ABOUT THE COURSE:This course will provide knowledge and background on how components used in energy generation facilities are manufactured. Course will deal with material selection and manufacturing process selection for gas turbines, steam turbines, hydro turbines and wind turbines. Students opting for this course will be get the basic as well as state of the art knowledge on these topics.INTENDED AUDIENCE: UG (mechanical, production, metallurgy)PREREQUISITES: Basic manufacturing processesINDUSTRY SUPPORT: GE,Simens,LM Wind ,BHEL,Airbus
Overview
Syllabus
Week 1: Introduction, manufacturing concepts and classification of engineering materials Week 2:Selection of materials and manufacturing processes, manufacturability of materials, materials vs. manufacturing processes Week 3:Manufacturing of gas turbines, selection of materials, properties of superalloys, process requirements, Week 4:Manufacturing of gas turbines: Casting processes- investment casting, single crystal casting, hot isosttic pressing (HIP), laser beam machining (LBM), creep feed grinding (CFG), thermal barrier coating (TBC)Week 5:Manufacturing of steam turbines: Steam turbine material requirements, Casting (Investment casting process), Deformation (Rolling), Laser metal direct fabrication, Machining (CNC milling, drilling or advanced machining)Week 6:Manufacturing of hydro turbines: Challenges in material selection for hydroturbines, Casting (Dry sand casting process) Deformation (Rolling), Machining (CNC milling, drilling or advanced machining) Surface modification (for corrosion and erosion resistance) using thermal spary methods.Week 7:Manufacturing of wind turbines: Material constraints for wind turbine blades, Composite materials and their classification, glass fibers and carbon fibers along their manufacturingWeek 8:Manufacturing of wind turbines: Hand-lay up Spray up, Vacuum bag molding (VBM), Vacuum infusion process (VIP), RTM processing and its variants, Prepreg, Out of autoclave processing routes, testing and quality assurance.
Taught by
Prof. Sunny Zafar
