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ANNUAL REPORT 2009-2010

National Metallurgical Laboratory Council of Scientific and Industrial Research

Jamshedpur-831007, India

Annual Report 2009-2010

ORGANISATIONAL STRUCTURE

Director

Administration/ stores/ purchase/

accounts

R& D Divisions & Centre

Applied Chemistry & Corrosion

Business Development & Monitoring

Engineering

Materials Science & Technology

Metal Extraction & Forming

Mineral Processing

CSIR Field Station

Madras Centre, Chennai

Division Centre Analytical Chemistry

Information Management & Dissemination

Calibration

Non-Destructive Evaluation

Management council

Research council


Overview Of NML

The foundation stone for National Metallurgical Laboratory was laid by Hon‟ble Sri C. Rajagopalachari on 21st November, 1946. It was formally inaugurated and dedicated to the nation on 26th November, 1950 by Pandit Jawaharlal Nehru “in a spirit of hope and in a spirit of faith in the future”’. The laboratory was part of Sir Shanti Swaroop Bhatnagar’s vision of providing India with a network of research institutions for taking the country ahead in science and technology. NML played a significant role in the industrial revolution of India starting from 1950 especially in the areas of mineral processing, iron and steel making, ferroalloys and extraction of non-ferrous metals, notably magnesium. Asia’s largest creep testing facility was also set up at NML in the early 1970‟s and even today it ranks as the second largest creep testing lab in Asia. It continues to play a vital role in the quest of the country towards scientific and technological leadership and providing scientific solutions to the industries in the areas of minerals, metals and materials. Since inception NML has diversified its research areas ranging from extractive metallurgy, alloy development and import substitution, refractory material development, corrosion studies, mathematical and physical modeling of metallurgical processes, mineral research, advanced materials and materials tailoring, integrity evaluation of critical industrial components and cleaner and sustainable metals production. NML is also carrying out major activities for creating awareness among the common masses on issues relating to health, environment, rural technology and sustainable development. With a strong and committed staff having a wide spectrum of expertise and modern facilities, NML endeavors to move ahead to meet the challenges of the global economy and reach greater heights.

Vision

To become a global leader and an internationally benchmarked laboratory in mineral and metallurgical research and development.

The Inspiration

“ ..…But when I come to Jamshedpur it is not the past of India that comes up before me but some vision of the future comes before my eyes.” “ I do not wish any worker to come to these laboratories merely with the aim of earning his living. What I wish is that our young men and women who come here should have a zeal for working out problems which would have great consequence. That would give vitality to these Institutes. They should realize that service to science is real service to India – no, even to the whole world – science has no frontiers”.

Pandit Jawaharlal Nehru


Contents

Director’s Report

Targets Planned / Achieved

Flagship Projects

Mineral Beneficiation

Materials Characterisation

Materials Evaluation

Material Forming & Processing

Corrosion Testing & Prevention

Waste Reclamation

Analytical Chemistry

Business Development

Scientific & Support Services

R&D Outputs

Major Facilities

Important Events

Fellowships

Budget

Staff Position

Patents

Publications


NML Councils

RESEARCH COUNCIL

Dr. Baldev Raj Chairman - RC Distinguished Scientist & Director Indira Gandhi Centre for Atomic Research Kalpakkam – 603102

Dr. R. R. Sonde Executive Vice President R&D Technology and Innovation Thermax Ltd, MIDC, RD Aga Road Pune 411 019

Dr. Pradip Senior Scientist Tata R&D Design Centre (Division of Tata Consultancy Services Ltd.) 54B, Hadapasar Industrial Estate Pune – 411 013

Shri A. C. R. Das Industrial Adviser Ministry of Steel Udyog Bhawan New Delhi 110011

Dr. G. Malakondaiah Director Defence Metallurgical Research Laboratory PO: Kanchanbagh, Hyderabad-500 058

Prof. T. C. Rao Former Director 501, Jagadish Residency Road No. 5, R. K. Puram

Hyderabad -500035 Dr. Debasish Bhattacharjee Chief, R&D and Scientific Services Tata Steel, Jamshedpur – 831 001

Dr. H. S. Maiti Director Central Glass & Ceramic Research Institute 196, Raja S.C. Mullick Road

Kolkata – 700 032 Prof. R. Shekhar Head Department of Materials & Metallurgical Engineering Indian Institute of Technology Kanpur – 208 016

Director National Metallurgical Laboratory, Jamshedpur -831 007

Prof. Indranil Manna Chairman, CRF Department of Metallurgical & Materials Engineering Indian Institute of Technology, Kharagpur – 721302

Head or his representative R&D Planning Division CSIR, Rafi Marg, New Delhi-110001

MANAGEMENT COUNCIL Director NML Chairman - MC

Dr. Ratnakar Singh Scientist

Dr.S. Prakash Head – BDM

Dr. (Mrs) S. Sagar Palit Scientist

Dr. A. Bandopadhyay Scientist

Dr. J.K. Sahu Scientist

Dr.J. Konar Technical Officer

Shri Bhushan Mishra Finance & Accounts Officer

Shri Bal Krishna Administrative Officer


Director’s Report It is such a great privilege to be penning the foreword for NML’s annual report of 2009-10. I assumed office just about two months back and I feel overawed occupying this chair of this great institution which has such an illustrious heritage and legacy, occupies such a unique position in the country’s R&D hierarchy and enjoys the patronage and goodwill of not only the scientific community but the people at large. I can’t but resist quoting Pt Jawaharlal Nehru when he inaugurated NML on the 26th of November 1950 “I think of the combination of this laboratory with the steel works in this city, of the marriage of science with industry for the progress of both...”. Sixty years hence, these words are as relevant as it were then, in fact more so now. It is my pledge to remain committed to NML’s pursuit of marrying science with industry for the progress of both.

The year 2009 -10 for NML has been both eventful and productive. The saddest event for us this year was the untimely demise of our past director Prof. Patcha Ramachandra Rao, an outstanding scientist, a compassionate human being and one of the most ardent well wishers of NML. With a deep sense of grief, we at NML pay homage to our beloved friend, philosopher and guide. His thoughts will remain etched in our memory for a long time. During this year, our previous director Prof. Surya Pratap Mehrotra also completed his tenure at NML and left to rejoin IIT Kanpur. We thank him for his significant contributions in taking NML forward. Dr. Sukomal Ghosh took over the acting directorship and did a wonderful job in managing the laboratory for close to a year. NML recorded its highest ever external cash flow of close to Rs 11.5 crores last year and the highest ever number of SCI publications. I take pride in complimenting team NML for raising the bar and setting new benchmarks of performance. We pursued a wide range of projects during this period which included multi-laboratory networked projects, the supra-institutional project on steel funded by CSIR, a large number of industry sponsored projects and also a significant number of innovative research projects funded by the grant-in-aid bodies. We had set ourselves specific goals, science and technology targets and deliverables in each of these projects. It is gratifying to mention that in most of the projects, the promised deliverable and targets were achieved within the time deadline and received a favorable review. It is also appropriate to acknowledge that in at least one project, we could not fulfill the expectations of the review committee and we are putting in place mechanisms to ensure that with respect to project deliverables, we are on brief, on time and on budget all the times. The projects undertaken have resulted in technology development and transfer or development of new materials or development of new evaluation protocols or economic savings to the industry or new scientific insights. Some of the significant project outcomes in the last year are the installation and commissioning of 150 tonnes/day sillimanite beneficiation plant at Indian Rare Earths at Chavara, development of commercial flotation reagents for iron ore in collaboration with M/s Somu Organics, development of complete technology packages in collaboration with MECON for iron ore beneficiation plants at Gua and Bolani, carrying out site trials of the Real Time Process Simulator developed by NML in the blast furnaces of Bhilai Steel plant, reduction in galvanizing losses of Zn in several galvanizing industries, transfer of technology for a portable Automatic Ball-indentation system, transfer of technology for the recovery of Pb from Zn leach residue, NDE protocols for damage assessment, rejuvenation protocols for high temperature materials, development of magnetic sensor and sensor devices and steel foams.


Major programs on recycling of electronic waste, processing of ocean nodules, bio-processing of minerals, direct reduction iron making processes, smelting of ferroalloys, electrothermal extraction of Na, coal mine-water reclamation, processing of light metal alloys, failure analysis, creep property evaluation and fatigue & fracture behavior database for a wide range of materials, rapid solidification processing of magnetic alloys, biomimetic materials, corrosion evaluation and mitigation, industrial waste processing and standard reference materials are continuing. Over the past several years, NML has continued to be in the national limelight with respect to national awards and prestigious fellowships. This year, NML has bagged one of the “Metallurgist of the Year” award of the Ministry of Steel and Mines and a fellowship to the Indian Academy of Engineering. Several of the younger scientists have secured prestigious fellowships such as the Raman Research Fellowship, Boyscast Fellowship and Indo-US fellowships. Stepping into the next year, we have set ourselves much higher goals and S&T targets and we keep in mind the increasing emphasis placed by the government on the relevance of our research to industry and the society and its impact. We will be working for a larger share of industrial funding, focusing more towards technology development in partnership with the stakeholders and more effective utilization of the scientific and technical infrastructure available. We are striving to change; to keep up with the changing times; change to bring in more focus, more relevance, a more professional work culture, accountability, transparency and more impact; change ultimately to meet the aspirations and expectations of the stakeholders and the people – a change that is consistent with continuity. In this context, I am once again tempted to quote Pt. Jawaharlal Nehru during his inaugural speech at NML “We carry a heavy burden of the past and the past helps us and the past hinders us; and the problem is how to combine that past with the present and the future, how to have changes and how to have continuity and how to have both together”. I look forward to your continued support and patronage in realizing our goals and vision.

S. Srikanth Director

National Metallurgical laboratory


Targets Achieved

Performance Targets

Objectives Achieved 1. a) External Cash Flow Rs 11.48 crores b) Industrial Resources Rs 3.34 crores

2. Customer Satisfaction Index 4.16/5.00 3. Publications 140 4. Patents 13 5. Copyrights 6 6. Technologies Developed 2 7. Techno logies Transferred 2

Technological and Scientific Targets

Targets Planned Targets Achieved Installation and commissioning of 150 tons/day sillimanite beneficiation plant at IRE, Chavara

A 150 tons per day column flotation plant was designed, installed and successfully commissioned at IRE, Chavara

Technology package for 12.5 Mt/year Gua iron ore plant and 10Mt/year Bolani iron ore plant for SAIL

Developed complete flowsheet based on pilot scale trials for the Gua and Bolani iron ores and developed a technology package in collaboration with MECON and SAIL

Portable device for in situ determination of mechanical properties in minimally invasive manner

Technology for fabrication of portable ABI (PABI) system (see fig. below) transferred to M/s DUCOM, Bangalore.

Technology package for a 4 million ton pelletisation plant at Gua for SAIL

Pilot scale trials for pelletisation carried out and technology package developed in collaboration with MECON and SAIL

Development of magnetic sensor and sensor devices

Design of magnetic NDE based (hysteresis and magnetic noise based) portable system completed

Damage quantification and rejuvenation of hot-gas path components

Validation of concept of rejuvenation on Udimet 520 through high resolution, high temperature x-ray diffraction


Initial preparation of Cu- and Zr- based bulk metallic glass

Cu-based bulk metallic glass has been prepared

Real Time Process Simulator for Blast Furnace: Development of the technology

First version of the technology in the off -line mode has been installed at BSP, Bhillai

Reduction roast – ammonia leaching – SX - EW of sea nodules

100 Kg/day reduction roasting with coal as reductant, leaching on 50 Kg/day, leach residue smelting on 5 Kg scale done.

Reduction smelting-matte formation - ammoniacal pressure leaching of sea nodules

Smelting parameters optimized on 20 Kg scale, matte formation parameters studied, leaching of matte on bench carried out

Design of 50 A high temperature electrolytic cell

Ascertained the feasibility of producing sodium metal in NML‟s designed 50 A open cell

NDE protocols for damage assessment of boiler tubes, petrochemical storage vessels etc.

Creep damage assessment by magnetic NDE technique, AE characterization of pitting corrosion

Development of process for Pb recovery from Zn plant residue

Process developed and technology transferred to M/s Chakradhar Chemicals Pvt Ltd.

Database of fatigue and fracture behavior for design analysis of Indian nuclear power plant components

Substantial database on SA333 Gr.6 steel, 304LN stainless steel and 20MnMoNi55 steel with regards to fracture and fatigue created

Synthesis of nanosized iron oxide for ferrofluid

Biocompatible nanosized iron oxide for ferrofluids has been synthesized

Preparation of functionally graded ribbons by melt-spinning technique

FeSiB and CoSiB bi-layer has been prepared by melt-spinning technique

1


γ'''' coarsening

After Rejuvenation

Service Exposed

γ'''' coarsening

After Rejuvenation

Service Exposed

Flagship Projects

In the Tenth Plan, CSIR created innovative knowledge networks across its constituent laboratories. Emphasis was laid on networking of resources and capabilities of the laboratories in multi-disciplinary areas so as to increase value through S&T inputs. These network projects aim at core R&D projects and capability building and facility creation. Keeping in tune with the spirit of networking of CSIR, National Metallurgical Laboratory too, has been involved in network projects in the Tenth and Eleventh Five Year Plans. The Eleventh Plan witnessed NML participating in twelve network projects. NML is the nodal agency for two of these projects and a participating laboratory for the other projects. Additionally NML has initiated its Supra Institutional project on Special Steels. In one of the flagship projects titled “Technology for assessment and refurbishment of engineering materials and components ” NML is investigating engineering materials with emphasis on damage accumulation during service and with the aim of development of strategies for health monitoring, life assessment and rejuvenation of critical engineering components. It has joined hands with other sister laboratories such as CGCRI Kolkata, CMERI Durgapur, IMMT Bhubaneshwar, NAL Bangalore, NPL New Delhi and SERC Chennai in this project. The second network project “Nanostructured Advanced Materials” involves inter-related research on biomaterials, ceramics, composites and hard coatings, magnetic materials and structural materials. NML is collaborating with NAL, Bangalore, NCL Pune, IMMT Bhubaneshwar, CGCRI Kolkata, CMERI Durgapur, CEERI Pilani and AMPRI Bhopal in executing the program. The other network projects in which NML plays a major role are : Development of cost effective mine water reclamation technology for providing safe drinking water, Development of specialty inorganic materials for diverse application, Development of advanced light weight metallic materials for engineering applications, Nanomaterial and nanodevices for application in health and diseases, Engineering of structure against natural and other disasters, Zero emission research initiative, Advancement in Metrology, Use of natural occurring minerals for providing safe drinking water at domestic level in the state of Jharkhand. The Supra Institutional project “Development and forming of performance driven speci al steels” is a program encompassing the different competencies of the laboratory. This is a project laying emphasis on networking within the laboratory and has as its deliverables: ultrahigh strength steels, high strength high formable steels, advanced joining and surface modification protocols, steel foams and virtual platforms for process and material optimization.


PROCESSING

1

MINERAL


National Clientele served • Essar Mining & Industries Ltd, Bhubaneshwar • Tata Steel, Jamshedpur • Central Mining Planning & Design Institute Ltd • MECON, Ranchi • Ashapura Minechem Ltd, Mumbai • Jindal Power & Steel, Angul • ACC Ltd, Jhinkpani • McNally Bharat • Indian Rare Earths International Clients • Korea institute of Geosciences and

Mineral Resources (KIGAM), Korea • Ispat-Karmet, Kazakhastan

Competence state-of-the-art facilities exist in characterization, laboratory and pilot scale beneficiation and agglomeration of ores, minerals and industrial wastes. Research areas include: • Characterization of ores, minerals and

products of mineral processing • Development and design of Mineral

Processing and agglomeration flow-sheets and plant layouts • Consultancy services on technical and

economical feasibility • Beneficiation of ores , minerals, coals and

industrial wastes • Commissioning of plants and trouble-

shooting • Agglomeration of ore fines and

concentrates • Education and training of technical

personnel

Projects executed/ undertake n in 2009 -10 Some of the major projects carried out in the year under review were as follows : • Beneficiation of iron ores of Bolani & Gua • Bench scale beneficiation studies on iron

ore fines • Filtration studies on floatation products of

limestone • Study of particle dynamics and

development of control strategy for improved performance in teeter bed separator • Physico-chemical studies on the oxide

mineral systems in the presence of surfactants and polymers for beneficiation of iron ores

Significant Achievements • Designed, installed and commissioned a commercial scale flotation column having a capacity of

6 tons /hr (150 tpd) for the beneficiation of sillimanite at Indian Rare Earths Ltd., Chavara, Kerala.

• Developed complete flowsheet based on pilot scale trials for the Gua and Bolani iron ores and developed a technology package in collaboration with MECON and SAIL Pilot scale trials for pelletisation carried out and technology package developed for 4 million ton plant of SAIL in Gua in collaboration with MECON and SAIL


METAL

EXTRACTION


Submerged arc furnace Competence NML has a wide range of activities in different extractive processes. This includes hydrometallurgical, pyrometallurgical as well as electrochemical extraction routes. The main areas of focus are extraction of Mg, recycling/processing of metallic and metallurgical wastes, bio-processing of minerals, metal extraction from sea-nodules, new iron making processes, smelting of ferroalloys and electrothermal extraction of Na and Ti. Various processing routes are developed and/or simulated and process optimization done frequently through physical and mathematical modeling.

Projects executed/ undertaken in 2009 -10 A few selected projects: • Processing of Polymetallic sea nodules by Reduction roast – Ammonia leaching – Solvent extraction – Electrowining & residue smelting route, to recover Cu, Ni, Co and Mn. • Bio-mineral Processing of Narwapahar Uranium Ore • Investigation on production of high purity TiO2 from ilmenite by selective reduction and segregation of iron • Design and Development of Sodium Metal Production process by high temperature electrolysis of fused salts • Process analysis for the production of ferro-chromium at the Plants of TICOL, New Delhi • Recovery of Pb and Sn from the liberated resin of PCB's swelled by organic • Reduction of coke rate using probing and modeling techniques in BF no : 6 and BF. No : 7 of Bhilai Steel Plant • Pilot Scale Smelting and pre-feasibility studies on Nickel-Chromium-Cobalt bearing Magnetite Ores of Nagaland • Recovery of lead from zinc plant residue. • Pre-treatment of hot metal in induction furnace

Clientele • Indian Technomac Co.Ltd. New

Delhi • Borochemie (India) Pvt Ltd, Mumbai • Chakradhar Chemicals Pvt. Ltd. • Tata Steel, Jamshedpur • TICOL, New Delhi • UCIL International Clients • KIGAM Korea • ISCOESR, Russia

Significant Achievements • Installed and tested Real Time Process Simulator at Bhilai steel plant resulting in significant reduction in coke consumption in the blast furnace • 100 Kg/day reduction roasting of sea nodules with coal as reductant, leaching on 50 Kg/day, Leach residue smelting on 5 Kg scale done


Orientation Image Mapping

CHARACTERIZATION

MATERIALS


Competence NML has one of the best characterization facilities in the country, with its arsenal of electron microscopes, auger spectroscope, electron probe micro analyser, various XRD instruments, Atom force microscopes and the likes. Projects executed/ undertaken in 2009-10 NML has executed a number of projects in 2009-10 in the areas of materials characterization. A few selected ones are provided below. • Failure Analysis of Super Heater Coil and Water wall tubes of boiler • Failure Analysis of the Die Holder of a MPM 1600B Hammer 6T • Failure Analysis of turbine blade - gas turbine • Failure Analysis of heavy weight drill pipe • Materials Characterisation of steel Forging stock of MIPSL • Failure analysis of Fractionator Furnace Tubes in Hydrocracker Units • Significant Achievements

Validation of concept of rejuvenation on Udimet 520 through high resolution, high temperature x-ray diffraction National Clientele served • Indian Space Research Organisation • National Thermal Power Corporation • Hindustan Petroleum Corporation Ltd • Vikram Sarabhai Space Centre • Gas Turbine Research Establishment, Bangaluru • Central Power Research Institute, Bangaluru • Indian Air Force • Tayo Rolls, Jamshedpur • Thermal Power Station Chennai • Cunningham Lindsay, New Delhi • Numaligarh Refinery Ltd. Assam

Phase Quantification - EBSD Phase Quantification - EBSD

Strain Induced Martensite in Stainless Steel

TEM Micrograph of Nano/Ultrafine Grain Austenitic Stainless Steel


MATERIALS E V A L U A T I O N


Competence NML has extensive experience and expertise in the areas of structural integrity assessment, failure analysis, development of rejuvenation protocols for high temperature alloys and detailed microstructural characterization. NML has the largest and arguably the best creep testing facilities in the country. Additionally it has one of the most comprehensive fatigue and fracture evaluation facilities. Projects executed/ undertaken in 2009-10 NML has executed a number of projects in 2009-10 in the areas of materials evaluation. A few selected ones are provided below. • Studies on creep and deformation behavior of steel using magnetic NDE

technique • Assessment of short term creep and stress rupture properties of boiler

tube(T91) / Pipe (p91) • Assessment of Stress Rupture test on Boiler Tubes • Stability of Structure and magnetic properties of nanostructured alloys

produced by RSP • Effect of repetitive strain and anneal on Microstructure and mechanical

properties of metastable austenitic stainless steel Significant Achievements • Technology for fabrication of portable ABI (PABI) system transferred to M/s DUCOM,

Bangalore.

National Clientele Served • GE India Technology Centre Pvt.Ltd. • CPRI, Bangalore • BARC, Mumbai • VSSC, Thiruvanthapuram • Graphite India Ltd, Bangalore • Indo Gulf Fertilizer, Lucknow • ISTM Ltd, Pune • BPCL, Mumbai • IGCAR, Kalpakkam • West Bengal Power Dev. Corp. Ltd. • Kerala State Electricity Board • Kolaghat Thermal Power Station • Indian Farmers Fertilizer Cooperative Ltd. • Reliance Industries Limited • MECON Ltd • Neyveli Lignite Corporation Ltd. • Indian Oil Corporation Ltd.


MATERIALS

FORMING

PROCESSING &


Competence Diverse expertise and infrastructural facilities exist at NML for a wide range of materials synthesis including various solidification, solution and biochemical synthesis routes and processing techniques including rolling and forging. Projects executed/ undertaken in 2009-10 NML has executed a number of projects in 2009-10 in the area of materials forming and processing. A few selected ones are provided below. • Development of brazing foils by rapid solidification technique • Development of Ilmenite based materials for varistor applications. • Development of a process and design of a closed cell for production of sodium metal by fused

salt electrolysis of sodium chloride • Biomimetic hydroxyapatite coating on zirconium based biocompatible alloys • Development of nanoquasi crystalline Al-Fe-Ti-Cr/V alloys for airframe and automotive application • Interaction of phases in Mechanically Treated Multi-component Systems • Thermodynamics of the Inverse melting Phenomenon in Binary Alloys: Experimental Studies and ab initio simulation • Hot Rolling and Cold Rolling of High carbon Low alloy steels Significant Achievement • Biocompatible nanosized iron oxide for ferrofluids have been synthesized

Clientele International Client • Tata Steel • KIGAM, Korea • SAIL • MSPL • DRDO • Hi-Tech Fly Ash Pvt Ltd • Borochemie (India) Pvt Ltd, Mumbai • Valley Refractories Ltd., Chirkunda • National Aluminium Company • Hindustan Zinc • United Phosphorus, Jhagadia • Rohit Ferro-Tech, Kolkata • Heavy Water Board

Simulation of Forging

Laser Cladding


CORROSION TESTING

AND

PREVENTION


Competence The domain expertise available at NML in the areas of high temperature and aqueous corrosion and prevention include modeling high temperature corrosion, high temperature corrosion experiments under simulated gas atmospheres, pitting corrosion, galvanic corrosion, development of inhibitors, wide range of coatings development including PVD, CVD, thermal and plasma spray and others. Activities in this area are focused towards providing industrial research solutions to a wide range of corrosion related issues. Projects executed/ undertaken in 2009-10

A number of projects have been executed in this area. Some of the significant ones are as follows: • Stochastic and non-destructive assessment of corrosion pit growth in airframe alloys • To improve zinc utilization factor for wire galvanizing • Training to R&D and Production personnel on Hot Dip Galvanizing • A study on desorption/mobilization of arsenic species from Oxy-hydroxides of iron • Low temperature sensitization and intergranular corrosion of stainless steels • Laser cladding of stainless steels

Significant Achievements • Significant zinc utilization during galvanizing effected in different industries

Clientele

• ARDB • Mainawati Steel Industries Pvt. Ltd, Nepal • Institute for Steel Development & Growth • Jindal Industries Ltd, Hisar • Tata Steel, Mumbai • BARC, Mumbai • Sardar Sarovar Narmada Nigam Ltd. • Alcobex Metal Ltd. • Navdeep Chemical Pvt.Ltd. • Mehta Alloys Ltd. • Visakhapatnam Steel Plant • Metoil Corporation • NTPC, Noida • SAIL, Durgapur • USHA ALLOYS, Adityapur • Meghalaya State Electricity Board • GAIL (India) Limited, Lakwa • Durgapur Steel Plant • Philips Carbon Black


ANALYTICAL

CHEMISTRY


Projects executed/ undertaken in 2009 • Evaluation of CRMs for validation of ferrous base metallurgical product • Development of hydrogen standards for zirconium alloys • Development of colored gold alloy • Preparation of certified reference material for coal and sponge iron

0

20

40

60

80 75

6055

2009-102008-092007-08

Rs.

in L

akhs

Year

Clientele • Midhani • SAIL • Lafarge India Ltd • Northern Coalfield Limited, Singrauli • CMPDI, Ranchi • Power Grid Corporation of India Ltd • The Oriental Chemical Works Pvt Ltd, Kolkata • Fine Chemical Kolkata • Usha Martin Jamshedpur • Aryan Mining & Trading Corporation Pvt. Ltd. Kolkata

Significant Achievements • Preparation of Certified Reference Materials

National Metallurgical laboratory, Jamshedpur is the only supplier for reference materials of metallurgical products. During this period 5 new range of plain carbon steel standards have been prepared and certified by 10 laboratories. Now NML has the entire range of plain carbon steel standards starting from 0.1% C to 0.5% C. In this financial year ANC Centre earned Rs. 75.0 Lakhs for marketing the CRMs. • Preparation of Certified Reference Material for Coa l

and Sponge Iron The main objective is to prepare coal and sponge iron CRMs.. Moreover, during this period spectro-graphic standards of plain carbon steel have been prepared and sale of the products has begun. The Coal CRMs is being processed and within very short time NML will be in a position to market these standards.

Annual Earnings from CRM Sale


WASTE

UTILIZATION


Competence Waste utilization activities involve the use of fly ash, red mud and blast furnace slag for the production of cheap and useful products for use by the industry and society at large. These materials have been successfully used to make wear resistant ceramics, ceramic floor and wall tiles, synthetic granite tiles, blended cement and geopolymer.

Projects executed/ undertaken in 2009 • Production of Wear Resistant Ceramics from Fly Ash • Development of cost effective mine water reclamation technology for providing safe drinking water • Dev. of processing technology for recycling and reuse of electronic waste • Processing of nickel-cadmium spent battery • Process for recovery of lead from zinc plant residue : Demonstration and transfer • Recovery of Pb and Sn from the liberated resin of PCBs swelled by organic • Processing of spent nickel cadmium batteries • Selective reduction of copper, nickel and cobalt for production of high pure metal powder • Development of a process for the removal of hazardous metal elements from leach liquor of electronic scraps following solvent extraction and recovery of valuables • Technologies for recovery of non-ferrous and rare metals from technogenous raw materials by

using binary reagents • Bioleaching of zinc tailings and biosynthesis of zinc based nanomaterials • Biosynthesis of iron based nanomaterials from industrial wastes and applications in effluent

remediation • Bioremediation of tannery and electroplating waste solutions • Recovery of valuable metals from tungsten containing alloy scraps using hybrid processes

Significant Achievements • Set up of Prototype for mine-water reclamation • 5 square feet wear resistant ceramic tiles from fly ash was produced and given to M/s Hi-Tech Fly Ash for evaluation at Tuticorin Power Plant. • Development of process for Pb recovery from Zn plant residue and transfer of technology

completed

Clientele International Clients • Hi-Tech FLy Ash (India) Pvt.Ltd. © ISCOESR, Russia. • Uranium Corporation of India Limited © KIGAM South Korea • Hindustan Zinc Limited (Vedanta) • GMDC • TATA STEEL • Chakradhar Chemicals • Panipath Refineries • Modison Metals Ltd. Mumbai • ECO RECO Pvt Ltd. • E-Parisara Pvt. Ltd.

Mine-water reclam ation


&

BUSINESS DEVELOPMENT

KNOWLEDGE MANAGEMENT


Business Development The Business Development activities facilitate the process of generating wealth through technology transfers, collaboration with industries, market research studies, licensing of IP and scientific & technical services. One of the main activities of the group in 2009-10 was the development of a definitive business plan for the laboratory. The group responsibilities include: Identification of application domains and conduction of market research to ascertain techno-commercial feasibility of innovations, coordination with various entrepreneur/industry associations, explore investment opportunities, set up mechanisms for licensing innovations for business development and equitable benefit sharing with the innovators, and, helping to promote and diffuse innovations.

Project Management

The planning, monitoring and evaluation of R&D projects is an important activity undertaken by the Business Development and Monitoring Division. A total of 105 projects were handled during the period.

Technology Agreements

13 Agreements were signed with various national and international clients belonging to different industrial sectors.

Intellectual Property Assets Management

13 patents and 8 copyrights have been filed during the current financial year.

International S&T Activities

14 International collaborations with various organizations were established. Some of these are: ICTRERM, Russia, Caribbean Industrial Research Institute, Trinidad & Tobago, Institute of Solid State Chemistry and Mechanochemistry, Russia, KIGAM, South Korea, IFNTUOG,Ukraine, Department of Materials Science & Metallurgy, University of Cambridge.

Knowledge Management

Portal Development

Interactive sites for the network and supra-institutional projects were developed. These websites allow project information management & monitoring through dynamic content addition and verification, Information and knowledge sharing and act as a Knowledge repository and experts opinion mechanism. The IMDC site which provides a repository of technical knowledge became fully functional during the period. An on-line microstructural and fractographic image database of materials WikiMicroGraphia (M-Wiki) based on the Wiki (What I Know Is) principle, was initiated by NML as part of the open source philosophy of CSIR. WikiMicroGraphia is an effective collaboration platform for unifying meso-scale materials informatics.


Information Management & Dissemination Centre (IMDC )

Information Management & Dissemination Centre (IMDC) supports NML scientists with up to date R&D information back-up through well organized Library knowledge resources, Institutional Repositories / Archives (both Print and Online), documentation, photography and printing facilities. It projects Laboratory’s capabilities and expertise to its target groups by bringing out Laboratory’s quality publications and promotes laboratory’s business through institutional membership, media coverage and participation in exhibition / Trade Fair and business meets. It also organizes sale of library information services and information products of the laboratory. Notable institutional clients of IMDC Tata Steel, Usha Martin Industries Limited, Auto Fiber Craft, Jindal Stainless Limited, Hissar, Jindal Steel & Power Limited, Raigarh, Shri Sant Ganjanan Maharaj College of Engineering, Shegaon, Birla Institute of Technology, Patna, DRK Metallurgical Pvt. Limited, Kolkata, National Institute of Technology, Jamshedpur, Gunupur Institute of Engineering and Technology, Gunupur. During 2009-10 the following documents were brought out:

• Journal of Metallurgy and Materials Science, Vol. 51(1-4), 2009, ISSN 0974-1267 (online) & ISSN

0972-4257 (Print) • Electronic Waste (Proceedings of NASEW-2010), ISBN 81-87053-60-7

Information under RTI Act: During the reporting year 11 applications were received and all of them were responded within the time schedule. So far no appeals were referred to CIC for review.

Scientific & Technical Services A total of 118 Technical queries were serviced in 2009-10.

Customer Satisfaction Evaluation

The average Customer satisfaction Index (CSI) for the year under review was 4.16 on a scale of 5.

ISO 9001:2000 Quality Management System

The Functional Group on ISO 9001 : 2000 Quality Management System (QMS) at NML ensured a progressive enhancement of the “Performance Indices” of the laboratory through internal auditing, external auditing, arranging training programmes and other related activities to achieve the ‘Quality Objectives’ of the Laboratory. The systematic functioning of QMS has improved the overall motivation of the staff members at NML. This has also helped to instil greater confidence about NML in internal/external customers.


Scientific & Support Services Competence The engineering services caters and co-ordinates the engineering needs, both R&D and infrastructural, of the laboratory. The services encompass various areas such as, Developments of Prototypes, Design & drafting, Workshop activities, setting-up of Bench scale experiments and scaling up to Pilot scale, Engineering Support for running of Pilot Plants, Augmentation & modernization of Existing Facilities, Calibration etc.

Technological services Prototype and New Equipment fabrication

A pulse column designed and fabricated in-house for solvent extraction

The Prototype of the Portable Ball Indentation Unit

Infrastructural services

Bio-mimetic Laboratory Sea-nodule treatment facili ty Power factor improvement

Facilitation of technology development • Portable Ball Indentation machine • Wide Metallic Glass Ribbon production


R & D Outputs PATENTS External Cash Flow

Patent

16

7

18

13

0

5

10

15

20

2006-07 2007-08 2008-09 2009-10

Year

No.

of P

aten

ts

External Cash Flow

626

11481016946

0

200

400

600

800

1000

1200

1400

2006-07 2007-08 2008-09 2009-10

Year

Am

t. in

Lak

hs

PUBLICATIONS AVERAGE Impact Factor OF PUBLICATIONS

Publications

107

140119113

020406080

100120140160

2006-07

2007-08

2008-09

2009-10

Year

SCI P

ublic

ati

ons

AVG. IMPACT FACTOR

0.98 1.021.19 1.2

1.28

0

0.2

0.4

0.6

0.8

1

1.2

1.4

2004-05 2005-06 2006-07 2007-08 2008-09

Year

Avg

. IF


R & D Outputs

NML Citation Report 2005-2009 2005 2006 2007 2008 2009

Cumulative Articles till Mar’10 793 899 1010 1118 1223

Cumulative Citations till Mar’10

1626 2120 2723 3597 4691

No. of Articles published (SCI) 73 106 111 108 105

No. of Articles Cited till Mar’10 57 82 78 57 27

Citing Articles including self-citation as on 31.03.10

407 518 301 189 35

Citing Articles without self-citation as on 31.03.10

372 448 274 175 28

Avg. Citations per paper as on 31.03.10

5.58 4.89 2.71 1.75 0.33

Maximum Cited single paper (Cumulative) as on 31.03.10

31 28 16 11 3

h-index as on 31.03.10 12 11 7 6 2

Citations

Year


Important Events Distinguished Guests

• Dr.T. Ramasami , Secretary, DST

• Dr. Roger A Brooks , Addenbrooke's Hospital, University of Cambridge, UK

• Dr. B. V. R. Tata , Scientific Officer H, IGCAR Kalpakkam

• Prof. B.K. Mishra , Director, Institute of Minerals & Material Technology, Bhubaneswar • Dr. Juergen Mattusch , Sr. Scientist, Analytical Chemistry Division Helmholtz Centre for Environmental Research Leipzig, Germany • Prof. Ing. Ivo Dlouhy, Head, Brittle Fracture Group, Institute of Physics of Materials, Academy of Science of Czech Republic, Czech Republic • Prof. P. Ramachandra Rao , Raja Raman Fellow (Department of Atomic Energy) ARCI Hyderabad • Dr. K.H. Park, Distinguished Principal researcher, Korea Institute of Geoscience & Mineral Resources, South Korea

Significant Events

• Earth Day : 22nd April, 2009

• CSIR-Innovation Day : 14th August, 2009

• CPYLS : 13-14th Oct, 2009

• NML Foundation Day : 9th Dec, 2009

• Hindi Pakhwada : 8th – 14th Sept, 2009

• Visit of Russian delegates : 10th Sept, 2009

• CSIR Foundation Day : 26th Sept, 2009

• National Seminar on Electronic Waste : 21-22nd January, 2010

• Training of IAF officials : 9th – 13th Nov, 2009

• Metallurgy for Engineers : 14th – 16th Dec, 2009


Resources

Budget Head 2009-10 A. Recurring Rs in Lakhs Salaries 2535 Contingencies 267 Human Reso urce Development 8 Maintenance 134 Chemical & Consumables 42 Total Recurring (A) 2986

B. Capital Rs in Lakhs Works & Services 130 Apparatus & Equipment 114 Office Equipment 5 Furniture & Fittings 3 Library Books 110 Total Capital (B) 362 Grand Total (A+B) 3348

EXTRA BUDGETARY REOURCES I. External Cash Flow (ECF) Rs in Lakhs Grant-in-Aid 516 Other Technical Services 67 Sponsored Research 528 Consultancy Programmes 30 Collaborative Research 7 Total 1148


Intellectual Property Created Patents Filed

• An improved process for electroless nickel coating on Mild Steel substrate. • An improved extraction process for the separation of zinc and cobalt. • A biomimetic process for the synthesis of aqueous ferrofluids for biomedical applications. • An Improved extraction process for the selective recovery of cadmium from spent nickel cadmium

battery. • An improved process for beneficiation of coking coal fines. • A process for the synthesis of aluminium hydroxide sol for removing fluoride from contaminated

water sources. • A process for making fluxed sinter through micro-pelletization utilizing waste iron oxides fines. • A process for reducing the electrical resistivity of naturally-occurring illmenite. • A process for the hydrothermal synthesis of high purity nanosize nickel zinc ferrites from spent

catalyst. • An improved process for the recovery of manganese as ferro-silico-manganese from leached sea

nodule residue. • Fabrication of tailored hardness nano-composite coating with low coefficient of friction. • A process for the recovery of lead from zinc plant residue. • Portable Automated Ball Indentation (PABI) System for in-situ evaluation of mechanical

properties of metallic components. Copyrights Filed

• CONTPLOT - a software for plotting contours • EROSIM-INTEGRATED (An integrated software framework for simulation of Fly Ash’s Erosion on

Boiler Grade Steel • Software for online detection of Non-Linear Ultrasonic parameter • A process simulator for thermo chemistry for ferro chrome submerged arc furnace • A simulator for electrical characteristics and parameters of ferro-chrome production (FERALSIM2) • FERALSIM3 (A simulator for current and powder density in ferro alloy production). • NEURAL-ROLLSIM:(an artificial neural network based software for prediction of mechanical

properties of high strength low alloy strip rolled steel). • Titanium binary alloy transformation diagram. • Non-equilibrium solution phase transformation in the Fe-C System. • Non-equilibrium precipitation of carbide in iron-carbon system

Technologies Transferred • Designing a prototype for production of continuous metallic glass (amorphous) ribbon • Arsenic removal water purification process • Process for lead recovery from zinc plant residue


Publications

BRAZILIAN JOURNAL OF PHYSIBRAZILIAN JOURNAL OF PHYSIBRAZILIAN JOURNAL OF PHYSIBRAZILIAN JOURNAL OF PHYSICSCSCSCS • 2009, 39, 297- 300

BULLETIN OF MATERIALS SCIENCEBULLETIN OF MATERIALS SCIENCEBULLETIN OF MATERIALS SCIENCEBULLETIN OF MATERIALS SCIENCE • 2009,32, 401- 405

CANADIANCANADIANCANADIANCANADIAN METALLURGICAL METALLURGICAL METALLURGICAL METALLURGICAL QUARTERLYQUARTERLYQUARTERLYQUARTERLY

• 2009,48, 387- 397

COLLOID AND SURFACES BCOLLOID AND SURFACES BCOLLOID AND SURFACES BCOLLOID AND SURFACES B---- • 2009,74,186-190 • 2009,73,146-151

CURRENT SCIENCECURRENT SCIENCECURRENT SCIENCECURRENT SCIENCE • 2009,96,1441- 1442

DESALINATIONDESALINATIONDESALINATIONDESALINATION • 2009, 249, 167 - 174

ENGIENGIENGIENGINEERING FAILURE ANALYSISNEERING FAILURE ANALYSISNEERING FAILURE ANALYSISNEERING FAILURE ANALYSIS • 2009, 16, 1454 - 1460 • 2009 ,16, 2371 - 2381

ENGINEERING FRACTURE MECHANICSENGINEERING FRACTURE MECHANICSENGINEERING FRACTURE MECHANICSENGINEERING FRACTURE MECHANICS • 2009, 76, 1822 - 1832

ENVIRONMENTAL POLLUTIONENVIRONMENTAL POLLUTIONENVIRONMENTAL POLLUTIONENVIRONMENTAL POLLUTION • 2009, 157, 3351 - 3353

GEOCHIMICA ET COSMOCHIMICA GEOCHIMICA ET COSMOCHIMICA GEOCHIMICA ET COSMOCHIMICA GEOCHIMICA ET COSMOCHIMICA ACTAACTAACTAACTA

• 2009, 73, A933 - A933

HHHHIGH TEMPERATURE MATERIALS & IGH TEMPERATURE MATERIALS & IGH TEMPERATURE MATERIALS & IGH TEMPERATURE MATERIALS & PROCESSESPROCESSESPROCESSESPROCESSES

• 2009, 28,35 - 53 HYDROMETALLURGYHYDROMETALLURGYHYDROMETALLURGYHYDROMETALLURGY

• 2009,99,170 -174 • 2009,98,192 -195 • 2009,97, 237 - 242 • 2009,96,230 -234 • 2009,95, 70 -75

INDUSTRIAL & ENGINEERING INDUSTRIAL & ENGINEERING INDUSTRIAL & ENGINEERING INDUSTRIAL & ENGINEERING CHEMISTRY RESEARCHCHEMISTRY RESEARCHCHEMISTRY RESEARCHCHEMISTRY RESEARCH

• 2009, 48, 6145 - 6161 • 2009,48,2149 - 2156

INTERNATIONAL JOURNAL OF APPLIED INTERNATIONAL JOURNAL OF APPLIED INTERNATIONAL JOURNAL OF APPLIED INTERNATIONAL JOURNAL OF APPLIED CERAMICERAMICERAMICERAMIC TECHNOLOGYC TECHNOLOGYC TECHNOLOGYC TECHNOLOGY

• 2009,6, 345 - 354

INTERNATIONAL JOURNAL OF COAL INTERNATIONAL JOURNAL OF COAL INTERNATIONAL JOURNAL OF COAL INTERNATIONAL JOURNAL OF COAL PREPARATION AND UTILIZATIONPREPARATION AND UTILIZATIONPREPARATION AND UTILIZATIONPREPARATION AND UTILIZATION

• 2009,29,34 - 47

INTERNATIONAL JOURNAL OF INTERNATIONAL JOURNAL OF INTERNATIONAL JOURNAL OF INTERNATIONAL JOURNAL OF HYDROGEN ENERGYHYDROGEN ENERGYHYDROGEN ENERGYHYDROGEN ENERGY

• 2009, 34, 4693 - 4700

INTERNATIONAL JOURNAL OF INTERNATIONAL JOURNAL OF INTERNATIONAL JOURNAL OF INTERNATIONAL JOURNAL OF MINERAL PROCESSINGMINERAL PROCESSINGMINERAL PROCESSINGMINERAL PROCESSING

• 2009,91,41- 49 • 2009,90, 101- 104


IIIINTERNATIONAL JOURNAL OF NTERNATIONAL JOURNAL OF NTERNATIONAL JOURNAL OF NTERNATIONAL JOURNAL OF PLASTICITYPLASTICITYPLASTICITYPLASTICITY

• 2009,25,2222 – 2247

ISIJ INTERNATIONALISIJ INTERNATIONALISIJ INTERNATIONALISIJ INTERNATIONAL • 2009,49,1325 - 1332 • 2009, 49,902 - 910 • 2009,49,210 - 219

JOURNAL OF ALLOYS AND JOURNAL OF ALLOYS AND JOURNAL OF ALLOYS AND JOURNAL OF ALLOYS AND COMPOUNDSCOMPOUNDSCOMPOUNDSCOMPOUNDS

• 2009,480, 765 - 770 • 2009, 479, 699 - 703 • 2009, 478, 474 - 478

JOURNAL OF APPLIED PHYSIJOURNAL OF APPLIED PHYSIJOURNAL OF APPLIED PHYSIJOURNAL OF APPLIED PHYSICSCSCSCS • 2009,105, 074301-1:074301-7 • 2009,105, 07A943-1:07A943-4

JOURNAL OF COLLOID AND JOURNAL OF COLLOID AND JOURNAL OF COLLOID AND JOURNAL OF COLLOID AND INTERFACE SCIENCEINTERFACE SCIENCEINTERFACE SCIENCEINTERFACE SCIENCE

• 2009, 330, 243

JOURNAL OF EARTH SYSTEM SCIENCEJOURNAL OF EARTH SYSTEM SCIENCEJOURNAL OF EARTH SYSTEM SCIENCEJOURNAL OF EARTH SYSTEM SCIENCE • 2009,118,619 - 641

JOURNAL OF HAZARDOUS MATERIALSJOURNAL OF HAZARDOUS MATERIALSJOURNAL OF HAZARDOUS MATERIALSJOURNAL OF HAZARDOUS MATERIALS • 2009,171,61 - 75 • 2009,166,1540 - 1544

JOURNAL OF IRON AJOURNAL OF IRON AJOURNAL OF IRON AJOURNAL OF IRON AND STEEL ND STEEL ND STEEL ND STEEL RESEARCH INTERNATIONALRESEARCH INTERNATIONALRESEARCH INTERNATIONALRESEARCH INTERNATIONAL

• 2009,16,1101- 1107

JOURNAL OF MAGNETISM AND JOURNAL OF MAGNETISM AND JOURNAL OF MAGNETISM AND JOURNAL OF MAGNETISM AND MAGNETIC MATERIALSMAGNETIC MATERIALSMAGNETIC MATERIALSMAGNETIC MATERIALS

• 2009,321,2865 - 2870 • 2009,321,1034 - 1038

JOURNAL OF JOURNAL OF JOURNAL OF JOURNAL OF CHEMISTRYCHEMISTRYCHEMISTRYCHEMISTRY • 2009, 19, 6810 - 6815

JOURNAL OF MATERIALS JOURNAL OF MATERIALS JOURNAL OF MATERIALS JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCEENGINEERING AND PERFORMANCEENGINEERING AND PERFORMANCEENGINEERING AND PERFORMANCE

• 2009,18,849 – 855

JOUJOUJOUJOURNAL OF MATERIALS RNAL OF MATERIALS RNAL OF MATERIALS RNAL OF MATERIALS PROCESSING TECHNOLOGYPROCESSING TECHNOLOGYPROCESSING TECHNOLOGYPROCESSING TECHNOLOGY

• 2009,209,798 - 804

JOURNAL OF MATERIALS SCIENCEJOURNAL OF MATERIALS SCIENCEJOURNAL OF MATERIALS SCIENCEJOURNAL OF MATERIALS SCIENCE • 2009,44,2288 - 2299 • 2009,44,1069 - 1075 • 2009, 44, 1094 - 1100 • 2009,44,433 - 440

JOURNAL OF NANOSCIENCE AND JOURNAL OF NANOSCIENCE AND JOURNAL OF NANOSCIENCE AND JOURNAL OF NANOSCIENCE AND NANOTECHNOLOGYNANOTECHNOLOGYNANOTECHNOLOGYNANOTECHNOLOGY

• 2009,9,5600 - 5603

JOURNAL OF NONJOURNAL OF NONJOURNAL OF NONJOURNAL OF NON----CRYSTALLICRYSTALLICRYSTALLICRYSTALLINE NE NE NE SOLIDSSOLIDSSOLIDSSOLIDS

• 2009,355,1552 -1555

JOURNAL OF JOURNAL OF JOURNAL OF JOURNAL OF PHYSICS D:APPLIED PHYSICS D:APPLIED PHYSICS D:APPLIED PHYSICS D:APPLIED PHYSICSPHYSICSPHYSICSPHYSICS • 2009,42, 245004 – 245009 • 2009, 42, 95006 – 95011 • 2009, 42, 65007 – 65014

JOURNAL OF TESTING AND JOURNAL OF TESTING AND JOURNAL OF TESTING AND JOURNAL OF TESTING AND EVALUATIONEVALUATIONEVALUATIONEVALUATION

• 2009,37,566 - 572


JOURNAL OF THE GEOLOGICAL JOURNAL OF THE GEOLOGICAL JOURNAL OF THE GEOLOGICAL JOURNAL OF THE GEOLOGICAL SOCIETY OF INDIASOCIETY OF INDIASOCIETY OF INDIASOCIETY OF INDIA

• 2009,74,395 - 401

KEY ENGINEERING MATERIALKEY ENGINEERING MATERIALKEY ENGINEERING MATERIALKEY ENGINEERING MATERIAL • 2009,395, 15 - 38

MATERIALMATERIALMATERIALMATERIALS AND CORROSIONS AND CORROSIONS AND CORROSIONS AND CORROSION 2009, 60, 431 – 437

MATERIALS AND MANUFACTURING MATERIALS AND MANUFACTURING MATERIALS AND MANUFACTURING MATERIALS AND MANUFACTURING PROCESSESPROCESSESPROCESSESPROCESSES

• 2009,24,145-149 • 2009,24,68 - 77

MATERIALS CHARACTERIZATIONMATERIALS CHARACTERIZATIONMATERIALS CHARACTERIZATIONMATERIALS CHARACTERIZATION • 2009, 60,863 - 868 • 2009,60,234 - 239

MATERIALS CHEMISTRY AND PHMATERIALS CHEMISTRY AND PHMATERIALS CHEMISTRY AND PHMATERIALS CHEMISTRY AND PHYSICSYSICSYSICSYSICS • 2009,113, 803 - 815 • 2009 , 113, 57 - 62

MATERIALS SCIENCE & ENGINEERING MATERIALS SCIENCE & ENGINEERING MATERIALS SCIENCE & ENGINEERING MATERIALS SCIENCE & ENGINEERING CCCC----BIOMIMETIC AND BIOMIMETIC AND BIOMIMETIC AND BIOMIMETIC AND SUPRAMOLECULAR SYSTEMSSUPRAMOLECULAR SYSTEMSSUPRAMOLECULAR SYSTEMSSUPRAMOLECULAR SYSTEMS

• 2009,29,1326 - 1329 • 2009, 29, 1330 - 1333 • 2009,29,779 - 784 • 2009,29,1942 - 1949

MATERIALS SCIENCE AND MATERIALS SCIENCE AND MATERIALS SCIENCE AND MATERIALS SCIENCE AND ENGINEERING AENGINEERING AENGINEERING AENGINEERING A

• 2009, 527, 225 - 234 • 2009, 523, 312 - 315 • 2009, 525, 211- 211 • 2009, 513 - 14, 389 - 393

• 2009, 510 - 11, 136 - 141 • 2009, 509, 111- 114 • 2009, 508, 1-14

2009, 505, 96 – 104

MATERIALS SCIENCE AND MATERIALS SCIENCE AND MATERIALS SCIENCE AND MATERIALS SCIENCE AND ENGINEERING C .ENGINEERING C .ENGINEERING C .ENGINEERING C .

• 2009, 29, 1326 – 1329 • 2009, 29, 1330 - 1333 • 2009,29,1942 - 1949 • 2009, 29, 779 - 784

MATERIALS SCIENCE AND MATERIALS SCIENCE AND MATERIALS SCIENCE AND MATERIALS SCIENCE AND TECHNOLOGYTECHNOLOGYTECHNOLOGYTECHNOLOGY

• 2009,25, 542 - 548

MATERIALS SCIENCEMATERIALS SCIENCEMATERIALS SCIENCEMATERIALS SCIENCE----POLANDPOLANDPOLANDPOLAND • 2009, 27, 373 - 384

METALLURGICAL AND MATERIALS METALLURGICAL AND MATERIALS METALLURGICAL AND MATERIALS METALLURGICAL AND MATERIALS TRANSACTIONS ATRANSACTIONS ATRANSACTIONS ATRANSACTIONS A

• 2009,40A, 3138 - 3146 • 2009,40A, 3226 - 3234 • 2009,40A, 2938 - 2949 • 2009, 40A , 2369 - 2376 • 2009, 40A,1219 - 1234 • 2009, 40A, 637- 645 • 2009, 40A, 450 - 461

METALLURGICAL AND MATERIALS METALLURGICAL AND MATERIALS METALLURGICAL AND MATERIALS METALLURGICAL AND MATERIALS TRANSACTIONS BTRANSACTIONS BTRANSACTIONS BTRANSACTIONS B

• 2009, 40, 877- 885 • 2009, 40, 662- 675

MINERAL PROCESSING AND MINERAL PROCESSING AND MINERAL PROCESSING AND MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEWEXTRACTIVE METALLURGY REVIEWEXTRACTIVE METALLURGY REVIEWEXTRACTIVE METALLURGY REVIEW

• 2009, 30, 136-162


MINERALMINERALMINERALMINERALS S S S AND METALLURGAND METALLURGAND METALLURGAND METALLURGICAL ICAL ICAL ICAL PROCESSINGPROCESSINGPROCESSINGPROCESSING 2009, 26, 141-150 MINERALS ENGINEERINGMINERALS ENGINEERINGMINERALS ENGINEERINGMINERALS ENGINEERING

• 2009, 22, 572- 574

PROGRESS IN ORGANIC COATINGSPROGRESS IN ORGANIC COATINGSPROGRESS IN ORGANIC COATINGSPROGRESS IN ORGANIC COATINGS • 2009, 65, 229 - 236

RESOURCES CONSERVATION AND RESOURCES CONSERVATION AND RESOURCES CONSERVATION AND RESOURCES CONSERVATION AND RECYCLINGRECYCLINGRECYCLINGRECYCLING

• 2009, 53, 464 - 469

REREREREVIEW OF PROGRESS IN VIEW OF PROGRESS IN VIEW OF PROGRESS IN VIEW OF PROGRESS IN QUANTITATIVE NDEQUANTITATIVE NDEQUANTITATIVE NDEQUANTITATIVE NDE

• 2009, 1096, 1252 - 1258

SCRIPTA MATERIALIASCRIPTA MATERIALIASCRIPTA MATERIALIASCRIPTA MATERIALIA • 2009, 61, 588 - 591

STEEL RESEARCH INTERNATIONALSTEEL RESEARCH INTERNATIONALSTEEL RESEARCH INTERNATIONALSTEEL RESEARCH INTERNATIONAL • 2009, 80, 785 - 792

THIN SOLID FILMSTHIN SOLID FILMSTHIN SOLID FILMSTHIN SOLID FILMS • 2009, 517, 4502 - 4508

• • 2009, 517, 2912 - 291

• TRANSACTIONS OF THE AMERICAN TRANSACTIONS OF THE AMERICAN TRANSACTIONS OF THE AMERICAN TRANSACTIONS OF THE AMERICAN

FOUNDRY SOCIETYFOUNDRY SOCIETYFOUNDRY SOCIETYFOUNDRY SOCIETY • 2009, 62, 275 - 278 • 2009, 62, 331 - 335 • 2009, 62, 35 – 40

TRANSACTIONS OF THE TRANSACTIONS OF THE TRANSACTIONS OF THE TRANSACTIONS OF THE INSTITUTE OF INSTITUTE OF INSTITUTE OF INSTITUTE OF METAL FINISHINGMETAL FINISHINGMETAL FINISHINGMETAL FINISHING

• 2009, 87, 221 - 224

TRANSACTIONS OF THE TRANSACTIONS OF THE TRANSACTIONS OF THE TRANSACTIONS OF THE IIM SECTION CIIM SECTION CIIM SECTION CIIM SECTION C • 2009, 118, 78 – 84 • 2009, 118, 10 - 17

ULTRAMICROSCOPYULTRAMICROSCOPYULTRAMICROSCOPYULTRAMICROSCOPY • 2009,109, 741- 747

VACUUMVACUUMVACUUMVACUUM • 2009, 83,1464-1469

WEARWEARWEARWEAR • 2009, 266, 995-1002


Awards/Fellowships

• Fellow of the Indian Academy of Engineering : Dr.S. Srikanth, Director NML • Metallurgist of the Year Award (2009) : Dr. Soumitra Tarafder • Nijhawan Award (2008) for the Best Technical paper : Dr. R. Singh, Dr. S.G.Chowdhury and Dr. I. Chattoraj .

• Altekar Award (2008) for the Best Technology : Dr. Amitava Mitra, Mr. K.K.Paul, Mr. A.K.Mallik, Dr. A.K.Panda, Mr. Arvind Kumar • Award of Excellence in In-house Research a) 1st Prize : Dr. Sanjay Kumar, Dr. Rakesh Kumar, Dr. A. Bandopadhyay, Dr. Swapan Kr. Das , Dr.B. Ravikumar, Mr. B.K.Mitra and Prof. S.P.Mehrotra . b) 2nd Prize : Mr. B.Sarkar, Dr. Avimanyu Das, Mr. K.K.Bhattacharya and

Mr. S. Chandrasekhar .

• Raman Research Fellowship : Dr. L. Sharmistha Sagar Dr.S.Sivaprasad • Boyscast Fellowship : Dr.A.K. Mohanty, Dr.Arpan Das, Dr. Durbadal Mandal

• Indo-US Fellowship : Dr. Mainak Ghosh • DAAD Fellowship : Dr.Sanchita Chakravarti


Human Resource

Human Resources as on 31.03.2010

142

534869

83

88

Group IV Scientific

Group III Technical

Group II Technical

Group I Technical

Administration

Admin Group D Non-Technical

Research Groups

1413

17

10

158928

26

38

Mineral Processing Materials Characterisation

Materials Evaluation Waste Utilisation

Buss Dev & Know Managmt Corr Protection

Analytical Chemistry Metal Extraction

Material Forming & Processing Scientific & Support Services


Scientific Staff (Gr IV)

10%8%

10%

7%

8%4%

18%

18%

11%

6%

MP

MC

ME

W

BD

CP

AC

Mex

MFP

SS

Technical Staff (Gr III)

4% 4% 6%4%

9%

0%11%

6%4%

52%

MP

MC

ME

W

BD

CP

AC

Mex

MFP

SS

MP – Mineral Processing MC-Materials Characterisation ME – Materials Evaluation W – Waste Reclamation BD – Business Dev & Knowledge Management CP – Corrosion Protection AC – Analytical Chemistry Mex – Metal Extraction MFP – Materials Forming & Processing SS – Scientific & Support Services


Targets Planned for 2010 - 2011

Performance Targets

Objectives Planned

1. a. ECF Rs 13 crores

b. Industrial ECF Rs 5 crores

2. Customer Satisfaction Index 4.25

3. Publications 145

4. Patents 15

5. Copyrights 7

6. Technologies Developed 4

7. Technologies Transferred 4

Major Technological & Scientific targets Planned fo r 2010-2011

Targets for 2010 -11 1 Refinement of the analysis software and development of user friendly

GUI for the PABI system that has been developed

2 Fatigue behavior of piping material of nuclear power plant under combined tension-torsion-internal pressure (i.e. mu ltiaxial) loading

3 Leak-before -break justification with regard to ratcheting behavior of piping components (task continued from the previous year)

4 Optimized Plasma nitriding protocol for gears/piston rings

5 Validation of existing RLA data using ALIAS softwar e

6 Establishing bioactivity of biomimetic biphasic nan ocomposites developed at NML

7 Bioactivity evaluation of 3d -biomimetic scaffold for bone tissue engineering

8 Fabrication of transparent polymer hydrogels

9 To study low temperature sensitization on SS 304 LN Stainless Steel Materials

10 Solvent extraction protocol for remov al of hazardous metal elements from the leach solution of electronic scrap and rec overy of valuables

11 To develop a protocol for paint systems suitable to extend life of steel structures in different zones of India

12 Creep behavior cataloguing of Mg -alloys


13 Al -Ni-Ln based (Ln =lanthanide elements) amorphous alloy ribbons

* Strength obtain 800- 1200 MPa with elongation ~ 8 -2 %

* Evaluation of hardness of these alloys with the p rogress of crystallization

14 Failure mechanism at the co ating/alloy interface High cycle fatigue behavior of coated and bare alloy (substrate) at 60 0oC at 40 Hz

15 Installation of the 25000 LPD coal mine water recla mation plant in collaboration with CIMFR

16 Development of Prototype GMI sensing Device

17 Preparation of Ti -based bulk metallic glass rods

18 Development of injectable scaffold

19 Evaluation and identification of corrosion resistan t coating (mixed zirconia oxide).

20 Synthesis and characterization of inorganic ion -exchange material (hydrotalcite).

21 Produce high purity cobalt and cobalt oxide through organometallic route

22 Expansion of the database on naturally occurring mi nerals as water purifiers and put it in web as an open access resou rce.

23 To develop silt erosion resistant material f or turbine hydrogenerators

24 Recovery of tungsten and copper values from tungste n alloy scrap

25 Development and characterizations of Cu -based bulk metallic glass

26 Preparation of Hydrogen standard in Zirconium alloy


A Tribute

Prof. P. Ramachandra Rao

(21st March 1942 – 10th January 2010)

Rejuvenation

Protocol

For Turbine Blades

annual report 2009-2010 · annual report 2009-2010 major programs on recycling of electronic waste,...

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