In a significant academic achievement, Amrita Vishwa Vidyapeetham, a renowned academic institution, has secured funding for an ambitious project aimed at enhancing the durability of steel tubes in extreme industrial environments. The project, titled "Synthesis and Characterization of Ceramic Layered Steel Tube Using Centrifuge Thermite Process for High-Temperature Applications," is led by Dr. N. Radhika, Professor at Amrita School of Engineering, Coimbatore, in collaboration with her co-investigators Dr. M. Ramu and Dr. M. Sathishkumar M, both from ASE Coimbatore and ASE Chennai, respectively.
The project is funded by the Department of Science & Technology through its Science and Engineering Research Board, reflecting the critical importance of the research in advancing industrial materials science.
Steel tubes are a cornerstone in various industries, from power generation to chemical processing, mining, and metallurgy. These industries often require materials that can withstand harsh conditions such as high temperatures, corrosion, and abrasion. The steel tubes in use today are susceptible to significant wear and tear due to these extreme factors, leading to frequent maintenance needs and short lifespans.
This new project focuses on developing ceramic-coated steel tubes capable of enduring such extreme conditions. By using ceramic coatings, the steel tubes will see an improvement in their wear and corrosion resistance, offering industries a more reliable and durable solution for their high-temperature applications.
The research team employs an innovative technique known as the centrifuge thermite process to create the ceramic coatings on steel tubes. This method utilizes a thermite reaction, which involves mixing iron oxide and aluminum and igniting the mixture using an oxy-acetylene torch. This highly exothermic reaction generates the necessary high temperatures to create the ceramic coating.
Once the reaction occurs, centrifugal force is used to deposit the ceramic coating on the inner surface of steel tubes. The result is a dense, homogeneous ceramic lining that is crucial for applications where steel is subjected to erosive, corrosive, and high-temperature environments. This method stands out from traditional techniques, allowing for thicker and denser coatings, which are more resilient to wear and corrosion.
The expected outcomes of this project are substantial for a variety of industries. First and foremost, the team aims to produce steel tubes with thicker ceramic coatings that provide enhanced resistance to abrasion and corrosion compared to conventional methods. These coatings will help extend the lifespan of industrial tubes and equipment, reduce maintenance costs, and improve the overall efficiency of operations.
The project's innovations could impact industries that rely on steel tubes exposed to extreme conditions, such as:
• Petrochemical Industry: Steel tubes used in refining processes can withstand high temperatures and corrosive chemicals.
• Marine Applications: Steel structures used in marine environments require coatings to protect against saltwater corrosion.
• Cement Production: Equipment in cement factories is exposed to high heat and abrasive materials, necessitating durable coatings.
• Sewage Treatment: Steel pipes used in sewage treatment plants must endure harsh, corrosive environments.
These industries will directly benefit from the longer lifespan and reduced maintenance costs of the ceramic-coated steel tubes.
The collaboration between Amrita School of Engineering campuses in Coimbatore and Chennai brings together diverse expertise in materials science and engineering. This interdisciplinary approach ensures that the project’s outcomes will be impactful for both academia and industries alike.
The support from the Department of Science & Technology’s SERB has further bolstered the credibility of the research, highlighting the project's potential to contribute to sustainable and cost-effective solutions in industrial sectors. The grant underscores the importance of developing advanced materials that can meet the growing demands of high-temperature, high-stress applications.
