BHPV-The Lost Opportunities

There were many opportunities for BHPV to become a giant organisation but because the top management was timid and lacked imagination we let go of those opportunities. At least I know of three opportunities which would have catapulted BHPV to big league.
Let me narrate the first opportunity.
In early 1980's I was a member of the Polar Satellite Launch Vehicle (PSLV)design review team. Almost every month I used to go to ISRO at Trivandrum to participate in the design review. The review committee consisted of eminent people from design,materials,fabrication, testing etc. My job was to review welding and non-destructive testing procedures.
Rocket motor casing is nothing but a pressure vessel subjected to very high pressures. The entire design philosophy is to make the rocket shell as thin as possible but still meeting the safety and structural stability requirements. There were two teams who were designing the casing. It was understood that which ever team comes out with the best design in terms of least weight of the rocket meeting all structural stability requirements will be admitted. To give an idea of the intense competition between the teams, one team adopted the weld efficiency as 1.1 and another team adopted the weld efficiency as 1.08. At first glance this difference appears to be small. But this made a significant difference in the weight of the rocket motor casing. If one were to adopt weld efficiency of 1.08 one has to adopt a stringent welding procedure and an advanced method of detecting weld defects. The crack size was specified by the fracture considerations. My additional assignment was to find out the method of detecting the crack and if necessary specify an instrument measure the crack. The design review used to go from morning to evening and continued even during dinner time. it was the most stimulating experience i had.
I met several authorities in various fields and this experience was humbling.

During one of such meetings the Project Director of PSLV who knew me well called me aside and gave a bundle of drawings and told me that they were the preliminary drawings of PSLV and told me that he wanted BHPV to examine the drawings and give there consent for fabrication of Rocket Motor Casings. He also told that they want BHPV has to set up exclusive facilities for the manufacture and ISRO will completely fund the facilities. ISRO wanted air conditioned clean room facility, automatic TIG welding machines, assembling jigs, online testing facilities etc. which will also be funded by ISRO.ISRO wanted a guarantee that these facilities will not be used for any other jobs. I was excited for identifying BHPV for such a prestigious job. I told him that I will do my best to convince top management to accept the challenge.

What was the reaction of BHPV's management's reaction for this proposal will be the subject of next blog.

Establishing R&D in Bharat Heavy Plate and Vessels (BHPV)

In 1975 i joined BHPV as chief of R&D. Prior to my joining BHPV there was a small nucleus 3 post graduate engineers. Soon after I joined BHPV there was a change in the top management. I was reporting directly to the chairman and managing director and I had to wait for the appointment of chairman and managing director. After the new CMD took over he called me and asked me to go ahead and recruit M.Tech's from IIT's. We went to IIT, Madras,and IIT, Kharagpur. From these institutes we selected 8 M.Techs.4 M.Techs were from Chemical Engineering, 2 from manufacturing and 2 from welding. Till R&D building was constructed we worked from one single room. Our work shop was the the workshop of Training Centre which had primitive facilities. Within one and half years we had our own building. BHPV is a vast organisation with excellent fabrication facilities. But I soon realised that we cannot depend on the main manufacturing facilities for our prototype fabrication as the main manufacturing facility was not keen to divert their main machinery and workforce for our work. I argued with the CMD for our work shop. He granted us the finance to construct a work shop. The work shop and one shaping machine, one radial drilling machine,one milling machine, one lathe and several welding machines.Training centre sent us some trainee welders. We took them trained them again to meet our needs. When we needed shaping machine operators, milling machine operators, drillers and machinists the troublesome workers from the main shops were transferred to R&D work shop. Since we had no choice we accepted them. But within a short time we realised that these workers were really good. They were labelled"bad " because they always challenged established practices. We needed such people who can challenge existing practices.
In two years we had about 16 M.Techs in our group. 4 engineers formed the Chemical Engineering group, 4 formed the Cryogenic Engineering group, 4 formed the Manufacturing Technology Development group and 4 welding Technology Development group.
Each research engineer was allowed to work on 3 projects simultaneously and one project of his choice.Two engineers can join together and work on project when the project was big. When the project involved a prototype construction, the team may consist of one from chemical engineering who was responsible for process design, one was from product development to select material and method of manufacture and from welding technology group to welding methods and supervise welding. Thus a project team was a blend of various expertises.
Projects were selected based upon the organisation's need. We were constantly in touch with Sales to find out which ou the tenders the could not respond because of lack of technology. If such rejections are many, we would consider developing the missing technology. For example, at one time Sales could not respond to the customer inquiry for Titanium Heat exchangers. Acquiring the technology from abroad was expensive. Hence we initiated a programme to develop welding Titanium. We also went inside the workshop to find out the difficulties they are facing in manufacturing and initiated development projects to overcome this lacuna.
I also decided that at least a part of R&D expenses must be earned by accepting contract research. We approached, Defence Research & Develpment Orgniasation(DRDO)' Defence Metallurgical Research Laboratory(DMRL), Mishra Dhatu Nigam(MIDHANI)etc. for sponsoring projects. We were successful in obtaining a contract from DRDO to establish a manufacturing process for Titanium Gas Bottles for PRITHVY and TRISUL missiles. This project when completed successfully resulted in obtaining continuous orders of few crore Rupees. Similarly with DMRL for developing Armour welding and MIDHANI for Maraging steel welding.In these projects the entire development cost was funded by the respective organisations and also ensured that future business comes to BHPV. One of the contract clauses we insisted upon was that once the development was completed any hardware resulting from our development should be offered to us for series manufacture. If it was not aggreable, we were not we were not willing to take up contract research.
Another contract research we accepted was to design and develop compact heat exchangers for TEJAS supersonic aircraft being designed by Aeronautical Development Agency. The fabrication of the heat exchanger involved vacuum brazing of aluminium parts. In imported vacuum brazing furnace would have costed several lakhs of Rupees which neither ADA can afford nor BHPV can afford. We realised that a vacuum furnace is nothing but an externally pressurised vessel to contain vacuum and some heating elements and controllers to maintain predetermined temperature. We looked within BHPV and found that we were good at creating and maintaining vacuum, good at fabricating vacuum tight vessel and what we lacked was the expertise in control system for electric heaters. We decided that we will purchase the control system and integrate with the vacuum vessel and the heaters. We were successful in this gamble and we could build the vacuum furnace at a fraction of the cost of imported furnace. Not only this, we opened a new business of designing and building vacuum furnaces. Using this furnace we have brazed several aluminium heat exchangers. Later we built a high temperature vacuum brazing furnce for brazing stainless steel
When BHPV wanted to buy several kilometers of superinsulated pipe for transporting liquid oxygen and liqiid nitrogen from production plant to storage system BHPV found that the imported price of these pipes was busting its budget. We stepped in and offered to the Management that we could manufacture these pipes in R&D at a much lower cost. Mnagement was sceptical. We offered that we will build a trial pipe line selected by the Design department and subject the test pipe to any test desired by the QC department and if QC is satisfied with the performance, then we should get an opportunity build the entire pipe linr. R&D pipelines fully passed all the tests specified in the design document and we desined, manufactured and supplied the entire pipe line.
Another innovative idea I introduced was the transfer of technology to shops. I realised that a product or a process when transferred to the shop fails because it is not nurtured properly in the shops. Whenever a new product developed by R&D was transferred to the shops we insisted that the people who developed the product should also move to the shops. The engineer who developed it and the welders, fitters and others who worked in the projects were transferred along with the project. They can remain till the shop people absorbed the new technology successfully and felt confident to run it without R&D's help. We also offered that any of the staff so transferred desired to continue in the Shops can do so provided we are allowed to recruit new people in their place. This worked nicely for us.In one stroke we ensured that whatever we developed did not fail on the shop floor.
I think this is the first time any body thought of such a process of transfer of technology from R&D to shops.
A short list of various projects developed is given in my blog Dr. G.J.Guru Raja.

Starting and Running R&D

Before joining BHPV I was working in Central Mechanical Engineering Institute,(CMERI) Durgapur,West Bengal. CMERI was set up by Council of Scientific and Industrial Research,(CSIR). CMERI building was majestic and had very good infrastructure. It had overstaffed administration, finance department, purchase department etc. There was an elaborate system for purchasing any material. The system was so rigid that purchasing any material needed for Research was a tedious affair. Some times we had to wait for years before we can receive any material. Consequently Research workers had lost interest by the time the materials arrived. There was no system of review of the projects. Projects were started without identifying who is the end user. Projects were dropped without assigning any reason. Even serious minded people who were interested in Research got disillusioned and left CMERI. A quick analysis of the state of affairs revealed that the budget allocated was skewed. More than 70 percent of the budget went for maintaining the infrastructure. There was very little money left for actual Research. There was no accountability. Since the Institute was located in Bengal, non-Bengalis were discriminated. Studying all these at close quarters,I dreamed that at any time I had to lead a R&D group, I will allocate 70 percent of the budget to purchase machinery, materials, instruments etc. and remaining money for infrastructure. If necessary, have a separate budget for infrastructure and the budget for R&D will be decided by R&D staff. Also once a budget is allocated for a R&D project the spending cannot be questioned. There shall be continuous monitoring of the projects both for progress and budget.Any increase in the budget should be justified. Every project proposed should identify an end user and what benefit we are going to get once the project is completed. How some of these ideas were implemented in BHPV will be the subject of next blog.

Transport of Metal during welding Part-2

In my previous Blog which was published in May 2010, I had promised that I will write about the work done to explain under what conditions the molten weld metal moves backwards.

In 1970's A number of papers were published exploring how the crater is formed when an electron beam strikes a metal object. But we did not find any published work explaining how the molten metal moves backwards. As suggested by the Physics Professor in Moscow Power Institute we looked at the possibility of Thermocapillary phenomenon playing a part.

It is a well known fact that the surface tension force of metal depends upon upon the temperature. Higher the temperature lower will be the surface tension force. Therefore, in addition to the normal force acting on the molten metal a tangential force along the surface of the molten metal develops.The tangential force is determined by the surface tension gradient.This is represented by the equation
P(t) = grad(sigma)
A positive sign before the gradient indicates that the force P(t) moves the metal from a region of lower surface tension to a region of higher surface tension, i.e the molten metal will move from a region of higher temperature to a region of lower temperature which means from the front of the weld pool to the back of the weld pool.

When the electron beam moves over the metal surface the front portion of the crater is at a higher temperature and back of the crater will be at the melting temperature of the metal. As a result of the temperature gradient thermocapillary effect manifests it self. Hence under thermocapillary forces the molten metal flows from the front of the crater to the back of the crater.

The experiments reported in Part-1 confirmed that Thermocapillary effect is responsible for metal movement.

We also attempted to theoretically examine the metal flow.

To quantify the metal moved from the front to the back of the crater, neglecting the radius of curvature of the crater, as a first approximation, the flow of metal is treated as a two dimensional flow and relevant differential equations with boundary conditions were solved. The solution resulted in calculating velocity of the moving metal and the quantity of metal moved from the front of the crater to the back of the crater. The thickness of the liquid metal in the crater was calculated considering the temperature distribution in the crater. With this input we calculated the volume of metal moved from the front to the back. The theoretical calculations agreed closely with the measured values.

We were the first to identify thermocapillary effect as my Ph.D thesis was defended in 1972 and the work was done in 1971.

We published our work in Svarochnoe Proisvodstvo. Later my professor teamed up with the Professor of Physics mentioned earlier and together they published another paper extending the work to consider the flow as three dimensional. As our work was in Russian it reached not many people. But in spite of the disadvantage of language later I could identify 5 citations of the first paper published on Thermocapillary flow.

A practical application of this work was used to develop welding very thick aluminium blank of over 200mm in single pass by electron beam welding. Here the electron beam was located along the Y-axis as against the convention of beam impinging from top to bottom. In addition to the gravitational force, Thermocapillary force drove the metal away from the molten zone exposing virgin metal which aided in increasing the depth of penetration.

Transport of metal during welding-Part 1

Prof. Olshanskii suggested that I should examine what forces were responsible for driving the molten metal from the front of the pool to the back of the pool where the metal solidifies.
To visualise the flow of metal during welding I did some ingenious experiments. In a stainless steel plate of 10mm thick a hole of 2mm dia was drilled. Wires of copper,titanium,tantalum etc were embedded tightly in to these holes.A full penetration Electron beam weld passed over these metals embedded in the stainless steel.The welds were sectioned along the axis of the weld.The specimens were polished and etched to reveal the distribution of these tracer metals. The tracer metals had moved over a distance 6 to 8 mm in a direction opposite to the direction of welding. The concentration of the tracer metals along the depth of the weld and along the length of weld was measured using an electron micro probe analyzer.The maximum concentration was found at the top of the weld.

We were at a loss to explain how the metal could move such long distances considering that the dimensions of the electron beam welds are generally small.We searched entire literature to see whether any body had come across such a phenomenon. We could not find any thing similar to us.We realised that we have stumbled upon a new phenomenon. Finally my professor decided to consult one of the top class Physics Professor who was working in the same institute, that is, Moscow Power Engineering Institute. My professor took me to the Physics Professor and made me explain my experiments and also show him the results obtained till now. The Physics professor thought for some time and told me that I should look for "Thermocapillary Effect" and suggested that I should read a book on physics which was in the library. The meeting ended and we came out. I was disappointed with the meeting and I told my professor so. Then he told me something which I have not forgotten and which is helping me even now. He told me " I talked to several professors and all of them suggested that he is the right person to guide us. You may take a long time to find out the right person to consult. Once you have found him follow his advice implicitly. You jolly well go to library and read that book" I went to the library and read the book suggested by the Physics Professor. Indeed the back word movement of the metal could be explained by thermocapillary effect which will be the subject of next blog.

Dimensional Analysis applied to predict depth of penetration

The second portion of my thesis was to find an equation for predicting depth of penetration for a given welding parameter for a given material.

The formation of weld bead in EBW is controlled by many factors and to predict bead formation by rigorous mathematical analysis was not possible.While width of weld in EBW was not a significant parameter, depth of penetration is. Many research papers published at that time depended on fitting equations to the experimental data. These curves are applicable in limited field. To get a generalaised equation covering all metals and all welding parameter needed a different approach.

I had some experience in Dimensional Analysis and thought of applying this technique to predict depth of penetration.

The various factors that control depth of penetration are: beam current, beam voltage,beam diameter, welding speed and material properties such as thermal conductivity,melting point,specific heat,and latent heat of fusion. An advanced method of Dimensional Analysis was applied to solve the resulting equations. Three non-dimensional parameters were obtained. The first parameter related to the ratio of heat lost by conduction to the beam power, the second, the heat required to melt a given volume to the beam power and the last was the heat required to heat a given volume to the melting temperature to the latent heat of fusion. Plotting these parameters one against the other we got graphs which predicted the depth of penetration.The theoretical depth of penetration closely followed our Experimental results and the data obtained from other workers.These equations can used to predict depth of penetration in EBW for any metal at any given voltage,current and speed.

This was the first time any one had applied dimensional analysis to solve a welding problem.

Ph.D programme

After passing the Russian language exam which was conducted six months after joining the course, I was allowed to join the Department of Technology of Metals for my Ph.D programme. Taking in to account my background Prof.Olshanskii suggested that I study the temperature distribution during Electron Beam Welding and correlate the metallurgical changes that take place in the metal with measured temperature distribution. In addition he suggested that I should develop a method of predicting depth of penetration for a given welding parameter.

At first instance the problem appeared to be simple. But experimentally determining the temperature distribution had its own problems. Platinum-Platinum Rhodium thermocouples were used for measuring the temperature. The Heat affected Zone in Electron Beam welds are extremely narrow and to locate the thermocouples precisely in that zone was very tricky. Initial experiments were done to measure the width of the heat affected zone for various weld parameters. The welding chamber was equipped with a precision table which can move in the X and Y direction. The table was adjusted such that the electron beam passed through the centre of the table in the Y-direction. A jig was prepared such that the electron beam passes through the centre of the jig. The jig was bolted to the traverse table. Test specimens were machined such the they fit snugly in to the jig. Holes were drilled in the test plate and thermocouples were embedded to measure the temperature in the heat affected zone.The location of thermocouples was decided by the earlier experiments done to measure the width of the heat affected zone. The thermocouples were taken out of the welding chamber and connected to a high speed strip chart recorder. Welding was started and the temperatures were recorded. These experiments look simple but it was very difficult ensure that the electron beam traverses precisely where you want. Slightest changes in parameters or alignment of the test plate will result in the electron beam going over the thermocouples or going far from the thermocouples. The recorded temperature distribution was compared with the theoretical temperature distribution considering the heat transfer is two dimensional, The specimens were sectioned and were subjected to metallurgical tests.Several test specimens were welded to establish the repeatability. The first portion of the assignment was finished and the next was to find a method of predicting depth of penetration for a given welding parameter.

Precautions while working on high voltage equipment

Electron Beam Welding(EBW) machines generally operate on accelerating voltages of 60Kv to 150Kv. There is rule in Russia that those who work on such machines must pass an examination. Classes were conducted for all students, teaching us what precautions must be taken to handle the high voltage equipment. We were taught how to check glows and ensure that we use the tools and tackles rated for repairing high voltage equipment.While repairing any electrical system we should switch off the mains and remove the fuses and keep it with you and not leave them at the fuse board. Otherwise some body may see the fuse board open and fuses lying unplugged and may insert the plugs leading to disaster. There were many DO's and DONT's which we had to remember and at the end of the course we had a written exam and viva. I failed the exam even though I thought I did well. I failed for the second time and I went and complained to my Professor. He smiled and said that he had asked the examiner to be tough on me because if I am not thorough and if any accident occurs and I am injured he will end up in Siberia because he did not take good care of a Foreign student! Finally I passed the exam and then i was allowed to operate the high voltage EBW. I am writing this because the training we got in Russia was thorough in all respects.We had the disadvantage of learning every thing in Russian. But at the end I was happy that I came to Russia for my higher studies because I learned a new language and worked under an eminent professor.

How to repair diffusion pump

We were four Ph.D students and we had one Electron beam welding (EBW). Hence we had to book the machine in advance.In case the machine goes out of order when you are working it is your responsibility to put the the machine back in to working. You cant walk away if the machine is down.
Vacuum in the welding chamber is created by one mechanical pump and one diffusion pump. First the mechanical is switched on and after the desired vacuum is achieved in the chamber, the mechanical pump is isolated by closing a valve and then a valve is opened to connect the diffusion pump. If by chance the diffusion pump is brought in to operation with out isolating the mechanical pump, air will rush in to the diffusion and the oil in the diffusion pump will burn and the diffusion pump stops operation. Then you have to clean the diffusion pump and put it back in to operation.
One day while working in the machine I opened the wrong valve and the diffusion pump conked off. I shut off the machine and was waiting for some worker to come and dismantle the pump and repair it.Prof. Olshanskii happened to come to the laboratory and saw me not working. I told him that the diffusion pump is not working. "Repair it". I told him I don't know how to repair it. He shouted"Then learn it". He called the foreman of laboratory and asked him to give me a set of tools. He then told me to dismantle the pump and see what has gone wrong.He saw me struggling to open the heavy bolts he provided me a hefty worker,Kolya, to dismantle the pump. When the pump was dismantled I found that the internal shrouds in the pump was coated with a thick layer of burnt oil. The shrouds were made of aluminium and cleaning process involved using emery papers to remove the muck accumulated on the shrouds. It is slow and back breaking.Here Kolya helped me. After cleaning every shroud, they have to be degreased for which industrial alcohol was used. By the time cleaning was over it was late in the night and Kolya agreed to fix the diffusion pump in position. I left for my hostel. Next morning I was hauled up before the Foreman of the laboratory because Kolya drank the rest of the alcohols and had passed out in the laboratory. It seems that it was my responsibility to have used the entire alcohol for cleaning and not leave with the worker! This experience gave me confidence that I can repair any diffusion pump.

How I learnt to operate an Electron Beam Welding Mchine

I am not going to write about what is an electron beam welding machine about which anyone can read in a standard welding text book. I am going to write how students were trained in Moscow Power Institute.

There were two electron beam welding (EBW) machines in the Department of Technology of metals where I joined for my Ph.D program under Prof. N.A.Olshanskii. One was operating at high voltage and the other was operating at a low voltage. The one operating at a high voltage was built by Prof. Olshanskii and the other was a factory built machine. New students were asked to start with the machine built by Prof.Olshanskii and after mastering the principles of operation of EBW they were allowed to go on the factory built machine. There was a reason behind this exercise. The machine with which we started to learn operation of EBW used to go out of order often as it was very old. The cathode which was a filament made of
tungsten used to burn up fast either due to our wrong handling of the machine or due to its life being over. When that happened we were supposed to take out the electron gun and replace the tungsten filament. During this process we learnt how the electron gun looks, how to make the tungsten filament, how to mount the filament and how to align the filament properly etc. All EBW machines are connected to a fore vacuum pump which is a mechanical pump and an oil diffusion pump. Whenever these pumps went out of order we were supposed to strip them open, rectify the mistakes and put them back in to operation. These exercises gave the new entrants enough confidence to handle any EBW machine. When you made mistake no one asked any questions but you were only required to set the mistake alright.This was totally different from the approach of Indian institutions.After my quota of mistakes, when Prof. had the confidence that I can handle factory built machine he allowed me to go on that machine.

There is a particular procedure for opening and closing of various valves to create vacuum. In today's machines everything is automated. In 1968 all these operation were manual. Fist you have to switch on the electric heater to heat the oil in the diffusion pump and after some time you switch on the fore vacuum pump and when the fore vacuum has reached a predetermined level you close the valves of fore vacuum pump and open the valves connected to the diffusion pump. If valves connected to the diffusion pump is opened when the valves connected to the fore vacuum pump is not closed air enters diffusion pump and oil burns and vacuum is lost.Then you have to switch off the machine, clean up the mess and put the machine back in to operation.

I will write in next blog what happened when I burnt the oil in diffusion pump.

Moscow Power Engineering Institute

I was selected by Government of India in 1968 on a USSR scholarship to do my Ph.D in Moscow. After reaching Moscow I was admitted to Moscow Power Engineering Institute.

Moscow Power Engineering Institute was set up in in 1930 to solve technological problems associated with power generation, distribution, control etc. The Institute was so huge that in 1970's the student strength was around 24000. The institute was training students from undergraduate level to post graduate level including Ph.D's and D.Sc's. There are 70 Departments in MPEI, 550 laboratories for students and more than 100 research laboratories. More than 500 Ph.D students out of which 100 foreign students are studying at any given moment. The faculty consists of over 1700 professors, assistants professors and lecturers. Many of the professors are Academicians.Selection to Undergraduate programme was similar to our IIT entrance exams. Very tough and students from all over USSR wrote the exams. If the students are not selected they used to cry their heart out. The admission to Postgraduation depended upon the performance in the Undergraduate programme and the the desire of the Professor to accept a Graduate student. All Postgraduate student got a scholarship of old 200 Roubles. In addition students are allowed to coach undergraduate students for which they were paid another 100 Roubles per month.

My Professor was Alexander Nikiolaevich Olshanskii.
All welding processes are based on heating the metal to be joined to its melting temperature and prevent the molten metal from contamination by oxygen and nitrogen in the atmosphere. For example, in manual metal arc welding, heat is generated by striking an arc between the base metal and the stick electrode. To prevent contamination the stick electrode is coated with chemicals which produce enough gas such as carbon di oxide, carbonmonoxide and other reducing gases. In addition a slag is deposited to blanket the molten metal to prevent contamination from atmospheric air. Some times alloying elements are added in the coating to improve the mechanical properties of the weld metal. Similarly in TIG welding and MIG welding Argon is used to shield the molten metal. The whole idea of using the gas is to displace the Air in the vicinity of weld. Thus whatever may be the heat source it is essential to ensure that weld metal is not contaminated by the atmospheric air.
There is another method of preventing contaminatin of the weld metal-by creating vacuum around the place where welding is going on.When you evacuate the place where welding is going on you have eliminated all gases from the vicinity of the weld. The part to be welded is kept in a chamber which is evacuated and welding is done as usual. This was in 1960's.When Prof. Olshanskii proposed this new process his peers laughed at him and asked him whether he plans to go to space to carry out welding. But undaunted he worked out the process of welding in vacuum for which he got his Ds.c. He had the last laugh when soviet astronauts did weld in space and brought back welded specimens for evaluation.
After successfully establishing welding in vacuum he conceived a new process of Electron Beam Welding about which I will write in the next blog.