IIM METAL NEWS Vol. 23 No. 12 December 2020

C DR PLACID RODRIGUEZ MEMORIAL LECTURE - 2020 O Accelerated Materials Innovation using Knowledge 6 Systems and High-Throughput Experiments N - Surya R Kalidindi T TECHNICAL ARTICLE Development and Certification of Superalloys for Aero- 12 E Engine Applications - D B A Sagar, Santanu Saha, M S K Rao, S K Jha and B Saha N News Updates 19 T Member News 23 S Recent Developments 24 Information from International Metals Study Groups 25 IIM Chapter Activities 28 Obituary 31 Conferment of IIM Honorary & Fellow Membership 2020 32 Crude Steel Production 33 Non-Ferrous Metals Statistics 34

The IIM Metal News and The Indian Institute of Metals do not accept any responsibility for the statements made and the opinion expressed by the author(s) in the technical articles.

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Vol.23 No. 12 DECEMBER 2020 3 IIM METAL NEWS THE INDIAN INSTITUTE OF METALS

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FORMER PRESIDENTS 1946-48 Late J J Ghandy 1977-78 Late V A Altekar 1992-93 Late A C Wadhawan 2007-08 Dr Srikumar Banerjee 1948-50 Late P Ginwala 1978-79 Late T R Anantharaman 1993-94 Dr R Krishnan 2008-09 Mr L Pugazhenthy 1950-52 Late Phiroz Kutar 1979-80 Late P L Agrawal 1994-95 Dr S K Gupta 2009-10 Dr Sanak Mishra 1952-54 Late G C Mitter 1980-81 Late EG Ramachandran 1995-96 Mr R N Parbat 2010-11 Dr D Banerjee 1954-56 Late M S Thacker 1981-82 Late C V Sundaram 1996-97 Late P Rodriguez 2011-12 Mr M Narayana Rao 1956-58 Late K S Krishnan 1982-83 Late Samarpungavan 1997-98 Late S Das Gupta 2012-13 Mr H M Nerurkar 1958-60 Late S K Nanavati 1983-84 Late J Marwaha 1998-99 Dr C G K Nair 2013-14 Prof K Chattopadhyay 1960-62 Late G K Ogale 1984-85 Late A K Seal 1999-00 Prof S Ranganathan 2014-15 Dr R N Patra 1962-65 Late Dara. P. Antia 1985-86 Dr J J Irani 2000-01 Mr V Gujral 2015-16 Mr S S Mohanty 1965-67 Late B R Nijhawan 1986-87 Late Y M Mehta 2001-02 Late P Parvathisem 2016-17 Prof Indranil Manna 1967-70 Late M N Dastur 1987-88 Dr V S Arunachalam 2002-03 Late P Ramachandra Rao 2017-18 Dr Biswajit Basu 1970-72 Late Brahm Prakash 1988-89 Late S R Jain 2003-04 Dr S K Bhattacharyya 2018-19 Mr Anand Sen 1972-74 Late P Anant 1989-90 Late L R Vaidyanath 2004-05 Dr T K Mukherjee 2019-20 Dr U Kamachi Mudali 1974-76 Late FAA Jasdanwalla 1990-91 Dr P Rama Rao 2005-06 Late Baldev Raj 1976-77 Late S Visvanathan 1991-92 Dr T Mukherjee 2006-07 Mr B Muthuraman

FORMER SECRETARIES / SECRETARY GENERALS* 1946-57 Late Dara. P. Antia 1968-76 Dr M N Parthasarathi 1986-97 Late S S Das Gupta 2006-13 *Mr J C Marwah 1958-67 Mr R D Lalkaka 1977-86 Late L R Vaidyanath 1997-06 Mr J C Marwah 2013-15 *Mr Bhaskar Roy 2015-18 *Mr Sadhan Kumar Roy

IIM METAL NEWS 4 Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 5 IIM METAL NEWS DR PLACID RODRIGUEZ MEMORIAL LECTURE - 2020

Accelerated Materials Innovation using Knowledge Systems and High-Throughput Experiments

Surya R Kalidindi

Preamble automated identification of salient features in images, and the identification/prediction of material I feel deeply humbled and honored to be delivering chemistries and internal structures with unusual/ the Dr. Placid Rodriguez Memorial Lecture-2020. superior combinations of properties. Although I am extremely thankful to the Indian Institute of these successes have identified many exciting new Metals for giving me this incredible opportunity. research avenues, they have also identified a central Dr. Placid Rodriguez was a world-class eminent gap in the field today. It is generally observed that scientist, who inspired and mentored multiple a simple brute-force application of the established generations of materials scientists and researchers. machine-learning tools to problems and challenges His legacy on metallurgy and atomic energy in India encountered in advanced materials development is indelible. Although I did not have the good fortune and deployment often fails to deliver the expected to interact with Dr. Placid Rodriguez directly, I have benefits. This is mainly because such explorations been inspired by his seminal work on the role of fail to leverage the vast amount of the previously dislocations in plastic deformation of metal alloys accumulated domain knowledge in the materials subjected to a broad range of loading conditions field. Therefore, in the materials innovation efforts, and extreme environments. He was a pioneer in the there is a critical need and a tremendous opportunity development of metal alloys for nuclear applications for the development and deployment of novel in India. It is therefore, with utmost humility, I frameworks that facilitate synergistic use of the present my thoughts on the emerging paradigms in emergent data-analytic tools in conjunction with the materials innovation at this anniversary celebration of established toolsets used in the materials science and Dr. Placid Rodriguez’s many significant contributions engineering domain. The latter includes a broad suite to sciences and humanity. of sophisticated physics-based multiscale materials- 1.0 Materials Data Sciences modeling tools and multi-resolution materials Data analytics and machine learning tools have structure and response-characterization protocols. been shown to be invaluable in establishing low- It is highly desirable to develop integrated computational cost surrogate models for a broad mathematical frameworks that take advantage of variety of applications ranging from recommendation the relative strengths of the different approaches systems to cancer detection to self-driving cars. They mentioned above (i.e., data analytics, physics-based are now being explored increasingly for addressing computations, multi-resolution experiments). For challenges related to accelerated materials discovery example, most machine learning tools are inherently and development – the central focus of the Materials aimed at the interpolation of the available (usually Genome Initiative (MGI). Some of the notable small number of data points) high-dimensional successes in this direction include the automated data, with some of them paying special attention extraction of materials data from published reports, to uncertainty quantification (e.g., Bayesian

Interim Director, Novelis Innovation Hub Regents Professor and Rae S. and Frank H. Neely Chair Professor, Georgia Institute of Technology, Atlanta, GA 30332 Multiscale Technologies Private Limited, Hyderabad – 500 082, Telangana, India E-mail : [email protected]

IIM METAL NEWS 6 Vol.23 No. 12 DECEMBER 2020 approaches). On the other hand, physics-based basis). However, there is currently no framework models and simulations provide the only avenues for for providing objective guidance to the researcher building models with the potential for high fidelity on where one should invest their time and effort extrapolation. It is also important to recognize that (e.g., Should one do more experiments or physics- experiments provide the only avenue for collecting based simulations? If so, which ones?) in order to ground truth data. Therefore, it is clear that the best optimally reach their targets in materials innovation strategy for accelerated materials innovation lies in (e.g., attain a specified combination of material our ability to develop and deploy novel frameworks properties or performance metrics). All of the capable of exploiting the relative strengths of all above discussion points to the critical need for a the different classes of toolsets mentioned above. It is also important to recognize that vast differences foundational framework that can systematically and exist in the cost and fidelity of the different classes comprehensively extract the embedded knowledge of tools mentioned above. For example, multi- in the physics-based simulations and multimodal resolution experiments spanning multiple material multiresolution experimental datasets, and express length scales often require significant investments this core knowledge in forms that can objectively of time and money, while physics-based simulation support and guide the accelerated materials tools are generally less expensive (on a relative innovation envisioned by MGI.

Figure 1. Schematic depiction of the formulation of the core knowledge needed to support accelerated materials innovation, expressed in the form of homogenization and localization PSP (process-structure-property) linkages formulated at a hierarchy of materials structure/length scales.

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 7 IIM METAL NEWS A central tenet in the field of materials science experiments or simulations are to be performed to and engineering is that the processing history obtain the required insights are often made in an ad- controls the material’s internal structure over a hoc manner by relying largely on their individual hierarchy of length scales, which in turn controls analysis of the data/information accessible to them. the effective (macroscale) properties or performance Consequently, the decisions made in the current characteristics exhibited by the material. The core workflows do not usually lead to optimal learning of materials knowledge needed to drive materials the critical knowledge needed to drive the targeted innovation is therefore most conveniently captured materials innovation. in the form of process-structure-property (PSP) The novel concept presented in Figure 1 linkages. Such PSP linkages can be formulated at fundamentally argues that it would actually be salient material structure/length scales to facilitate much more beneficial to pursue the aggregation and computationally efficient scale-bridging in both curation of the PSP linkages in a variety of materials directions (i.e., homogenization and localization). classes and structure/length scales in a fully Briefly, homogenization focuses on aggregating decoupled manner. The overall scheme presented information from the lower material structure/length in this figure allows the different experts engaged in scale to the next higher scale, while localization the many different aspects of materials science and addresses the spatial distribution (i.e., partitioning) engineering to generate and contribute their datasets of imposed quantities at the higher material structure/ for community-level curation of the underlying length scale to the next lower scale. The envisioned materials knowledge. In this context, it is important network of linkages is presented schematically in to recognize that any single dataset (from either Figure 1, where it is implied that a large library of experiments or simulations) is unlikely to produce low computational-cost, reduced-order (surrogate), the PSP linkages depicted in Figure 1. This is because PSP linkages could optimally drive the materials any dataset produced from a single source (i.e., either innovation effort. One of the salient aspects of the an experimental set-up or a software framework) is aggregated and curated PSP linkages shown in this likely to provide only a partial clue to the overall figure is that their uncertainty will be rigorously puzzle. It should be further recognized that even modeled in a suitable Bayesian framework. this partial clue comes with an inherent uncertainty Consequently, at any given time, one will be able that can be attributed to many factors, including (i) to answer instantly any materials-related queries insufficient knowledge of the governing physics, and arising from design/manufacturing experts, while (ii) the limitations of the tools and machines used to also quantifying the confidence levels in the provided generate the data. answers. Simultaneously, the queries themselves The discussion above emphasizes the critical need could be used to prioritize and streamline future for a rigorous framework for the objective (i.e., data- efforts aimed at refinement and/or expansion of the driven) extraction of knowledge from disparate, PSP linkages in order to provide a better answer in incomplete, and uncertain datasets produced by future. the different experts in the materials science and The vision and paradigm presented in Figure 1 engineering field. The strategy outlined in Figure are distinctly different from the current practices 1 effectively decouples the data generation and in multiscale materials-innovation efforts, which aggregation tasks (these can be broadly referred largely design and launch experiments/simulations as materials data management tasks) from the in response to the specific needs of the design/ knowledge extraction tasks (these can be broadly manufacturing end-user. Since most multiscale referred as materials data analytics tasks). This materials experiments and simulations demand fundamental separation of the tasks should allow significant time and effort, the data collection efforts the materials community to seek the envisioned are invariably slow (often requiring several months materials knowledge in a highly systematic and or even years). Most importantly, the decisions made organized manner. Potentially, a community- by the domain specialists regarding which specific level organization of the overall effort involved

IIM METAL NEWS 8 Vol.23 No. 12 DECEMBER 2020 can lead to highly optimized exploration of the measure the properties directly at the length scales unimaginably large materials space spanning a of interest (i.e., the grain-scale in polycrystalline hierarchy of material length/structure scales. Indeed, metals). the proposed transformation of the current practices Multi-resolution measurements of mechanical in the materials innovation efforts could streamline responses in multiphase polycrystalline metals the efforts of the broader materials community are critically needed to extract new insights into into building systematically and optimally the how the microscale constituents interact with each core materials knowledge of high value sought by other in accommodating the imposed macroscale the design/manufacturing stakeholders. The novel deformation. Such insights are not only essential for mathematical framework and the associated toolsets improved fidelity of multiscale material constitutive needed to address the grand challenge depicted in models, but they are also critical to establishing new Figure 1 are being referred as the AI-based Materials design rules for the new/improved materials needed Knowledge Systems (AI-MKS). for advanced technologies. A significant challenge 2.0 Multi-resolution High-Throughput Mechanical in microscale mechanical testing comes from the Testing fact that most of the testing protocols at the lower Most structural metals and alloys being explored to length scale need highly specialized equipment and advance technology exhibit complex hierarchical sophisticated expertise for both sample preparation internal structures spanning multiple length scales and testing, and incur significant cost in both time (often referred as microstructures). Examples and effort. Given our interest in studying the local include titanium alloys being used to improve the mechanical responses of a large number of microscale performance of jet engines and the dual-phase steels constituents (e.g., various thermodynamic phases of being explored for increased crash-worthiness of differing chemical compositions, grain and phase automobiles. The microstructures of these alloys boundaries of different characters), it is imperative often contain distinct spatial distributions of multiple to develop novel experimental protocols that can be (thermodynamic) phases along with a variety of executed quickly and within acceptable cost. defects at different length scales (e.g., dislocations, For more than a century, the indentation test has been grain and phase boundaries). Microstructure- one of the most commonly employed techniques for sensitive models are critically needed to aid in the characterization of the mechanical properties of a vast accelerated and cost-effective development and range of materials. In a typical test, a hard indenter deployment of such structural alloys in emerging of known geometry is driven into a softer sample advanced technologies. These physics-based by applying a preset load or displacement. The models often rely on experiments for parameter dimensions of the resultant imprint are then measured calibration. As a specific example, one needs and correlated to a hardness index number. With the suitable experimental data to calibrate the values of advent of higher resolution testing equipment, it the slip resistances and slip hardening parameters has now become possible to continuously control in order to successfully utilize crystal plasticity and monitor the loads and displacements of the theories in accurately modeling the anisotropic indenter as it is driven into and withdrawn from mechanical response of most polycrystalline metals. a sample material. Known as nano-indentation Most currently employed protocols addressing this (or instrumented indentation testing, or depth- need utilize bulk mechanical tests (e.g., uniaxial sensing indentation), this significantly expands the tension and compression tests) conducted on the capabilities of the traditional hardness testing method. polycrystalline samples. Since the calibration is only Instrumented indentation has significant advantages performed at macro-scale, it is only reasonable to over conventional indentation testing, since it can associate the values of the fundamental grain-scale potentially produce reliable measurements of stress- properties established using such protocols with high strain curves from fairly small indentation depths levels of uncertainty. Ideally, one would desire to (of the order of a few nanometers).

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 9 IIM METAL NEWS Indentation offers several advantages compared to ion-irradiated materials in nuclear applications) is the other competing techniques for interrogating the currently possible only with indentation techniques. local mechanical properties at micron length scales This high throughput methodology, when used in that rely largely on testing miniaturized samples in conjunction with structure information measured nominally homogeneous deformation/stress modes. locally at the indentation site, has the potential to For example, the compression testing of micro-pillars become a key tool in efforts aimed at the development produced by removing material around a selected of physics-based multiscale materials models. region of interest using a focusedion beam (FIB) has A common limitation in a majority of the indentation been demonstrated successfully by many researchers. analysis methods used today is that the estimation However, these techniques typically require of material properties, such as Young’s modulus tremendous resources in terms of sample preparation, and hardness, is typically made from the measured test conditions and operator time. On the other hand, unloading segments of load-displacement curves instrumented nano-indentation aided with proper (after some amount of elastic-plastic loading) under analysis methods is capable of producing the desired the assumption that the unloading segments are information at significantly lower effort and cost. predominantly elastic. In this approach, the plastic Moreover, reliable and quantitative measurement deformation induced during the loading segment of mechanical degradation of surface layers (e.g., is likely to strongly influence the values of the

Figure 2. Multi-resolution indentation data obtained on dual-phase steel samples. Indenters with different tip radii have been used to measure the stress-strain response of individual phases (i.e., ferrite and martensite) as well as the bulk response.

IIM METAL NEWS 10 Vol.23 No. 12 DECEMBER 2020 mechanical properties (e.g., hardness) extracted from been more successful with spherical indenters, these experiments. This problem has been recognized where their relatively smoother stress fields and since the early 1890s and numerous attempts have larger initial elastic segments (compared to sharper been made to measure the ‘absolute hardness’ indenters) allow one to follow the evolution of the of a material. However, quantitative estimates of mechanical response in the material, from initial absolute hardness, generally defined as “resistance elasticity to the initiation of plasticity to behavior at to permanent deformation” or “the intensity of the finite plastic strains (see Figure 2 for examples). maximum pressure which just produces yielding” in indentation, have not been feasible before the arrival Acknowledgements of modern instrumented test methods. The authors gratefully acknowledge funding for In recent years, my research group has developed this work from numerous US federal agencies and demonstrated novel data analyses protocols including National Science Foundation and the Air for spherical nano-indentation that transform the Force Office of Scientific Research. Much of the entire load-displacement dataset, including both the material presented here is taken from the following loading and the unloading segments, into much more references, which provide additional details: 1. S. meaningful indentation stress-strain curves. The R. Kalidindi, “Feature Engineering of Material use of these indentation stress-strain curves makes Structure for AI-based Materials Knowledge it possible to analyze the initial loading segments Systems”, Journal of Applied Physics, 128, 041103, of spherical indentation, thereby allowing reliable 2020; and, 2. Khosravani, C. M. Caliendo, and S. measures of indentation modulus and indentation R. Kalidindi, “New insights into the microstructural yield strength of the material prior to the changes changes during the processing of dual-phase steels induced by the indentation itself. The ability to from multi resolution spherical indentation stress- produce indentation stress-strain curves has generally strain protocols”, Metals, 10, 18, 2020.

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EDITORS CORRESPONDENTS Dr Manojit Dutta Dr Chiradeep Ghosh (Jamshedpur) Prof J Dutta Majumdar Sri Rishabh Shukla (Pune) Dr R Raghavendra Bhat Sri N K Kakkar (Delhi) Prof Sudhanshu Shekhar Singh Dr L Ramakrishna (Hyderabad) Dr Mithun Palit Sri Utpal Kumar Parui (Visakhapatnam)

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 11 IIM METAL NEWS TECHNICAL ARTICLE

Development and Certification of Superalloys for Aero-Engine Applications

D B A Sagar1, Santanu Saha2, M S K Rao1, S K Jha2 and B Saha1

Abstract only used at elevated temperatures but also maintain their strength and toughness at these temperatures. This paper explains the concurrent development and certification of various aeronautical-grade Superalloys are employed largely in the superalloys manufactured at M/s. MIDHANI, a manufacturing of turbine components of aero- premier defence PSU. The certification methodology engines, such as blades, rotors and vanes. Two followed for indigenization of various alloys at processes are extremely relevant to the development MIDHANI has been discussed in detail. Several and production of components using superalloys: Nickel- and Iron-based super alloys have been Vacuum Furnace technology and Investment Casting successfully indigenized, certified and supplied for techniques. Additionally, the complex geometry of various prestigious projects of Indian Defence. aero-engine components, such as blades and rotors generally do not allow the intense use of machining Key words: Superalloys, Process technologies, processes for fabrication. Thus, the use of investment Certification casting process was decisive for the success of 1.1 Introduction superalloy products. Aero-engines provide some of the most challenging M/s MIDHANI, the defence PSU was commissioned demands for structural applications. Present day in 1982, with a view to achieving self-reliance engines operate at a very high temperature, near about in production and supply of various superalloys, 85% of the melting point of the component material special steels, Titanium alloys, materials for defence and under severe dynamic stress. Engine components and other strategic sectors of nuclear, aeronautical are in addition subjected to some damaging and space applications. The critical superalloys corrosion, oxidation and erosion conditions during which were developed and successfully met the their life cycle. The superalloys referred to as Ni and airworthiness requirements of aero-applications are Co-alloys are high temperature alloys that are not listed at Table 1. Table 1 : List of Super Alloys Type Approved for Aero applications Grade Type testing Nominal composition Equivalent Typical applications approval international no for specification Aero- application AE 868 762 25Cr - 14W - 0.5Ti TY14-1-286-72 Combustion chambers, pipe lines, -Bal Ni TY 14-1-1747-76 reheating chambers, diffusers, casings, TY 14-1-997-76 nuts & bolts AE 435A 566 19Cr-.15Ti-0.15Al- TY14-1-1471-76, Combustion chamber parts, hot zone Bal Ni TY14-1-378-72, pipe line, reheating chambers, diffusers, NC 20T fasteners AE 602 1006 19Cr-1.8Mo-0.35Ti- TY14-1-1747-76 Aero-engine components such as 0.35Al-Bal Ni Deflectors, flame tube details, flanges

1 RCMA(Materials), CEMILAC, DRDO, Kanchanbagh, Hyderabad 2 M/s MIDHANI, Kanchanbagh, Hyderabad

IIM METAL NEWS 12 Vol.23 No. 12 DECEMBER 2020 AE437A 1007 19Cr-2.4Ti-.5Al-Bal TY14-1-75-71, Valves and Valve seats in IC, Engine Ni Ty14-1-402-72 high temp bolting stationary gas turbine blades furnace component, Diesel engine combustion chamber aero- engine components such as tie rod, bushes, compressor, stator blades ZS6Y-VI 1292 TY1-92-177-91 Turbine blades and nozzle-guided vanes of R 25 engine of MiG 21 B aircraft. SUPERFER 1005 10Cr-18Ni-2.3Ti- AE 696M, TY14- Bolts, Pins, Plugs, Nuts, Flanges, Washers, 696M 0.5Al-Bal Fe 1312-72 Rings BZL12Y-VI 1416 8.5Cr-2.7Mo-0.5V- TY1-92-177-91 0.5Nb-4.2Ti-1W- 5.4Al-Bal Ni Super cast 1489 8Cr-9.3W-5.4Al AMS 2280, CM The exceptional castability of CM 247 247A 0.6Ti-3.1Ta-1.4Hf-Bal 247LC LC has resulted in its selection for Ni conventionally cast vanes, nozzles and structural turbine components for aero and industrial gas turbines SUPERNI 929/904/929 20Cr-20Co-5.9Mo- GTM-SU-263/FS- Combustor liners, cooling rings, casings, 263A 2.1Ti-0.5Al-Bal Ni 1, MSRR 7035, flanges MSRR 7036, BS HR 10, AMS 5886, AMS 5872 SUPERNI 1291/905/922 19Cr-18Fe5Nb-3Mo- AMS,5662,5663, Heat exchanger tubing, hot tooling 718A 1Ti-0.5Al-52Ni MB637, B670, BS applications, high temp bosh & fasteners 2 HR2 cryogenic uses, compressor blades, gas turbine discs SUPERNI 495/546 20Cr-0.3Ti-Bal Ni BS HR 5, NC 20T, Aircraft engine component, flame tubes 75A AE 435, MSRR stator blades, aircraft valves, gas turbine 7007, 7004 components and boiler parts, exhaust of aero engine jet pipes of aircrafts

1.2 Processing Technologies for Superalloys 1.2.1 Vacuum Induction Melting (VIM) The initial years of superalloy development were It is the widely used primary melting process for devoted to alloy chemistry, whereas the subsequent production of nickel and cobalt-based super alloys. years have seen more emphasis on process Process benefits include precise control of chemical improvement. From a modest beginning of 10 % composition, low levels of gases and high melt of the total weight of the engine in 1950’s, use of cleanliness. superalloys has now reached a level of around Melting of a solid charge is done in a refractory- 60 %. This was possible because of simultaneous lined crucible by virtue of electromagnetic induction availability of variety of newer processes to from a high frequency alternating current (AC) flow produce better alloys and defect-free products. This in an induction coil. The electromagnetic forces includes vacuum melting & refining, investment cause a stirring effect in the molten metal that aids in casting, directional solidification, single crystal and producing chemically and thermally homogeneous 3D-printing technology. melts. VIM processing involves melting, refining and A brief description of the key processing technologies composition adjustment under controlled conditions adopted in manufacturing of super alloys at M/s [1]. MIDHANI, Hyderabad is shown in Fig. 1 and also The initial charge normally contains all the non- presented in the following sections. reactive elements and sufficient carbon to facilitate

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 13 IIM METAL NEWS

Fig. 1 : Manufacturing Technologies of superalloys at M/s MIDHANI Fig. 1 : Manufacturing Technologies of superalloys at M/s MIDHANI an active carbon-oxygen reaction during melting. macrostructure due to progressive melting and The progress of refining is monitored by periodical controlled solidification in a water-cooled copper checks of the hot leak rate (a measure of out gassing) mould. In addition, progressive melting and and visual observation of gas-bubble formation from enhanced heat transfer conditions drastically reduce the liquid metal. After refining, the reactive elements the local solidification time and consequently the 1.2.1are added Vacuum along Induction with other Melting alloying adjustments.(VIM) extent of micro-segregation in the remelted ingot. At this stage, the power input is precisely adjusted The role of remelting technologies becomes even Itto is control the widely the liquid used metal primary temperature melting in process order to for moreproduction prominent of nickel during and the cobalt-based processing of super highly minimize the formation of inclusions by refractory− alloyed materials such as maraging steels, tool alloys.metal interactions. Process benefits Just before include tapping, precise the final control micro- ofsteels chemical and supercomposition, alloys. The low triple levels melting of gases route additions of specific alloying elements are done. (VIM+ESR+VAR) produces the very best quality andThis high all takesmelt cleanliness.place under controlled temperature products in terms of structural homogeneity and and reduced pressure to ensure reproducibility of the cleanliness and is recommended specifically for Meltingcomposition. of a solid charge is done in a refractory-linedsafety-critical crucible rotating by virtue components of electromagnetic of aero-engine viz. turbine discs, blades etc. induction1.2.2 Remelting from technologiesa high frequency alternating current (AC) flow in an induction coil. The ESR and VAR are the remelting technologies that 1.2.3 Electro Slag Re-melting (ESR) electromagneticnot only bring about forces further cause refining a stirring of effectprimary inESR the has molten been well metal suited that for aidshigh gradein producing nickel- and chemicallymelted products, and thermally but also enablehomogeneous a well-defined melts. VIMcopper-based processing superalloys involves and melting,special steels, refining which and composition adjustment under controlled conditions [1]. IIM METAL NEWS 14 Vol.23 No. 12 DECEMBER 2020 The initial charge normally contains all the non-reactive elements and sufficient carbon to facilitate an active carbon-oxygen reaction during melting. The progress of refining is monitored by periodical checks of the hot leak rate (a measure of out gassing) and visual

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have to meet extreme requirements and qualification facilitated by melting clean material with a constant, norms. ESR ingots have been successfully used for relatively small (6–10mm) electrode gap in a vacuum the production of isotropic materials having uniform furnace, in the absence of any stray magnetic fields. properties in all directions. It has special applications The metal droplets falling through the arc gap are in the production of heavy forgings for power exposed to vacuum and the extreme temperatures of industry. These days in superalloy production, it is the arc zone, lead to removal of dissolved gases and not just sufficient to adjust to the required chemical vaporization of tramp elements resulting in refining. composition but one aims at achieving the utmost Gas levels are typically brought down below 20 ppm cleanliness in the material. by VAR. ESR is a consumable electrode-remelting / Towards the end of the process, the power is refining process where the material to be refined is gradually reduced to provide a controlled hot top, progressively melted under a layer of highly reactive thereby maximizing the yield of useful product. slag; it is then solidified in a controlled manner in a 1.2.5 Thermo-Mechanical Processing water-cooled copper crucible. The slag acts primarily as the refining media and is superheated above the The structure of superalloy ingots consists of liquidus temperature of the metal by virtue of its high primary dendrites, which are solute-lean and inter- resistivity when a high current is passed through it. dendritic regions, which are solute-rich. For those alloys with sufficient aluminum, titanium, or Most of the ESR slags belong to the CaF –Al O - 2 2 3 niobium to exhibit useful age-hardening response, CaO ternary system and contain equal proportions it is necessary to thermally treat the ingot prior to of CaO and Al O , corresponding to the eutectic 2 3 deformation processing. The thermal treatment trough in the system. This provides a range of slag is referred to as ‘homogenization’ and consists of compositions having a liquid in the range 1350 –1500 extended exposure to temperatures approaching °C, making the slag suitable for remelting a wide the incipient melting temperature of the alloy. The variety of steels and super alloys. The ESR process is degree of segregation reduced by homogenization is characterized by continuous transport of liquid metal a function of the alloy composition and melt practice. through a slag layer, wherein the slag and metal While homogenization treatments are generally compositions change continuously according to the effective in producing a great leveling of differences prevailing thermodynamic and kinetic conditions of in microscale concentration in superalloys, some the melt. residual minor differences may remain in areas of 1.2.4 Vacuum Arc Re-melting (VAR) large primary dendrite formation. It is also used for secondary melting process for Forged products are produced through an vacuum refining and manufacturing of ingots with intermediate (billet) forging process, during which improved chemical and structural homogeneity the cast structure is refined and a recrystallized grain to get good and consistent mechanical properties. size is established. Subsequent die forging may The VAR process involves continuous remelting of further refine the structure or may simply impart the a consumable electrode by means of an arc under desired form while retaining the billet structure. vacuum. DC power is applied to strike an arc between Workability is affected primarily by composition the electrode (cathode) and the base plate (anode) and microstructure. Optimal strain and temperature inside a copper mould contained in a water jacket. conditions for working of superalloys can be defined Metal droplets appear on the bottom of the electrode by ‘processing maps’. In superalloys, high sulfur and quickly form a molten pool of metal. The gap levels may restrict the favorable processing range, between the melting electrode and metal pool (arc while additional elements such as magnesium may gap) is precisely maintained, and a controlled melt counteract the effect of sulfur and expand the process rate is established to achieve a stable melting process. range. An example of carbide films developed on Steady-state solidification is critically dependent prior-grain boundaries will restrict the range of on establishment of a stable and diffuse arc. This is processing conditions.

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 15 IIM METAL NEWS Grain-refinement requirements also may affect the which will enable to produce critical aero-engine forging process. To refine grain structure (to improve components like compressor and turbine discs. low-cycle fatigue resistance and/or stress rupture 1.2.7 Vacuum Investment Casting resistance) in forgings, it is common to process precipitation-hardening superalloys within a more The vacuum investment casting or ‘lost-wax’ process restricted temperature range. The temperature range is another facility of M/s MIDHANI used for the is restricted so that not all the precipitating elements production of superalloy components of complex are in solution during forging, thus leading to shape, e.g. turbine blades or nozzle guide vanes etc. pinning of grain boundaries and restriction of grain • Using the principles of the ‘lost wax’ process, growth. The forging conditions must be chosen and a ceramic mold is prepared and heated prior to controlled so that sufficient strain and temperature casting. A measured quantity of pre-alloyed metal are used to allow recrystallization at the same time, is then rapidly re-melted and poured into the not allowing the temperature to exceed the solution mold under vacuum. Investment casting produces temperature for the precipitate. The grain structure precision components while minimizing material obtained by such processing must be retained during waste, energy, and subsequent machining. It can heat treatment of the forging by either direct aging of also ensure the production of intricate parts. the forged structure or aging after a pseudo solution Normally, the investment casting process consists of the following steps:- heat treatment that does not exceed the true solution temperature of all the precipitate. As the thermal • Creating the pattern conductivity of superalloys is low, they need to be • Mounting the wax patterns and creating the tree heated to the hot working temperature at a slow rate. The forging temperature and cycle depend on • Creating the mould shell the composition of the alloy and to some extent on • Wax removal the heat treatment and the end use of the alloy. High • Melting & Casting forging temperatures cause grain growth in most heat-resistant alloys; the forging temperature ranges • Final operations are thus relatively narrow and need to be precisely 1.3 Commonly used Superalloys for Aero-Engines controlled. Lower hot working temperatures have 1.3.1 SuperNi 263A positive effects on the work piece, but will increase the forging load and erode the dies. SuperNi 263A is Ni-based precipitation-strengthened superalloy having high strength up to 800°C and 1.2.6 Isothermal forging oxidation resistance up to 1095oC. It has excellent Some of the alloys require to be worked in a fabrication characteristics. Table 2 shows the severely restricted range of temperature which chemical composition of SuperNi 263A used for makes it impossible to work with regular open aeronautical application. die press-forging. Isothermal forging is a process Alloy 263 A is widely used for critical applications where workplace and die are maintained nearly at of gas turbine hot-section components such as the same temperature, thereby maintaining forging moderate temperature combustors. This alloy is temperature in a narrow window and eliminating processed using the double-vacuum melting (VIM + die chilling resulting in uniform deformation of VAR) route, mainly to address complex issues such the material and near-net-shape components. M/s as precise chemistry control and product cleanliness. MIDHANI is in the process of commissioning an The typical mechanical properties of the alloy are isothermal forging module to the existing 6000 press shown in Table 3.

Table 2 : Chemical composition of SuperNi 263A Chemical C S Mn Si Cr Mo Co Cu Ti Fe Al B Al+Ti Ni Composition Weight % 0.04 0.007 0.6 0.4 19-21 5.6- 19-21 0.2 1.9- 0.7 0.3 - 0.005 2.4 - Bal -0.08 max max max 6.1 max 2.4 max 0.6 max 2.8

IIM METAL NEWS 16 Vol.23 No. 12 DECEMBER 2020 Table 3 : Mechanical properties of SuperNi 263A alloy Tensile Test 0.2 % Y S (MPa) UTS (MPa) EL% in 5D 780oC 400 540 12

Creep Test Axial Stress (MPa) 0.1% Plastic strain in 50 h 780oC 120

1.3.2 SuperNi 718A a) The aircraft operator / designer approaches a Regional Centre for Military Airworthiness SuperNi 718 A is a precipitation-hardened iron- (RCMA): based on the RCMA’s advice nickel based superalloy strengthened by coherent the operator selects a potential supplier/ γ’ precipitates. It is suitable for use at cryogenic manufacturer. After assessing the supplier’s temperatures and also upto 740°C. The alloy has capabilities, the RCMA circulates a ‘Draft excellent workability and can be age hardened. Table Development/Type Test Schedule’ for 4 gives its chemical composition. conducting a Local Type Certification The alloy is produced using vacuum induction Committee (LTCC) meeting chaired by the melting followed by VAR to maintain stringent Regional Director of the RCMA. Members of chemistry, cleanness and freedom from segregation- the LTCC include the relevant agencies and the related defects. Stringent control over primary and supplier and operator / designer. After the LTCC secondary melting practices are required to produce meeting, the RCMA finalizes the Development/ high-quality products for the critical aeroengine Type Test Schedule (D/TTS), which becomes applications. This alloy is age-hardenable and can the final qualification document for the material/ be annealed at 1035 °C followed by rapid cooling in component. air. The typical mechanical properties of the alloy are b) There are two stages involved in the approval of given in Table 5. a supplier/manufacturer of the material. Both tasks are carried out by teams from the RCMA 1.4 Airworthiness Certification methodology and the Directorate General of Aeronautical The certification of a new or existing material for Quality Assurance (DGAQA). Approval of aerospace applications is a systematic and thorough the material requires satisfactory processing procedure, consisting of many steps and stages. A according to the approved process documents detailed illustration of Certification Methodology and tests as per Development Test Schedule / is placed at Figure 2. Whenever there is (or appears Type Test Schedule typically from three batches to be) a new material requirement for the Indian for critical components and verification of Air Force, the general procedure adopted by the compliance with the D/TTS. The RCMA issues airworthiness agencies is as follows[4]: Provisional Clearances for each batch. Table 4 : Chemical composition of SuperNi 718A Chemical C S Mn Si Cr Ni Mo Co Cu Ti Al P Nb Fe Composition +Ta Weight % 0.08 0.015 0.35% 0.35% 17-21 50-55 2.8- 1.0 0.3 0.65- 0.2- 0.015 4.75- Bal Max max max max 3.3 max Max 1.15 0.8 max 5.5

Table 5 : Mechanical properties of SuperNi 718A Tensile Test 0.2 % Y S (MPa) UTS (MPa) EL% in 5D RT 1034 1275 12

Stress rupture Axial Stress (MPa) Life 23 h, % El of 4 650oC 690

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 17 IIM METAL NEWS c) After getting suitable number of Provisional f) The Type Approval issued to the supplier is Clearances depending upon RCMA’s renewed periodically by CEMILAC, contingent requirement, the supplier/manufacturer and the upon a mandatory re-application from the RCMA prepare the Type Record. The RCMA supplier and a subsequent recommendation then forwards the Type Record, along with a from the RCMA. recommendation, to CEMILAC in order to obtain Type Approval for the supplier. Once 1.5 Conclusions the Type approval is issued, the DGAQA and MIDHANI has successfully developed and certified RCMA prepare the Release Specification and issue it to the suppler. The production route is various grades of superalloys resulting in type sealed by the RCMA. approvals of more than 10 aeronautical grades in different mill forms from CEMILAC for various d) During regular production, all material / aero-engine applications. Huge amounts of foreign component batches processed according to the designed production route are released exchange was saved due to the successful efforts for supply by the DGAQA, as per Release of indigenization leading to the production. The Specifications and forwards copies of the Test important aspect of self-reliance and sustainability of Certificates to the RCMA. nickel-based superalloy for aeronautical applications has been developed over the years. MIDHANI is e) Any deviations noticed during series production are to be referred by the supplier/manufacturer now equipped with the advanced technologies and to the DGAQA, and via the DGAQA to the production capability to take up the challenge of RCMA. Based on the RCMA’s advice about indigenizing the future generation superalloys for production modifications, the supplier prepares strategic aero- programmes such as Kaveri Dry revised process sheets for approval by the Engine, STFE, AMCA and many more that would RCMA. drastically bring down the imports.

Fig. 2 : Detailed illustration of the certification methodology

IIM METAL NEWS 18 Vol.23 No. 12 DECEMBER 2020 1.6 References for Metals Production—An EPRI Sponsored 1. Special melting technologies, Aerospace R&D Applications Center, 3(3) materials and material technologies: Part 1; 3. “Electro slag remelting”, 2010, A technical Chatterjee M, Patra A, Babu RR, Narayana Rao information brochure by ALD Vacuum M; IIM-Springer publication, 2016 Technologies 2. Vacuum Induction Melting Technology—A 4. “Aerospace materials and Technologies: Vol unique electrical method for production of high II Aerospace Materials and Technologies”, quality and reliable alloys needed in critical Chapter 24, IIM Springer Publication, 2017, N applications”, 1987, A publication of the Center Eswara Prasad & R J H Wanhill

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NEWS UPDATES

Tata Steel, JSW Steel, other Indian steelmakers’ tubes, pipes, railway tracks, wires, tables and profits may jump as China bans Australian coal household items, tanks, containers, railway coaches The earnings of Indian steel manufacturers such as and rolling stock. JSW Steel, Tata Steel, etc, are likely to rise in the The move is part of the Centre’s efforts to boost coming months as the raw material — coking coal domestic production, for which it had put in place — is set to remain cheaper. The prices of coking public procurement norms a few years ago. Since coal are expected to dip as China has put a ban on then, the programme has moved from the ‘Make Australian coking coal. Softer coking coal prices in India’ campaign to ‘Atmanirbhar Bharat’ with shall directly support EBITDA per tonne accretion of steel being among the sectors that have come into around Rs 2,600 over FY21, for companies using the special focus. Steel is seen as a key input for a host of blast furnace route, said a report by India Ratings. sectors, ranging from construction to building ships It is to be noted that the Chinese ban on Australian and railway lines & coaches. coking coal has the ability to affect the global metrics In fact, the steel ministry, which has issued the order, of steel. had earlier pushed railways to buy domestically China and Australia are the largest coking coal trade manufactured rails at a time when the public partners in the world. While China’s imports form 40 transporter was citing the lack of capacity in the per cent of the overall imports, Australia’s exports country and was arguing for imports. make 65 per cent of the world’s overall exports. The latest order will extend to centrally sponsored Consequently, for the Indian steelmakers, the cost schemes, and even local bodies executing public of steel production is expected to fall by around Rs contracts will have to follow this if the procurement 1,800 per tonne on-year in the second half of the value exceeds Rs 5 lakh. The government has current fiscal year, while the cost of coking coal is specified minimum domestic value addition, ranging likely to drop to nearly Rs 7,300 per tonne, compared to Rs 9,100 per tonne in the same duration last year. between 20% and 50%, for various steel products. Financial Express Besides, the ministry has armed itself with powers to restrict import of iron and steel from countries 49 Indian steel, iron items to be preferred for that do not allow Indian companies to participate public works in procurement due to restrictive conditions. In The government has put in place a new mechanism case such instances are proven, then it can “restrict to offer preference to 49 domestically manufactured or exclude” bidders from that country from the iron and steel products in public contracts, including eligibility norms.

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 19 IIM METAL NEWS A supplier or bidder shall be considered to be from a We are certainly back to where we were before the country if the entity is incorporated in that country, pandemic and we expect the trend to continue through or majority shareholding or effective control of the FY22. The pandemic, however, is not behind us yet entity is from that country. It will face restrictions and we cannot let our guard down,” he said. even if over 50% of the value of the item being Financial Express supplied has been added in that country that restricts Indian steel companies’ access, the new order said. Stainless steel industry seeks zero duty on ferro- Times of India nickel, scrap in upcoming Budget Ahead of the Budget, the Indian Stainless Steel Steel demand should grow at GDP growth rate, says Tata Steel CEO T V Narendran Development Association (ISSDA) has urged the government to remove import duty on ferro-nickel Tata Steel CEO and Managing Director T V Narendran and stainless steel scrap. Currently, ferro-nickel said, the steel demand in the country should grow at and stainless steel scrap attract basic customs duty least at the rate of GDP growth or higher in FY22. (BCD) of 2.5 per cent. He expressed optimism about the demand for steel in India in 2021, backed by inflow of funds from across In its recommendations to Finance Ministry for the sectors and an uptick in the overall consumption; upcoming Budget for financial year 2021-22, ISSDA government’s efforts to improve infrastructure, has also sought removal of import duty on graphite coupled with the ‘Atmanirbhar Bharat’ policy and electrodes. ISSDA said "it has appealed to exempt the Production Linked Incentive (PLI) initiative. the 2.5 per cent BCD levied while importing key raw Additionally, the government’s focus on rural materials, including ferro-nickel and stainless steel infrastructure projects will also give an impetus to scrap". the steel demand. At present, both the raw materials are unavailable Commenting on the outlook on steel prices, he said, in the country, making their import mandatory, it globally, steel prices were likely to stay firm as China said. The Ministry of Steel has also at times batted was not expected to export large volumes owing to for zero duty on these items. Stainless steel industry a better balance in their domestic market, and there meets the bulk of its nickel requirements through were no other very significant exporters in the world ferro-nickel and stainless steel scrap route. market. “We are optimistic about the overall demand The Economic Times for steel and hence the performance of the steel industry and Tata Steel,” he said. High cost of production delays recovery of secondary steel companies On raw material prices, Narendran said it would be a mixed bag. Iron ore has seen a sharp rise in prices Steel prices are rising, but the responses of primary primarily because China has recovered quite well. and secondary makers of the alloy to the defining Coal prices have softened because of the geopolitical price movements are markedly different. Big, issues between China and Australia. Consequently, integrated players have reported a quicker return more coal is available from Australia in the world to normalcy, but weaker financials, limited product market and India being a big importer of coal is range and higher costs have combined to delay the witnessing softening of prices. recovery for secondary steel companies. He highlighted that currently, capacity utilisation “Most of the secondary steel plants are likely to be of most of the steel producers in the country has completely closed and it is a matter of time due to improved and they have healthy order books, really high manufacturing cost. After the pandemic, while maintaining a cautious stance with regards the cost of production between an integrated to the Covid-19 pandemic. “Most steel producers, steel plant and the secondary players has widened including us, do prefer to sell more in the domestic by around Rs 10,000 per tonne,” said RK Goel, market. Overall, the demand-supply situation favours managing director of Kalyani Steel, one of the top the steel producers with strong international prices. secondary steel companies in India.

IIM METAL NEWS 20 Vol.23 No. 12 DECEMBER 2020 CARE reported that India’s top six integrated steel said he also wants to see SAIL paying back at least producers (ISPs) together produced 5.9 Mt of crude 50 per cent of its debt in the near future. steel out of the total 9.2 Mt in November, up 7.5% Chaudhary who had joined SAIL as a Junior Manager on year. By contrast, the output at smaller players in 1984 would be superannuating from the top post fell 6%. on December 31, 2020 after serving the company for Secondary steel players continued to report on-year almost 36 years in various roles. decline in production for the 19th consecutive month “I have been associated with SAIL almost from the ended December. beginning of my career and have seen several ups India's steel making consists of two sectors; and downs traversed by the company... I was the integrated primary steel players contributing nearly Director Finance and then the Chairman during 55% and the secondary steel players comprising SAIL’s recent turnaround saga. SAIL emerged from the remaining 45%. The ratio isn’t the same as the the consecutive losses incurred since FY16 and industries clamber out of the pandemic-induced turned around,” Chaudhary told while replying to a contraction. question related to the most challenging phase of his The Economic Times career. 400 foundries in Coimbatore stop production On February 18, 2018 SAIL posted a standalone net over raw material price hike profit of Rs 43.16 crore for the October-December About 400 small and tiny foundries in the district quarter of 2017-18 fiscal, after remaining in losses remained silent as part of their indefinite strike to for several quarters back to back. draw the attention of the Centre to the spiralling Chaudhary further said in the last financial year price of raw materials since the last two months. 2019-20, SAIL became the largest steel producing The foundries, affiliated to the Coimbatore Tiny and company along with the largest miner of the steel Small Foundry Owners Association (COSMAFAN), making input materials. stopped production indefinitely, resulting in a loss of Rs 30 crores daily, its president Shiva “I want to see this glory touch new heights and I have Shanmughakumar said. full faith on the entire SAIL collective that it will take the Maharatna to newer heights,” the Chairman The increasing prices would not only affect the said. foundries but also related industries such as wet grinder, pump and motors, textiles and automobiles, At present, SAIL, under the Ministry of Steel, is the who are the large- scale customers of foundry country's largest steel maker having a total installed products, he said. The price increase was from 30 capacity of about 21 million tonne per annum to 55 per cent as compared to the period before the (MTPA). The company has set up a target to more lockdown due to the pandemic, he said. than double its capacity to 50 MTPA by 2030. The Economic Times Moreover, the hoarding by the traders creating artificial scarcity of the materials also contributed India’s crude steel output grows 3.5 percent to to the price hike, he said, adding that the entire over 9 million tonne in November industrial sector is seeking the intervention to the Centre to bring down the prices for its survival. India registered a growth of 3.5 per cent in crude The Economic Times steel production at 9.245 million tonne (MT) in November, according to World Steel Association. SAIL turnaround a challenging experience in The country had produced 8.933 MT crude steel 36-year-long career, says outgoing Chairman during the same month last year, the global industry The turnaround of SAIL from several quarters of body said in its latest report. losses was one of the most challenging experience, Crude steel production for the 64 countries reporting said Anil Kumar Chaudhary, the outgoing Chairman to the World Steel Association (worldsteel) was of the country's largest steel maker. The Chairman 158.261 MT in November 2020, a 6.6 per cent

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 21 IIM METAL NEWS increase compared to 148.417 MT in November a sharp plunge in demand for steel soon after the 2019. coronavirus pandemic and subsequent lockdowns “Due to the ongoing difficulties presented by the disrupted overall economic activities. COVID-19 pandemic, many of this month’s figures Adverse market conditions forced steelmakers to cut are estimates that may be revised with next month’s down their operations by up to 50 per cent in April. production update,” worldsteel said. According to There was a shortage of manpower as many workers the worldsteel data, China registered 8 per cent year- migrated to their native places amid the lockdown as on-year growth in steel output at 87.660 MT during well as limitations on the number of staff working at November 2020, compared to 81.191 MT in the an office or site after gradual unlocking. same period last year. The nationwide lockdown came into force in late The US production stood at 6.120 MT, down 13.7 March and the relaxations began in a phased manner per cent from 7.088 MT. Japan’s output slipped 5.9 only in June. While terming 2020 as a “catastrophe” per cent to 7.264 MT from 7.716 MT a year ago. for the steel industry, Indian Steel Association (ISA) South Korea’s steel production fell 2.4 per cent to Deputy Secretary-General Arnab Hazra said there 5.760 MT in the month under review, as compared to is a revival in demand now which will continue to 5.904 MT in the year-ago period. Germany's crude grow in 2021. steel output rose 14.8 per cent to 3.376 MT as against 2.941 MT. In 2019, the demand was around 100.2 million tonne (MT) and that will fall to 81 MT in 2020, he noted. Italy’s crude steel production was 2.049 MT in Helped by government spending and demand coming November 2020, up 3.2 per cent from 1.986 MT a from steel-intensive sectors, the overall steel demand year ago. France produced 1.149 MT of crude steel is expected to reach 100 MT in 2021. last month, 3.7 per cent lower from the year-ago period, while Spain’s steel production stood at 1.113 “Demand is clearly visible and going forward is MT, a rise of 11.2 per cent year-on-year. expected to become stronger which augurs well for the industry in 2021,” he said. With members in every major steel-producing country, Brussels-based worldsteel represents steel JSW Steel Joint Managing Director D Seshagiri Rao producers, national and regional steel industry said, 2020 is the worst year in the last 70 years and that associations, and steel research institutes. Its the unprecedented pandemic has had a devastating members represent around 85 per cent of global steel impact on the world economic growth. Even though production. the overall steel demand is expected to fall in The Economic Times 2020, the industry is experiencing improvement in realisation and margins, he added. Economic recovery, demand revival spark 2021 hopes for steel sector According to Rao, the company’s expansion plans and inorganic growth through acquisitions are Recovering economy, sprouting demand and expected to come to fruition by the end of March improving prices raise hopes for the country’s 2021 coinciding with a rebound in economic activity. battered steel sector as it steps into the new year after JSW Steel’s priority is to leverage the availability of pandemic-induced disruptions turned 2020 into a additional capacities to meet the incremental demand “disaster” for the industry. that would arise due to economic rebound to create As the sector experiences signs of better times, the value to stakeholders, he said. apex body of domestic steel makers, ISA, expects State-owned SAIL's Chairman Anil Kumar good days ahead and surely no more outbreak like Chaudhary said that from the third quarter of the that of coronavirus infections. ongoing fiscal, the market has started improving The Indian steel industry grappled with tough times and will continue to do better in the next fiscal year. in running their operations as well as witnessed The growth in the auto sector, infrastructure and

IIM METAL NEWS 22 Vol.23 No. 12 DECEMBER 2020 construction, white goods and agri equipment will JSW Steel gains as unit to acquire 31% stake in aid the steel demand in India, he said. Italy’s GSI Lucchini Electrosteel Steels Limited’s CEO Pankaj Malhan JSW Steel rose 1.25% to Rs 356.15 after the company said in the last few months since the lockdown was said its subsidiary entered into an agreement to lifted, things have improved and steel demand has acquire steel facilities at Piombino, Italy. started increasing as economic and manufacturing JSW Steel Italy, the company’s subsidiary, entered activity is starting to gain pace. He also said that into a share purchase agreement (SPA) dated 21 construction activity is also getting back to pre- December 2020 with Industrial Development COVID levels slowly and that the industry is bullish Corporation (IDC), South Africa, for acquisition on the price of steel for the next two quarters. of 30.73% share capital of GSI Lucchini for a Rashtriya Ispat Nigam Ltd (RINL) Chairman and cash consideration of 1 million euros. The balance Managing Director P K Rath said “the pace of 69.67% of GSI is held by JSW Steel Italy. GSI’s recovery of the market and surge in demand of steel manufacturing unit is located in Piombino, Tuscany in the third quarter has raised the hope of closing the Region in Italy. year on a better note. IDC is owned by the Government of South Africa JSPL Managing Director V R Sharma said the under the supervision of the Department of Trade passing year was globally one of the most challenging Industry and Competition. years for the industry as well as mankind due to the GSI is a producer of forged steel balls used in grinding COVID-19. mills with predominant application in mining Some steel companies scaled-down production of processing. GSI facilities are located within the their operations some had to close their plants, he premises of Piombino plant, providing easy access added. to export markets through the port of Piombino. The Economic Times Business Standard

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MEMBER NEWS

Prof. Dr. S. Ramesh Babu, Life member of the Indian Institute of Metals, an alumnus of IISc., Former Director, M.I.T., Aurangabad and Founder Director, “Top of the World” Centre for Excellence, Bangalore, became the first Indian to achieve a Century of records. Dr. Ramesh crowned two Inaugural World Records on December 11, 2020, as follows: • WR 91: FASTEST TIME TO POCKET 100 CARROM RING PAWNS BY TOP CUT THUMBING (Achieved in the maiden attempt, in just 4 Min. 41.12 Sec., at a striking speed of 25.8 pawns per minute) • WR 92: FASTEST STRETCHED ARM FIST PUNCHES BY A SENIOR CITIZEN (Achieved 178 punches in 30 sec. at a speed of 5.93 punches per second)

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 23 IIM METAL NEWS RECENT DEVELOPMENTS

Zebra stripes and other patterns on the skin of of New South Wales (UNSW) Sydney and their frozen metal alloys defy conventional metallurgy collaborators from the University of Auckland (the MacDiarmid Institute), RMIT, and UCLA used two- component metallic mixes, such as gallium-based alloys containing small amounts of bismuth. These alloys easily melt in one’s hand making experimental observation and control convenient. “We could observe the surface solidification process under an ordinary optical microscope and I was astonished when I first saw a solidification front on the liquid metal surface creating solid patterns behind it,” said Dr. Jianbo Tang, the leading author of the work. “You can imagine the scene of a glacier moving across the ocean surface, but everything seen under our microscope is metallic and microscopic.” Researchers from the University of New South Dr. Tang added. Wales (UNSW) Sydney discovered that diverse To see the finer details of the metallic glacier, electron types of patterns occur at the surface of solidified microscopy was used, and the researchers observed metal alloys. Zebra stripes, leopard dots, and other a kaleidoscope of highly ordered patterns including exotic patterns were observed under both optical and alternating stripes, curved fibers, dot arrays, and electron microscopy. some exotic stripe-dot hybrids. Surprisingly, the Pattern formation is a classic example of one of team found that, when these patterns are formed, nature's wonders that scientists have pondered for the abundance of the low-concentration element centuries. Around 1952, the famous mathematician bismuth at the surface region was much increased. Alan Turing (father of modern computers) came Such surface enrichment found in this study defies up with a conceptual model to explain the pattern conventional metallurgical understandings. formation process of a two-substance system. Such The researchers related the magic behind this newly patterns are also called Turing patterns thereafter. observed solidification phenomenon to the unique Pattern formation is also commonly adopted by surface structures of liquid metals and they also used manmade systems and this is especially true in the super computers to simulate the process. In their field of metallurgy. The sub-field of metallography computer simulations, the small-in-number bismuth specializes in the study of microscale patterns and atoms, seemingly moving around randomly in a sea compositions of metals and alloys. If you snap a of gallium atoms, were observed to accumulate at multi-component alloy apart and take a look at its the alloy surface. cross sections, there is a good chance that you will see “This previously ignored surface solidification alternating stripes or aligned spots of different metal phenomenon improves our fundamental components, just like a microscopic version of the understanding of liquid metal alloys and their phase patterns on the skin of a zebra or leopard. However, transition processes. In addition, this autonomous despite the ancient knowledge about the core of liquid surface process can be used as a patterning tool for metal alloys and their bulk solidification patterns, designing metallic structures and creating devices their surface pattern formation phenomenon has long for advanced applications in future electronics been overlooked until now. and optics.” said Prof. Kourosh Kalantar-Zadeh, a In a work published in the journal Nature corresponding author of the study. Nanotechnology, researchers from the University Source: ASM International

IIM METAL NEWS 24 Vol.23 No. 12 DECEMBER 2020 INFORMATION FROM INTERNATIONAL METALS STUDY GROUPS

LEAD AND ZINC MARKET FORECASTS Copper Supply The outlook for world demand & supply for lead and After a small decline of 0.2% in 2019, world copper zinc was presented during the ILZSG web- meetings mine production, adjusted for historical disruption held in October 2020. factors, was expected to decline by about 1.5% to 20.45 Mt in 2020 and then to recover by around Lead Usage 4.5% to 21.79 Mt in 2021. World refined production Global demand for refined lead was forecast to fall was expected to increase by about 1.6% in 2020 and by 6.5% to 11.39 Mt this year and to rise by 4.4% to 2021 to reach 24.52 Mt and 25.66 Mt respectively. 11.89 Mt in 2021. Copper Usage Lead Supply World apparent refined copper usage was expected The Group expected world refined lead supply to fall to remain essentially unchanged at 24.49 Mt in 2020 by 4.3% to 11.66 Mt in 2020. In 2021, a 3.6% rise to and to grow by about 1.1% to 24.75 Mt in 2021. 12.08 Mt was forecast. World Refined Copper Metal Balance World Refined Lead Balance World refined copper balance projections indicated The Group anticipated that the global supply of a deficit of about 50,000 t in 2020 and a surplus of refined lead would exceed demand by 276,000 t in about 70,000 t for 2021. 2020. In 2021, a further surplus of 192,000 t was expected. For further details, please contact Ana Rebelo at [email protected] Zinc Usage NICKEL MARKET FORECASTS World demand for refined zinc was forecast to fall by 5.3% to 12.98 Mt in 2020 and to rise by 4.2% to The INSG in its web-meetings on 12 and 13 October 13.52 Mt in 2021. developed its production and usage forecasts for world primary nickel. Zinc Supply Nickel Supply Global refined zinc production was forecast to increase by 0.9% to 13.60 Mt in 2020. In 2021, an World primary nickel production was 2.382 Mt in increase in world output of 2.9% to 13.99 Mt was 2019, and was forecast to reach 2.436 Mt in 2020 predicted. and 2.586 Mt in 2021. World Refined Zinc Metal Balance Nickel Usage The Group anticipated that global supply for refined World primary nickel usage was 2.403 Mt in 2019. zinc would exceed demand significantly in 2020 The INSG forecasted increases to 2.318 Mt in 2020 with the extent of the surplus forecast at 620,000 t. and 2.518 Mt in 2021. In 2021, supply was expected to continue to exceed demand resulting in a surplus of 463,000 t. World Primary Nickel Balance COPPER MARKET FORECASTS The Group anticipated surplus of 117 kt in 2020 and 68 kt in 2021. The world balance of refined copper production and usage was developed at the ICSG web-meetings held For further details, please contact Ricardo Ferreira in October 2020. at [email protected]

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 25 IIM METAL NEWS INSIGHTS AND ARTICLES PUBLISHED SELECTED STUDY GROUP PUBLICATIONS INSG 1. ILZSG World Zinc Factbook 2020  “Comment on the effect of the Covid-19 pandemic on the global nickel market” published in April 2020

 “Nickel: Key Contributors to Circular Economy” published in April 2020

 “An Analysis of the Economic Fallout of the COVID-19 Pandemic and Subsequent Stimulus Packages” published in April 2020.

 “An Overview of World Stainless Steel Scrap Trade in 2019” published in June 2020

 “The world nickel market in 2019 and first quarter of 2020 – from deficit to surplus”, published in 2. ICSG World Copper Factbook 2020 June 2020

 “The world nickel market in 2020 and 2021 – Covid-19 leading to surpluses”, published in December 2020”

ICSG

 “Impact of Lockdowns on Copper Fabrication and Recycled Copper Raw Materials” Published in May 2020

 “The Impact of the COVID-19 Pandemic on World Copper Supply” published in May 2020 3. Lead and Zinc: End Use Industry Statistical Supplement 2020  “The Impact of China´s Ban on Imports of Scrap on International Flow of Copper” prepared in 4. Lead and Zinc: National Trade Tariffs and response to a request from the ICSG delegation Measures 2021 from the United States. 5. ILZSG Lead and Zinc New Mine and Smelter Projects 2021  “The Use of Refined Copper and Scrap Directly 6. ILZSG World Directory of Lead and Zinc Melted in Intermediate Fabrication” prepared in Mines 2020 response to a request from the ICSG delegation from Poland. 7. ILZSG World Directory of Primary and Secondary Lead Plants 2020 Copies of these publications are available from the 8. ILZSG World Directory of Primary and Study Groups´ secretariats. Secondary Zinc Plants 2020

IIM METAL NEWS 26 Vol.23 No. 12 DECEMBER 2020 Metals Despatch 6 Jan. 2021 - No. 28

9.International ILZSG World Copper Lead Study Factbook Group (ICSG)2019

10.Mr PaulJoint White Study on Solid Wastes in Base Secretary-General Metal Mining, Smelting and Refining: A Ms Ana Rebelo DirectorComprehensive of Market Research Study andfor Statistics the Copper, Lead,

Mr CarlosZinc and Risopatron Nickel Industries 2019 ICSG Member States Director of Economics and Environment 11. Joint Study on Responsible Sourcing Mr Shairaz Ahmed Australia, Belgium, Brazil ManagerInitiatives of Statistical along Analysis the Minerals and Metals Chile, China, Democratic Republic of Congo,

Ms SupplyAna Paula Chains Calheiros 2019 European Union, Secretary Finland, France, Germany,

12.Tel: ICSG + 351 21Directory 351 3870 of Copper and Copper Alloy India, Iran, Fax:Fabricators + 351 21 352 (First 4035 Use) – December 2020 Italy, Japan, Luxembourg e-mail: [email protected] Mexico, Mongolia, Peru, Poland, 13.Website: ICSG www.icsg.org Directory of Copper Mines and Plants - Portugal, Russian Federation, August 2020 Serbia, Spain, 14.International ICSG Statistical Lead & ZincYearbook Study 2020 Group (ILZSG) Sweden, United States  Mr Paul White 15.Secretary ICSG- GeneralEuropean Semi-Manufactured Copper

Mr JoaoProduct Jorge Capacity 2019 Director of Market Research and Statistics 16. ICSG Smelting and Hydrometallurgy Mr Jianbin Meng DirectorTreatment of Economics for Copperand Environment Sulphide Ores and

Mr. ConcentratesJuan Luis Mamani 2019 Rodriguez Manager of Statistical Analysis

17.Ms NickelInês Lopes Production and Usage in Indonesia ILZSG Member States Secretary 2020 Tel: + 351 21 359 2420 Australia, Belgium, Brazil, 18.Fax: INSG + 351 World21 359 2429Directory of Nickel Production Bulgaria, China, European Union, e-mail:Facilities [email protected] 2020 Finland, France, Germany, India, Website: www.ilzsg.org Iran, Ireland, Italy, Japan, 19. INSG World Nickel Statistics Yearbook 2020 Republic of Korea, Mexico, Morocco, 20.International INSG Report Nickel on Study the Use Group of Nickel (INSG) in Batteries Namibia, Netherlands, Norway, Peru, Poland, Portugal, Mr Paul2018 White Secretary-General Russian Federation, Serbia, Sweden, Turkey, United States 21.Mr RicardoICSG Market Ferreira Study on Industrial Use of DirectorCopper of Market in Japan, Research Korean and Statistics Republic, Taiwan

Mr Jianbin(China) Meng and Vietnam 2018 Director of Economics and Environment

22.Mr FranciscoINSG World Pinto Nickel Factbook 2018 Manager of Statistical Analysis

23.Ms ILZSGInês Lopes Market Research Zinc Chemicals Secretary2017

Tel: + 351 21 356 7030 24. ILZSG Market for Zinc 2017 INSG Member States Fax: + 351 21 356 7039 e-mail: [email protected] 25.Website: ILZSG www.insg.org Study on the Main End Use Markets Australia, Brazil, Cuba, for Lead and Zinc in Europe 2017 European Union, Finland, France, Germany, 26.Common Joint SecreStudyt aonriat Social Address Acceptance of Mining Italy, Japan, Norway, Rua Almirante Barroso 38, 5-6 Floors Portugal, Russian Federation, 10002016-013 Lisbon Portugal Sweden, United Kingdom For further details, please refer to the Study Groups´ websites. - Received from L. Pugazhenthy, Former President, IIM

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Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 27 IIM METAL NEWS IIM CHAPTER ACTIVITIES

Bangalore Chapter importance of Al-alloy as material of high efficiency but the pros and cons if recycle Al is used. He 1) The Indian Institute of Metals, Bangalore presented an overview of some of the corrosion and Chapter has conducted a webinar on “Challenges in surface engineering aspects with his R&D effort at Qualifying Additive Manufacturing for Aerospace the Institute in achieving the glossy appearance or Applications” on Friday, 16th October, 2020. The optical properties without compromise in mechanical On-line technical talk was delivered by Dr Dheepa properties. The talk has triggered lot of questions by Srinivasan, Chief Engineer, Pratt and Whitney R&D the practising Engineers and the speaker cleared all Center, Bangalore. their doubts. The lecture was attended by more than The web talk was attended by more than 30 40 participants from India and Overseas. participants from aerospace, automotive and general 3) National Workshop on New Horizons in engineering industries apart from IIM members. Dr Metallurgy, Materials and Manufacturing : Dheepa Srinivasan dealt in detail on the advanced manufacturing methods and compared with the The Indian Institute of Metals Bangalore Chapter traditional manufacturing methods. Based on her conducted a three days long National Workshop hands-on experience with GE-A in the development on ‘New Horizons in Metallurgy, Materials and of some of the 3D printed parts, she could demonstrate Manufacturing’, from 14th to 16th December 2020. to the participants that through this process it is This workshop was conducted through online possible to design parts, systems and shapes, once platform with live streaming of the seminars on thought impossible to make. It also allows complex youtube. The event commenced with the inaugural design geometries in making products lighter, address by Dr. Amol Gokhale, President IIM and stronger and more efficient thereby revolutionising Professor, IIT Bombay. Lectures were delivered by products in many industries. distinguished speakers from academia, industry and research organizations, on 14 topics in the fields of 2) IIM Bangalore Chapter organised an On-line metallurgy, materials and manufacturing. Technical talk on “Light Aluminium Alloys as Sustainable Material : Issues and Solutions” on 21st Audience/attendees participated enthusiastically November, 2020 at 5pm. The lecture was delivered during the question and answer sessions. The by Dr. Rajan Ambat, Professor in Corrosion and workshop was organised and sessions were moderated Surface Engineering, Department of Mechanical by Dr. Amber Shrivastava (IIT Bombay), Dr. Amit Engineering, Technical University of Denmark, Arora (IIT Gandhinagar), Dr. Chandan Srivastava (IISc Bangalore), Dr. Nikhil Dhawan (IIT Roorkee) Lyngby, Denmark. and Dr. Sudhanshu Shekhar Singh (IIT Kanpur). The Dr. Ambat has carried out extensive research work wide variety of topics attracted strong participation. in the area of Light Aluminium Alloys in the last 15 More than 1000 people registered for this event, years. From the economic consideration standpoint, including students and teachers from universities, recycled scrap plays an important role in making use scientists/researchers from research organizations of the full potential of Al-alloys as alternate material and professionals from various industries. The being lightweight especially in the Automotive feedback received from the speakers and attendees sector. He has thrown light on the role and control expressed their appreciation for the workshop and of impurity elements such as Fe and Si present in interest towards such events in future. The event Al-alloys in the subsequent surface protection such concluded with the summary and appreciation note as anodisation process. He has brought out the from Dr. Chandan Srivastava, IISc Bangalore.

IIM METAL NEWS 28 Vol.23 No. 12 DECEMBER 2020 The seminar topics and speakers are as follows: Sr. Topic Speaker 1 Advanced characterization and Calphad in design and Dr. R. Veerababu (DMRL) development of advanced high strength steels 2 Correlative electron microscopy and atom probe Dr. Surendra Kumar Makineni (IISc) tomography (EM/APT): Experimental techniques and its applications 3 Additive Manufacturing: Bringing a Paradigm Shift Dr. CP Paul (RRCAT) 4 Multiscale modeling in arc welding using secondary Dr. G. Phanikumar thermal cycle 5 Past Decade of Advances in Indian Steel Industry Dr. Siddhartha Misra (Tata-Bhushan) 6 Sustainability of Nonferrous Metal Industry: Challenges Dr. Vilas Tathavadkar (Aditya Birla) and opportunities 7 Material Recycling: Unearthing metals from Dr. Pratima Meshram (NML) anthropogenic and industrial resources 8 Process Development and Stability Modeling of High- Dr. Ramesh Kumar Singh (IITB) speed Micromachining 9 Materials degradation and its mitigation: Metallic Dr. S. Parida (IITB) materials 10 New Frontiers in Biomaterials Dr. Kantesh Balani (IITK) 11 Chemical sensing through modified graphene Dr. Abha Misra (IISc) 12 Fermentation derived cellulose (Bacterial Cellulose) Dr. Mudrika Khandelwal (IITH) for healthcare and environment 13 Composite Materials: An Overview and Recent Dr. Rakesh K. Gautam (BHU) Advances 14 An Odyssey from High Entropy Alloys to Complex Dr. Krishanu Biswas (IITK) Concentrated Alloys

Inaugural address by Prof. Amol A Gokhale, President, IIM

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 29 IIM METAL NEWS 4) On 23rd December, 2020 IIM Bangalore Chapter part of this memorial programme. This was followed organised a webinar. It was delivered by Prof. Ketul by the address of Dr. Shaju. K. Albert, Chairman C. Popat, Biomaterials and Surface Micro/Nano- PRML committee, in which he recalled Dr. Placid engineering Laboratory, Department of Mechanical Rodriguez’s multifarious contributions as an Engineering/School of Biomedical Engineering/ institution builder, a mentor who nurtured multiple School of Advanced Materials Discovery, Colorado generations of materials scientists, and his humane State University, Fort Collins CO, USA. He spoke approach which won many hearts. Dr. Divakar R., on “Micro/nano engineering of material surfaces Chairman, IIM Kalpakkam Chapter, introduced the for tissue engineering and regenerative medicine”. PRML 2020 speaker Dr. Surya R. Kalidindi, Regents He stressed the relevance of study of Biology in the Professor, Novelis Innovation Hub, Georgia Institute engineering curriculum for Engineers that could be of Technology, USA. useful in their professional career in the development of product. In his presentation he focused on using the At the outset, Dr. Surya Kalidindi paid homage to tools of micro-and-nano technology for applications Dr. Placid Rodriguez and shared his thoughts on the in biomaterials and tissue engineering. The objective inspiration he drew from the seminal work of Dr. of his research work is to design in-plants that induce Rodriguez on the plastic deformation of metal alloys controlled, guided and rapid healing. Further, he subjected to a broad range of loading conditions emphasized the use of well controlled nanostructured and extreme environments. In his lecture titled interfaces to enhance in-plant integration. He also “Accelerated Materials Innovation using Knowledge stressed the relevance of understanding physical Systems and High Throughput Experiments”, he surface parameters that influence cellular adhesion dwelt on the core knowledge needed to support and differentiation in the design of engineered accelerated materials innovation, in the form materials. The talk was attended by more than 50 of PSP (process-structure-property) linkages participants and is readily available on YouTube. The formulated at various material length/structure participants from different disciplines like physics, scales. Towards accelerating materials exploration material science, biology, biomedical engineering, and discovery, the Speaker highlighted the strategies mechanical and chemical engineering have attended involving synergistic use of data analytic tools in this lecture. conjunction with the established toolsets such as physics-based multiscale materials modeling tools, Kalpakkam and Chennai Chapters : Dr Placid multiresolution materials structure and response Rodriguez Memorial Lecture 2020 characterization protocols. As an example, the Speaker presented novel data analyses protocols of The Twelfth Placid Rodriguez Memorial Lecture spherical nanoindentation for stress-strain response (PRML) was organised on 29th October 2020 jointly of individual phases of dual phase steel as well as the by Kalpakkam and Chennai Chapters of the Indian bulk response. He concluded the lecture by stressing Institute of Metals. The programme was held online that advanced robotics, virtual and mixed reality, and by video conferencing through Webex platform as human–machine interfaces is already a reality for well as YouTube streaming. optimization of process parameter and manufacture Dr. T. Sundararajan, Chairman, IIM Chennai chapter of advanced alloys. welcomed the gathering. Dr. M. Kamaraj, Member, The lecture was well received by over 70 participants PRML Committee, briefly dwelt upon the genesis by engaging in discussions and interactions with the of Dr. Placid Rodriguez Memorial lecture. He speaker. Dr. Shaju. K. Albert presented an e-memento also presented the details of the series of lectures to Dr. Surya Kalidindi and the programme concluded conducted since 2009. The Chief Guest, Dr. V. with a vote of thanks by Dr. Rani P. George, Convener, Jagadeesh Kumar, Dean (Academic) IIT Madras, in PRML 2020. his address, recollected the humanistic side of Dr. Placid Rodriguez and expressed his pleasure to be a - Report from IIM Kalpakkam Chapter

IIM METAL NEWS 30 Vol.23 No. 12 DECEMBER 2020 Jaipur Chapter Kumar Vijayavergia, Consultant, Steel Research & Technology Mission of India, New Delhi delivered The Indian Institute of Metals, Jaipur Chapter the 2nd lecture. and Malaviya National Institute of Technology Jaipur, Department of Metallurgical & Materials Kolkata Chapter Engineering, jointly organised two Expert lecture The EC meeting of the IIM Kolkata Chapter was held on 17th October and 21st November, 2020 on on November 21, 2020. The meeting started with the the topic “Synthesis of Light Alloy Materials Technical Talk delivered by the Former Chairman into near net / net shapes via Powder Metallurgy of Kolkata Chapter Prof. Siddhartha Mukherjee on route” and “Carbon Dioxide reduction in Iron & ‘Nano Composites & unique Advanced Materials’. Steel Making” respectively. The first lecture was The lecture continued for an hour. The winner delivered by Dr. Vijay Navaratna Nadakuduru, of Essay/Elocution contest of BPMME 2020 at Assistant Professor, Department of Metallurgical Kalpakkam, Sri Aryaman Chowdhury of Birla and Materials Engineering, Malaviya National High School from the IIM Kolkata Chapter was Institute of Technology, Jaipur while Mr. Rajesh congratulated.

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OBITUARY

Shri S K Basu, Hon. Secretary, IIM Kolkata Chapter, left for his heavenly abode on December 31, 2020. He was a Life Member of the Indian Institute of Metals since 1989. He served the IIM Kolkata Chapter as the Honorary Treasurer for 10 years from 2005 to 2014 and later as Honorary Secretary for 6 years from 2014-2020. He has been awarded the IIM Distinguished Service Award in the year 2019 in recognition of his prolonged and dedicated services provided to The Indian Institute of Metals, Kolkata Chapter, Dec 9, 1943 - Dec 31, 2020 at various capacities. Earlier he worked in SAIL ASP and superannuated as AGM I/C Blooming and Billet Mills in 2003. He was a member of the Executive Committee of Steel Executive Federation of India (SEFI) from 1997-2002. IIM Kolkata Chapter is deeply indebted to his contributions to the Metallurgical society.

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ADVERTISERS’ INDEX Name of the Organizations Page No. JSW Steel Ltd Cover Durgapur Steel Plant 5 Nuclear Fuel Complex 3rd Cover Chennai Metco Pvt Ltd 4th Cover

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 31 IIM METAL NEWS CONFERMENT OF IIM HONORARY & FELLOW MEMBERSHIP 2020

Metallurgy Materials Engineering

Sr. No. Category Awardee Designation

1 IIM Honorary Membership Dr. U Kamachi Mudali President, IIM [2019-20]

2 IIM Honorary Membership Prof. JÃoeRGEN Director of the Erich Schmid Institute ECKERT of Materials Science of the Austrian Academy of Sciences, Leoben and Full Professor (Chair) 3 IIM Honorary Membership Mr.V. Babu Sathian Founder and Managing Director, M/s. Process Pumps (I) Pvt. Ltd. M/S Cathodic Control Company Pvt. Ltd., and Founder M/s Allcast Industries 4 IIM Honorary Membership Mr.J D Patil Whole-time Director, and Senior Executive Vice President for L&T’s Defence Business and New Age Smart Technology businesses (Smart & Safe Cities & Communication, and L&T NxT)

Sr. No. Category Awardee Designation

1 IIM Fellow Membership Dr. Raghavan Gopalan Regional Director, ARCI (Autonomous Institute under Dept. of Science & Technology) Hyderabad/ Chennai 2 IIM Fellow Membership Prof. Narendra B Dhokey Professor, College of Engineering, Pune 3 IIM Fellow Membership Mr. Sanjay Chandra Chief of Research and Development, TSL 4 IIM Fellow Membership Dr. Amit Bhattacharjee Scientist ‘G’, DMRL, Hyderabad

5 IIM Fellow Membership Dr. Sundararajan Head, Research and Development, Thiyagarajan Wheels India Ltd 6 IIM Fellow Membership Prof. Govind S. Gupta Professor, Dept. of Metallurgy, IISC Bangalore 7 IIM Fellow Membership Dr. (Mrs.) N.C. Santhi Professor, Department of Metallurgical Srinivas Engineering, Indian Institute of Technology (Banaras Hindu University), Varanasi

IIM METAL NEWS 32 Vol.23 No. 12 DECEMBER 2020 CRUDE STEEL PRODUCTION

Crude Steel Production ( December 2020 )

Country in million tonne Country in million tonne World 160.9 Poland 0.7 China 91.3 Netherlands 0.5 India 9.8 Austria 0.5 Japan 7.5 Australia 0.5 United States 6.4 Saudi Arabia 0.4 Russia 6.1 Sweden 0.4 South Korea 6.0 Thailand 0.4 Turkey 3.4 Czech Republic 0.4 Germany 3.1 Argentina 0.4 Brazil 2.9 Pakistan 0.4 Iran 2.7 Belgium 0.4 Ukraine 1.9 Kazakhstan 0.4 Taiwan, China 1.7 Finland 0.3 Vietnam 1.6 South Africa 0.3 Mexico 1.6 United Arab Emirates 0.3 Italy 1.5 Belarus 0.2 France 1.2 Serbia 0.1 Canada 1.1 Luxembourg 0.1 Egypt 1.0 Colombia 0.1 Spain 0.9 Greece 0.1 United Kingdom 0.7 Chile 0.1 Others 0.7 Peru 0.1 Source : WSA

Recovery Phase of Crude Steel Production during COVID-19 ( in million tonne ) Mar’20 Apr’20 May’20 Jun’20 Jul’20 Aug’20 Sep’20 Oct’20 Nov’20 Dec’20 2019 2018 World 147.0 136.2 148.6 149.5 156.1 159.0 157.3 161.5 156.9 160.9 1869 1814 China 79.0 85.0 92.2 91.6 93.4 94.8 92.6 92.2 87.7 91.3 996.3 920.0 India 8.1 3.3 6.3 7.7 8.7 8.9 8.5 9.1 9.5 9.8 111.2 109.3 Japan 7.9 6.6 5.9 5.6 6.0 6.4 6.5 7.2 7.3 7.5 99.3 104.3 USA 7.0 4.8 4.9 4.9 5.4 5.9 5.7 6.1 6.3 6.4 87.9 86.6 Source : WSA

Vol.23 No. 12 DECEMBER 2020 Vol.23 No. 12 DECEMBER 2020 33 IIM METAL NEWS NON-FERROUS METALS STATISTICS

Production ( unit : Metric Tonne )

Dec’20 Nov’20 Oct’20 2019 - 20 2018 - 19 ALUMINIUM National Aluminium Co Ltd 36,022 33,476 32,635 4,18,373 4,40,242 Hindalco Industries Ltd 1,07,530 1,02,747 1,04,889 13,11,849 12,94,502 Bharat Aluminium Co. Ltd 49,225 47,550 49,183 5,63,313 5,71,814 Vedanta Ltd 1,25,919 1,12,437 1,11,969 13,62,595 13,87,784 TOTAL 3,18,696 2,96,210 2,98,676 36,56,130 36,94,342

ZINC (One major producer) Hindustan Zinc Ltd 61,090 58,475 62,796 6,88,286 6,96,283

COPPER (Cathode) Hindustan Copper Ltd 0*** 0*** 0*** 5,340 16,215 Hindalco (Birla Copper) 18,007 15,794 17,560 3,25,568 3,17,600 Vedanta Ltd. 4,125 8,559 12,229 77,490 4,03,168 TOTAL 22,132 24,353 29,789 4,08,398 7,36,983 *** Metal-in-Concentrate (MIC) produced from ore in HCL is partially converted into refined copper & balance is directly sold in the market.

LEAD (One major producer) Hindustan Zinc Ltd 20,897 14,383 17,181 1,81,370 1,97,838 Source : https://mines.gov.in/

Prices in India ( as on 26th December, 2020 ) ( Mumbai Local Price in Rs. / kg )

Product Rs. / kg Product Rs. / kg Copper Armature 535 Brass Shell 40mm 463.04 Copper cathod LME ++ 616 Aluminium 6063 scrap Not available CC Rod LME ++ 619 Aluminium scrap Taint/Tabor do Copper Cable scrap 550 Aluminium Cable scrap do Copper shell 40mm 576 Aluminium Ingot 170 Electrolytic Copper strip 25mm 571 Aluminium utensil scrap 134 ACR Copper Coil 3/8 635 Zinc Slab 224 Brass Sheet scrap 412 Lead ingot 159 Brass Pales scrap Not available Tin Slab 1555 Brass Pallu scrap do Nickel Cathod 1305 Brass Honey scrap 345 Source : http://www.mtlexs.com/

IIM METAL NEWS 34 Vol.23 No. 12 DECEMBER 2020