM is 65x and the maximum is

300,000x.

Using the SEM

1) Turn on the power switch at the back.

2) Turn the key in the front to START and then back to ON. The computer

switches on automatically.

3) Neither the computer nor the software has a password. The software

starts automatically. Wait till the system initializes.

4) Click AIR on the screen to introduce air into the chamber. You can press

the button in control panel too. Wait until the * asterisks in the message

‘The chamber is processing AIR ****** have disappeared.

5) Place sample to be viewed on the stand and measure the height of the

sample with the help of the Height gauge. Note the diameter of the

stand.

6) Slide the compartment open slowly. Place the stand with the sample on

the stage.

7) Click Specimen setting and then click OK. Input the sample height and

the stand diameter. Click the Stage Move button. This lifts the stage into

position. (picture on the next page)

The sample height and stage size input box.

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Power Switch


8) Slide the compartment in until the sample is just below the roof guard.

The ideal position of the sample on the stage9) Ensure that the sample is lower than the roof guard. Click OK.10)Slowly close and hold the compartment, press the EVAC button and

release the compartment after 10 seconds.

The control panel in the front11)Ensure the lowest magnification is chosen.

12)Wait until you see the message ‘HV is ready’ (at the bottom left corner),

click the ON button in the top left corner.

13)An image of the sample will appear. Once you select the area of interest,

you can focus and auto-adjust the brightness and contrast. To take a

picture, click Capture and save it.

14)The Save button works like a screen shot of the image panel. This can be

used for sensitive samples.

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Stage

Roof GuardSample


15)You can choose the type of scan (F, S1, S3 or S5) depending on the

detail you want in the picture. Click Run to go to the viewing mode.

16)The High voltage (HV) needs to be switched off when switching

between VP – SEM and SEM

17)Once you’re done with taking pictures, turn off the HV and click on

HOMEZ65 in the top right corner. This brings the stage to its original

position. This may take a while.

The HV ON button. The HOME Z65 button.

18)Click AIR and wait for air to be introduced into the chamber. As before,

wait for the asterisks to disappear

19)Take out the sample if you are done or change it.

20)Slowly push the compartment back in and press the EVAC button. Press

and hold the compartment before pressing the EVAC button for 10

seconds.

21)Wait till the button glows a steady green, close the program. Shut down

the computer.

22)Turn the key in the front to OFF.

23)Wait for 5 minutes and switch off the power button at the back

MANUAL: Energy Dispersive X-ray Spectrum – EDX

The EDX software uses backscatter to qualitatively and quantitatively

analyze samples seen in the SEM. It is most often used to analyze qualitatively.

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Using the EDX1) Follow steps 1-13 from MANUAL: SEM.

2) The SEM can be in the viewing mode.

3) Power on the extension board.

4) Switch on the computer

5) Open the EMAX software

6) A screen with a flow chart will appear in Chinese. The English

translations are provided

7) You can skip steps 1 and 2. In step 3: SEM Settings, higher accuracy is

obtained if the collection rate is between 1-3 kcps. This is the ideal

collection rate. The ideal working distance (SEM Program) is 10mm.

Click on Step 4

8) Step 4: Area of interest. You can choose the specific area of interest you

want to analyze by clicking the button. Click on Step 5

9) Step 5: X ray electron collection. Choose a more specific part of the

picture. It can be an area, a point, a random shape or all parts with the

same colour in the picture. The analysis will run immediately after you

choose the area. Click on Step 6

10)Step 6: Element confirmation. Once the elements have been identified,

the noise peak has to be deleted. This is usually a peak without any label

on it.

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11)Once this is done, delete all the elements you know for sure don’t exist

in the sample being analyzed using this button. . Select the

element and click the button. Click on Step 7

12)Step 7: Quantitative Analysis. A screen will appear showing the w% and

the a% of the various components. Click on Step 8.

w% a%

13)Step 8: Report. This is an optional step. This produces a report that can

be printed out or saved.

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Project name1

23 1


The boxes in blue can be skipped. The boxes in green are very important steps and have to be followed in order.

MANUAL: CUTTING MACHINEThe rotating abrasive disk can cut through hard and soft steels and a

variety of other metals and alloys. More information on its working principle can be found in the library.

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Sample nameSEM Settings

Area of Interest

X-ray electron collection

Element Confirmation

Quantitative Analysis

Image settings

Comparison

Optimization of quantitative analysis

Quantitative Analysis settings

Power Switch

The mounts


Using the cutting machine14)Choose the right cutting disk based on the material to be

cut.15)A light will turn on when the machine has been switched

on.(power switch on the side)

16)Set the coolant outlet to Blade. Carefully fix the piece in place using the levers on the mounts so that it doesn’t move.

17)Tighten the mounts using two levers, close the cover and press the start button. The disk won’t start rotating if the cover is open.

18)Wait until the coolant (white-ish fluid) starts running. Now push down the lever on the side gently. Make sure you blade touches the material very slowly. If the blade comes in contact with the material too fast, it will result in deep scratches.

19)Maintain a small consistent pressure on the lever. The blade moves with the lever. The rate of cutting must be slow so as to keep the sample from

getting too hot.20)When you will feel a lack of resistance, it means the blade has gone

through all the material. Press the stop button. Raise the blade (lever) up and open the covering lid of the cutter.

21)Take out the cut piece carefully after loosening the mounts. 22)Rarely, material towards the rear of the machine may not get cut. This is

usually a very small part of the material. In this case, you can the clamp and a hacksaw blade to separate the pieces.

23)You can clean up the machine by setting the water outlet as Nozzle.24) Leave the lid open. Turn the power switch off.

MANUAL: MOUNTING MACHINEThe mounting machine sets the sample to be analyzed in a polymer resin

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base. This makes it easier to polish, etch and study. More information on its working principle can be found in the library.

Using the mounting machine1) Switch on the machine2) Make sure the water tap is on. (Tap near the wall)3) Turn the handle on the top and twist the top away from the machine.

The handle. The lift and lower buttons. The stage.

4) Press and hold the ^ button to lift the stage.5) Dust the stage and surrounding areas to get rid of any dirt.6) Place the sample on the stage with the side of interest facing down.7) Lower the stage and add an appropriate amount of the mounting resin.

Make sure to cover your sample with the resin.8) Press and hold the lower button to ensure that the stage is lowered all the

way. You will hear a different sound when the stage is totally lowered.9) Place the top over the stage. Secure it by pressing it down and turning it

clockwise until the machine locks it. Then turn it a little in the anti-clockwise direction.

10)Press the start cycle button11)The parameters are preset.12)The entire cycle takes about 7 minutes.13)Once done, open the top handle. Press the ^ button. The mounted sample

will rise. It will be hot.14)Use the brush and the scraper to clean any unused powder or resin

pieces on the stage and the surrounding areas.15)Switch off the machine and the water tap.

MANUAL: GRINDER AND POLISHER

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The green button on the side of the rotating arm

The settings


The grinding and polishing machine is used to smoothen the surface of a

mounted sample. This helps study the microstructure of the sample better. More

information on its working principle can be found in the library.

General instructions 1) Make sure both the air compressor and the water tap are on. Pull the

red button on the air compressor (below the bench) up to start it. Take

off the top of the grinder.

2) Switch on the machine. (switch at the back)

3) Press the On button near the settings panel.

4) Adjust the settings as needed. Move arm and place the appropriate

grinding/polishing disk on the plate.

5) To stop the grinding process midway, press the button

6) Fix the rotating arm on the disk area with the lever on the left.

7) Press and hold both the green buttons on the side of the arm to lower it.

8) Once it touches the plate, release the buttons. The arm will

come up slightly.

9) Place the sample face down in the slots on the rotating arm.

10)Press and release both the green buttons to start the grinding

process.

11) To change the disk, the arm needs to be moved away from the

grinding disk. Do this with the help of the lever.

12) Lift the existing disk off the plate and place the next

grinding/polishing disk on the plate.

GrindingIn grinding, you start off with the disk with the lowest number. As you

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go along, disks with higher numbers will be used. Same goes for polishing. Use

the disks in the proper sequence. Once grinding is done, polishing can be

started.

Polishing1) Place the polishing disk on the plate and lubricate it.2) Make sure the water is turned off.3) Repeat steps 4 to 10 from the general instructions.4) Spray the abrasive suspension once the disk starts rotating. Use enough

abrasive suspension to have foam near the sample.

4) When done, place the polishing disk back. Turn off the power button (near the settings panel) and the switch at the back.

5) Close the lid of the grinder. Turn off the water supply and the air compressor.

MANUAL: WEIGHING SCALE

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The lubricant used to polish

The 3µm diamond abrasive used to polish.


The weighing scale is an important tool while measuring out chemicals.

This precision weighing scale can measure solids accurately up to four decimal

places. There are two parts to this manual. Part A contains the easy to use

functions like weighing, formulation, piece counting, percentage weighing and

differential weighing. Part B contains more complicated functions like

Statistics and Density calculation. More information on its working principle

and sample measurements can be found in the library.

These are the functions of the weighing scale.

a. Weighing: Weighs up to four decimal places.

b. Formulation: Stores formulae and weights of individual

components.

c. Piece Counting: Counts the number of pieces by using the current

weight and the weight of each unit.

d. Percentage weighing: Tells the percentage of a set weight the

object being weighed is.

e. Differential Weighing: The Differential Weighing application is

used to analyze changes in the weight of one or more samples.

The first step is to determine the initial weight of the sample

(weighing in). After the sample has been processed, it is re-

weighed (residual weight). The balance then determines the

difference between the two weighed values. Procedures can be

drying, centrifugation, filtering, incineration, vaporization,

coating, etc.

f. Statistics: Shows statistics for up to 1000 samples.

g. Density: Enables you to determine the density of solid bodies,

liquids, and pasty substances.

Using the weighing scale – General Instructions

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1) Plug in the weighing scale

2) Wait till it shows 0.0000g (initializes). If a weight is displayed, press the

0 button.

3) Use the button or wave your hand over the sensor to open or close

the door

4) Open the door, place material on the scale and close the door.

5) If using a container,

a. Place the container on the pan and wait for the weight to show in black.

b. Press the tare (T) button. This means that the weight of the container

will be ignored. Only the weight of the chemicals added will be shown.

Close the door.

6) Add the chemical and wait till the weight shows in black. When the

weight is shown in blue, the scale is still weighing

7) Note down the weight of the material.

8) When done, press and hold the OFF button to switch off.

9) Clean up any chemicals that may have been spilt on the pan.

IMPORTANT: Ensure there are no chemicals on the pan while

measuring. This can affect the weights recorded.

FormulationThis is used for weighing in components that are to be combined in a

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specific ratio1) Switch on the weighing scale

2) Press this button (Options button) to choose the Formulation option.

3) Press this button (Application settings button) to define a formula.

4) There are two types of formulas you can define: Fix Component and % Component. Define the formula.

Fix Component: Absolute nominal weights are defined for the individual components.

% Component: Relative (percentage) nominal values are defined for the individual components, either in relation to the final weight or the first component.

5) The formula database can hold a maximum of 8 formulae with up to 12 components for each formula.

6) When using a particular stored formula, you can weigh out all the components.

Piece countingThis application allows you to count pieces. The application provides

several different methods for determining the reference piece weight.1) Select Piece Counting after pressing the Options button.2) Place the reference piece on the weighing pan. 3) Once the weight has stabilized, press the PcsWgt option.4) After the reference has been determined, place the pieces you wish to

count on the weighing pan. The result will be displayed.

Percentage WeighingThis enables you to weigh to a specified value (100 %) and detect

deviations from this target value.1) Choose percentage weighing from the options.2) Set your reference on the pan and press Set100%. This weight will

now be treated as 100%3) Now remove the reference and place another sample on the pan.4) The weighing scale will display what percentage of the reference the

new sample weighs.

Differential Weighing1) Choose Differential Weighing from the options.

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2) Place the first container without the sample on the pan and press T & wgh. in. The initial weight has been recorded.

3) You can now treat or process the sample.4) Once again place the sample in the container on the pan and press

Residual…5) This will give the weight difference.

PART B

Statistics1) Choose the Statistics option from the main menu2) Place the first sample on the pan and press M+. This transfers the weight

to the statistics.3) You can choose to Weight Transfer automatically from the application

settings instead. Choose Additive mode to tare automatically after each sample is weighed. You need not remove each sample after weighing it.

4) Once all the samples have been weighed, press the Result button to have the results displayed.

Density1) Choose the Density option from the main menu2) Choose an appropriate method depending on the type of substance

whose density is being calculated.a. Solid body: Density determination of non-porous solid using an

auxiliary liquidi. If using ethanol or water as the auxiliary liquid, enter the

temperature. Otherwise, enter the density of the alternative liquid.

ii. Press the Start button. Place the sample on the pan when prompted. Its weight will be displayed.

iii. When prompted, immerse the body in the auxiliary liquid and press OK.

iv. The density will be displayed on the screen.

b. Liquid: Density determination of liquids using a sinkeri. Select Liquid as the method in the application settings.

ii. Input the volume of the sinker and press OK.iii. Weigh the sinker with the container and when prompted, press

OK to Tare it.iv. Pour the liquid into a container. The sinker will experience a

buoyant force.v. Press OK to accept the value and the density will be displayed.

c. Pasty substances: Density determination of pasty substances using a gamma sphere

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i. Select Pasty Substances as the method in the application settings.

ii. Enter the volume of the gamma sphere being usediii. Press Start and when prompted, place the sample on the balance

without the gamma sphere.iv. When the weight is displayed, press OK to Tare it.v. Immerse the sphere in the substance when prompted.

vi. Press OK when the weight of the substance and the sphere is displayed.

vii. The result is displayed on the screen.

d. Pycnometer: For determining the density of liquids using a pycnometeri. Select Pycnometer as the method in the application settings.

ii. Enter the weight and the volume of the pycnometer and press Start.

iii. Place the pycnometer with the liquid on the pan when prompted.

iv. Press OK when the weight is displayed. The density will show up.

e. Solid porous: For determining the density of porous solid bodies by using a supplementary oil bathi. Select Solid Porous as the method in the application settings.

ii. Enter the temperature of the ethanol or water that is being used as the auxiliary liquid.

iii. To use other auxiliary liquids, enter the density of the liquid.iv. Press Start and when prompted, place the solid on the weighing

pan.v. Press OK when the weight is displayed.

vi. Immerse the sample in an oil bath and weigh it out again. Press OK.

vii. Immerse the oil coated solid in the auxiliary liquid. When the weight is displayed, press OK.

viii. The density will be displayed on the screen.

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MANUAL: MICRO HARDNESS TESTERThis manual talks about how to use the Vickers micro hardness tester.

There are two main usage methods of this indenter: simple mode (manual and

automatic) and test program (multiple indentations). In the simple mode, one

indent is made and the hardness is measured. In the test program, once the

number of indents is set, it will automatically indent and shift positions. More

information on its working principle and sample measurements can be found in

the library.

NOTE: A dialog box will pop up when the button is

clicked. You can choose Manual Measure, Auto Measure A or Auto Measure B.

The Manual Measure is chosen for the Manual mode. The Auto Measure A is

chosen for clean and flat surfaces. The Auto Measure B is chosen for unclean

and uneven surfaces. For the Auto measures, ensure the Do Manual Measure

on Fail box is checked. The selected option will apply to both manners of

usage (simple and test program)

Using the micro hardness tester – Simple mode

1) Switch on the computer and the microhardness tester. The switch for the

tester is on the back near the bottom.

2) Lower the stage and place the sample. There is a knob on the side near the

bottom that adjusts the focus.

3) Open the Minuteman software.

4) Click on LOG ON and choose either TMS 1 or TMS 2. They are the same.

5) For a new measurement, click on File and choose New Measurement

6) Click on New Sample and fill in the required details. You can change the

sample name here. Click New Sample once you are done.

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Test Force knob


7) Throughout the process, to exit the viewing mode, press Esc

8) Click the Vickers mode. . The three options are manual measure,

Auto A or Auto B. If the program can’t detect the edges of the indent

automatically, it will ask the user to manually place the boundaries on the

indent. For Auto Measures, ensure the Do Manual Measure on Fail box is

checked.

9) Go to the viewing mode

10)After selecting the desired magnification (10x or 40x; right click: objective

selection), focus on the sample. You can move the sample by

clicking and dragging across the screen.

11)Make sure the Test Force value chosen in the side panel matches

the value set on the knob to the right of the eyepiece. This is a

very important step!

12) Focus on the targeted area for the indent and press Enter. Click

the indent button. Once the indent is done, you will hear a

beep.

13)Click on and focus the microscope.

14) The orientation of the indent with respect to the axes must be as shown.

15)Place the red lines that appear on left clicking at the boundaries of the

indent.

16)The hardness will show on the bottom left of the screen once you left click.

17)Left click again to view the hardness on the excel sheet in the background.

18)Click on TMS1 and then on LOG OFF. Switch off the computer

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TEST PROGRAM: This runs several indents in one trial. You can decide

the number of points, their respective distances etc. This is used if the

hardness gradient (hardness across a sample) through different

phases/materials is needed. This is more useful if hardness varies across the

material.

1) Log on, click on View and select Test Program.

2) Double click the 3 C Setting of measurement row to edit it.

3) Change the parameters in the pop up box as required.

4) Select New Sample in the Auto box. This ensures that the blue arrow shows.

5) Click the blue arrow next to AUTO. Focus the image.

6) Choose the area of the first indentation. This can be at the boundary

between the two phases/areas being studied.

7) Position the sample and press Enter.

8) A start line along with a direction pointer will show. Once the start point

and direction is set, the indenter will start automatically. Again, ensure that

the Test Force selected on the screen matches the values of the knob.

9) When the indents are done, they will be measured. This will be done

automatically if the indent is clear. This will have to be done manually if the

indent is blurred. Even if the redlines appear by themselves, you can focus it

to maximize the green number.

10)The results will be displayed in the excel worksheet.

11)Remember to LOG OFF before closing the software.

12)Switch off the computer once you’re done.

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The wheel controlling the load setting


MANUAL: UNIVERSAL HARDNESS TESTER

This manual discusses the usage of the universal hardness tester. This

tester is mainly used for measuring hardness on the Rockwell scale. This is a

mechanical device. You will need to calibrate the machine before every test.

The calibration process is the same as the testing process. For calibration,

make sure that the indent size and the indenter match. More information on

its working principle and sample measurements can be found in the library.

Using the universal hardness tester1) Switch on the hardness tester. Ensure that the lever to the side

(near the top) is pointing towards you. 2) Lower the stage. Using the wheel below the stage. Turning it

clockwise raises it and anticlockwise lowers it3) Remember to choose Rockwell in the knob at the side.

The universal hardness tester with knob with the options – Brinell, Rockwell and Vickers.

The first symbol and the last symbols mean Off. The second

symbol from the left means Brinell. The third symbol means Rockwell. The fourth means it is in the Vickers mode.

4) Place the sample (or calibration block) on the stage. Ensure that the wheel (on the side) points to the proper load setting (according to A, B and C).

Table 1: Indenter size and load setting for different modes.Mode Indenter Size Load setting (N)

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The lever

The


A 0.2 mm 588.4C 0.2 mm 1471B 1.5875 mm 908.7

5) Raise the stage till the lines on the screen coincide at 100. The steel knob in the front helps fine tune the line.

The lines coincide at 100. The line alignment fine tuning knob.

6) Once the lines coincide, gently push the lever away from you.7) Wait for 5 seconds for it to stabilize. Then pull it back.8) You can now see the result on the screen. (Ensure that you are looking at

the value from the proper scale).9) Lower the stage and remove the sample.10) Turn off the hardness tester.

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MANUAL: BRINELL HARDNESS TESTERIn the Brinell hardness test, a hard spherical indenter is forced onto the

surface being tested. The load varies from 500kg – 3000kg in 500 kg

increments. The Brinell hardness number is a function of the load applied and

the diameter of the resultant indentation. More information on its working

principle and sample measurements can be found in the library.

Using the Brinell hardness tester1) Turn the power on.

2) Calibrate the machine by using the respective calibration blocks and

indenter sizes. To calibrate, follow the steps 3 to 14.

3) Lower the stage and place the sample. Ensure the indenter is in the

front (chosen).

4) Press TAB A to select the appropriate test load and indenter size.

Press OK

5) Ensure the load setting matches the load chosen. Same goes for the

indenter (for calibration only).

6) Press CLR – F to set the load to zero.

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The control panel of the tester

7) Raise the stage till the screen reads around 100 kg force. After this

point, the tester will automatically increase the load till the set limit.

8) Lower the stage and change the indenter to the microscope. The lens

has to click into place.

9) Be very careful not to move the sample. Focus the microscope.

10)In the eyepiece, you will see two lines. There is one knob on each

side of the eye piece.

11)Adjusting the left knob results in both the line moving. Adjusting the

right knob results in the right line moving.

12)Make sure the lines coincide. Press CLR – D to set the distance

between the two lines to zero on the screen.

13)Then shift the lines so that they are on the outer edge of the

indentation. Once in position, press the black button next to the

eyepiece.

14) Rotate the eyepiece 900 and do the same horizontally. Press the

black button again once this is done.

15) The hardness will be displayed on the screen.

16) Lower the stage and remove the sample. Switch off the machine.

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MANUAL: ULTRASONIC TESTERThe ultrasonic tester helps detect flaws that are inside of the material.

The tester needs to be calibrated at least once in six months. More information

on its working principle and sample measurements can be found in the library.

Using the ultrasonic tester

1) Ensure the surface is free from any dirt and foreign particles that may

affect the surface roughness.

2) Lubricate the surface of the piece to be tested with oil.

3) Plug in the ultrasonic tester and turn it on.

4) Choose from the angled probe or the normal probe. The angled probe

helps detect flaws in welds while the normal probe helps detect flaws in

steels, forged steels and cast irons and steels.

5) Connect the probe to the tester and place the probe on the intended test

site.

6) Choose a standard for testing. Each standard will result in a graph with

different a baseline.

7) Calibration is typically done once in three months or depending on the

usage. The CSK I A is used to find the front length and calibrate the K

value for the angled probe. The front length is the distance between the

source of the ultrasonic waves and the edge of the calibration block. The

K value is the tan of the angle of refraction.

8) For the normal probe, the CS–1–5 block is used to draw the baseline

(AVG curve )

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9) There are three baseline curves on a graph for the angled probe. These

are drawn during calibration with the CSK III A block (DAC curve).

10) The baselines are drawn according to values given by the standards. The

standards may also specify different blocks to be used for calibration.

11) The pink line can be adjusted based on user specific standards.

A sample baseline curveI: Any peak below this is acceptable.

II: The acceptance of any peak below I and above III depends on the flaw

size and the permitted flaw sizes according to the chosen standards.

III: Anything with a peak above this line is rejected

Cracks of any size are not acceptable.

12) Move the probe around to detect the highest peak. The highest peak will

turn pink once it crosses the pink line in the graph. The pink line on the

graph can be adjusted to any percentage desired.

13) Once flaws have been detected, the acceptance of the metal part is

based on the standards chosen and the values of acceptance of the user.

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MANUAL: MAGNETIC PARTICLE TESTERThis manual discusses the operation of the Magnetic Particle (MT)

tester. The magnetic particle is used to detect surface and slight subsurface

flaws in a metallic piece. More information on its working principle and sample

measurements can be found in the library.

Using the Magnetic Particle (MT) tester1) To run a trial, place the test patch face down and follow steps 2 - 6.

2) Prepare the area to be tested by cleaning it. Make sure it is free from

dust, dirt, lint and any foreign material that may interfere with the

working of the MT.

3) Spray the inspection area/test patch with the magnetic suspension. If the

surface needs contrast, you can spray white paint first.

4) Plug in the MT tester and turn it on.

5) Switch the tester to the AC or DC mode and hold it across the spot being

examined with the current on. In the AC mode detects flaws on the

surface while in the DC mode, surface and subsurface (3-5mm) flaws

can be detected.

6) Now hold it across the spot in another direction (900 from the initial

direction) with the current on.

7) Once done, there will be an impression of the flaw on the surface.

8) Turn off the current and unplug the MT. You can wipe the area clean and

mark it.

9) You can use black light instead of using the white paint for contrast.

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Appendix II – Photographs

Fig 49. Optical Microscope

Fig 50. Optical Stereoscope

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Fig 51. A photograph of the SEM at the Atlas Copco, Nanjing lab

Fig 52. A close up the SEM

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Fig 53. A photograph of the inside of the SEM. The sample is placed on a stage.

Fig 54. Side view of the inside of the SEM

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Fig 55. A picture of gold particles taken with the SEM. Magnification 30,000x

Fig 56. A picture of gold particles. Magnification 60,000x

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Fig 57. The cutting machine

Fig 58. The mounting machine

Fig 59. The grinder and polisher

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Fig 60. The precision weighing scale

Fig 61. The Vickers microhardness tester


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Fig 63. The digital Brinell hardness tester

Fig 62. The Universal hardness tester


Fig 65. The Magnetic Particle tester

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Fig 64. The Ultrasonic tester


Xu Zhou visit photographs

Fig 66. The Xu Zhou BUT company

Fig 67. The frames that were to be tested

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Fig 68. The frames that were to be tested

Fig 69. The weld to be tested prepared by applying oil/grease

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Fig 70. One of the six flaws detected by the engineers

Fig 71. Another flaw detected by the engineer.

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Fig 72. Hamsini Gopalakrishna using the UT machine

Fig 73. The BUT engineer, SGS engineer and Atlas Copco engineer examining the frame

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Atlas Copco, Wuxi visit photographs

Fig 74. Staff from Atlas Copco, Wuxi From L-R Lin Zhi Min, Xu Bin Jie, Charles Fu and Alex Xie.

Fig 75. From L-R Charles Fu, Hamsini Gopalakrishna and Alex Xie in front of the silent generator

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Fig 76. Hamsini Gopalakrishna in front of the silent generator

Fig 77. Oil carrying equipment used for testing

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Fig 78. A compressor testing rig

Fig 79. The failed aluminum part whose cause of failure was being discussed

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Fig 81. Side view of the oil separator

Fig 82. Side view of the separator

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Appendix III – Presentation of lab equipment and their uses

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***************************THE END****************************

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Atlas Copco Internship Report

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Transcript of Atlas Copco Internship Report