Case Study

Mesh Type Spacer for BARC

These spacers are used to maintain the spacing among the fuel rods in Fuel Rod Cluster Simulator for experimental study of thermal hydraulic behaviour of reactor fuel elements.

Mo Cladding on CuCrZr Alloy for IPR

For ITER project, Mo clad layer to the level of ~>100 µm to protect the base material surface from sputtering are developed using LAM with Ni-interlayer.
Conventionally, this Mo layer is achieved by Physical Vapour Deposition process, which the thickness ~3-5 µm.

SiC Clad Layers on Zr-4 for BARC

SiC clad layers (~ 100 µm) on Zr-4 is developed using LAM to improve the safety of nuclear reactor.

Conventionally, SiC coating is deposited using techniques, such as physical/chemical vapor deposition and magnetron-based techniques thickness is limited to 20 µm.

Gear Manufacturing Project

Parameter optimization of special alloy EN39 B is carried out, Deposited Gear billets for further machining, majorly MRO (Maintenance Repair and overhauling) of Discontinued or part that are not readily available are the key pain areas for major of the Defence Oriented organization. To overcome these issues rather than remanufacturing we can now repair those parts.

Pure Cu Coupling

Deposited Pure Copper Coupling at 1 mm beam diameter for one of our customers, Copper deposition is still a tedious task for most of the AM companies worldwide due to its low absorptivity properties.

Inconel 625 deposited on WC Drill-bit

We have Deposited cylindrical protrusion features of IN 625 of 1 mm diameter and 1.5 mm height on the WC Drill-bit tip for one of our customers, in order to avoid continuous chips formed during the machining process.

Inconel 718 : 90 Degree Bend Tube

Complex thin wall structures are the key area of research and development in DED based technology. We have manufactured a 90 Degree bend tube on our indigenously developed Laser PF-DED system TVASHTR 500. Showcasing our 5 axis, material processing, deposition strategy planning capabilities. The major challenge in the development was the stability of the wall due to formation of peaks and valleys.

Wall thickness 1.5 mm; Arc Radius: 50 mm

Hemispherical Dome in Inconel 718

The hemispherical dome finds widespread use in the aerospace industry, particularly in rocket engines. These domes are crucial components engineered to withstand high pressures and ensure the structural integrity of fuel tanks. Typically constructed from robust materials such as titanium or high-strength alloys, they are specifically designed to endure the extreme conditions of space travel and rocket launches.

Specifications:

Dome Diameter: 75 mm; Wall Thickness: 2.4 mm

L605 Cobalt 99.6% Dense Deposition on IN718

In718/IN625 super-alloy is used to manufacture Gas turbine blade.Deposition of Cobalt based alloy on Flue Gas Turbine BladesCritical components, such as turbine blades in flue gas turbines operating continuously in steel plants, are susceptible to damage caused by sulfur-induced oxidation and corrosion. To address this challenge, we have applied a cobalt-based alloy coating to the blades using the Laser Cladding Process.This deposition significantly enhances the lifespan and efficiency of the gas turbine, mitigating the effects of corrosion and extending operational efficiency and durability.

Orifice Plate: Inconel 625

Orifices having honey-comb type geometry were developed to meet the flow zoning requirements of fuel zone. These orifices being of very complex geometry requires precision methods of manufacturing to achieve the desired shape under specified tolerances. Hydraulics of these orifices is important in achieving the required pressure drop without cavitation.

Printed two phases to avoid supports

SS316 LN on SS304 Steel Pipe

We have fabricated a SS316LN 75 mm OD tube on existing SS304 Tube Substrate. These kinds of structure are advantageous wherever we require a Seamless T-Joint.

Further plan is to deposit on P91 Steel

Material SS316

Wall thickness 6 mm

Cu-Ni FGM

We have fabricated a Cu-Ni 18 mm OD tube. In which after every 2 layer of deposition one layers nickel is deposited Hot flue Gases generated in the power plant will flow from inside the Cu-Ni tube and the due to the change in thermal conductivity K, this will result in generation of electricity

Applications Developed By TVASHTR SiC Clad Layers on Zr-4 using LAM-DED Collaborator BARC Mumbai

SiC clad layers (~ 200 µm) on Zr-4 is developed using LAM-DED process to improve the safety of nuclear reactor during accident by avoiding the high temperature oxidation.

Conventionally, SiC coating is deposited using techniques, such as physical/chemical vapor deposition and magnetron-based techniques and thickness is limited to 20 µm due to delamination effect as a result of high thermal expansivity difference.

WC Clad Layers on SS304 using LAM-DED Collaborator BARC Mumbai

Successful deposition of WC on SS 304 steel achieved without any defect and crack using LAM-DED Process

Mo Clad Layers on CuCrZr using LAM-DED Collaborator IPR

For ITER project, Mo clad layer to the level of ~>100 µm to protect the base material surface from sputtering are developed using LAM with Ni-interlayer.

Conventionally, this Mo layer is achieved by Physical Vapour Deposition process, which the thickness ~3-5 µm.

Mesh Spacer For BARC