Electron Beam Machining (EBM)

Electron Beam Machining (EBM):-

It uses a focused beam of high-velocity electrons to remove material. In this process, a stream of electrons strikes an object and causes rapid melting and vaporization of the material. For drilling applications, a backing material is used on the rear side of the workpiece. When the beam penetrates through the workpiece and contacts the backing material, the high vapor pressure produced by the vaporized backing material expels the molten workpiece material, leaving a hole in the workpiece. The EBM process can be used to machine a variety of materials, and material properties such as hardness, ductility, electrical conductivity, thermal conductivity, and melting points are usually not limiting factors. The greatest industrial use of EBM is the precision drilling of small holes (0.1 to 1.0 mm, or 0.004 to 0.04 in.) in metals. Although some work has been done to apply the EBM process to nonmetallic and curvilinear cutting applications, this industrial application is very limited. Therefore, unless otherwise noted, the descriptions in this article apply only to metallic hole-drilling applications.

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Underwater welding

UNDERWATER WELDING-

Many of us won't have heard of underwater welding, but it's actually a very important thing in many industries. Underwater welding includes a lot of different processes that join steel on offshore oil platforms, pipelines, ships, and in many other applications.
It can be done at regular or at high pressures, and can be done in a wet environment or a dry one. Let's take a look at some of the benefits and downsides of different kinds of welding underwater, and the uses of this interesting technique.
Dry welding is the most useful method for making any weld in very deep water, or in cases where the weld needs to be extremely strong. On many sea structures and vessels, strength is extremely important.The problem is that most conventional dry welding techniques are very expensive, and takes a very long time. While some other techniques, using a smaller hyperbaric chamber for just the area of the weld, are being developed, they're not the standard yet. As they become more popular, wet welding may fall out of use entirely.That's because wet welding, while much cheaper and faster, just isn't all that strong. It tends to create pockets of oxygen and hydrogen gas, as well. These occur due to the electrolysis of water, and can be dangerous and even potentially explosive!
In addition, the majority of wet underwater welds won't last long. They're a temporary fix that needs replacement after only a little while. These welds are best used when time and money are short, and function needs to be maintained - they'll need to be redone again later using a dry process.It's important to remember that there are some limitations on how deep you can weld, as well. Dry welding can be done as deep as eighty meters below the surface of the water, but it requires special diving equipment. Wet welding is much less effective under high pressure, since the join isn't really strong enough to stand up to the forces additional depth will put on it.

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Plasma cutting

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Plasma cutting:

Plasma cutting is a process that is used to cut steel and other metals of different thicknesses (or sometimes other materials) using a plasma torch . In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut.

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Casting Process

Casting:-

Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

Advantages:-

1.Size of cast objects vary over large range. An object from 5gm to 200 tonn, anything can be cast.

2.Casting can be effectively used for complex shaped objects.

3.Component made with casting process is lighter than the component made with other machining processes.

4.Casting provides versatility. Wide range of properties can be attained by adjusting percentage of alloying elements.

5.Casting can be made with hair like precision provided proper molding and casting technique is employed.

Disadvantages:-

1.Though casting is cheapest for MASS Production, it becomes non economical in case of JOB production.

2.Sand casting leaves rough surface which needs machining in most of cases. It adds up the cost in production.

3.Again in sand casting, poor dimensional accuracy is achieved.

4.Cast products are superior for compressive loads but they are very poor in tensile or shock loads.(They are brittle).

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TEMPERING

TEMPERING:-

Tempering, in metallurgy, is a process of improving the characteristics of a metal, especially steel, by heating it to a high temperature, though below the melting point, then cooling it, usually in air.

The process has the effect of toughening by lessening brittleness and reducing internal stresses.

Suitable temperatures for tempering vary considerably, depending on the type of steel and designed application; for tool steels, the hardness of which must be retained, the range is usually from 200° to 250° C (400° to 500° F).

The term is also used for hardening by cold-working.

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Production Engineering:

Production Engineering:-

A combination of manufacturing technology with management science which encompasses the application of castings,machining processing, joining processes, metal cutting & tool design, metrology, machine tools, machining systems, automation, jigs and fixtures, and die and mould design and material science and design of automobile parts and machine designing and manufacturing. 

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3-axis water-jet cutting machine

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Ultrasonic welding process

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Hydropower plant

Inside a hydropower plant

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MODERN MANUFACTURING METHODS

Water jet machining

A water jet cutter,also known as a water jet or waterjet, is an industrial tool capable of cutting a wide variety of materials using a very high-pressure jet of water, or a mixture of water and an abrasive substance

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