Mete 400 - Department Of Metallurgical And Materials Engineering

Transcription

Summer Practice METE 400 Fall 2012/2013
Masoud Karim Beigli Kamran
Akdas Casting Ind. Trade Co.
Prof.Dr.Yavuz TOPKAYA
Akdaş Casting and Trade Company was founded in 1982 starting 500 tons/year capacity. After 30 successful years, now it has 2 smeltries, 2 processing factories and a welding construction factory at Sincan Organize
Sanayi Bölgesi in Ankara. The foundation has 36000 m2 closed area, total area is 60000 m2. Akdaş Casting has 70 tons at a time capacity and 25000 tons per year. It produces low and high carbon alloyed steels, corrosionresistant Mn steel, stainless steel, pig iron, grey iron casting.
Akdas has been manufacturing products in 7 major areas:
Automotive, Cement & Soil, Energy, Machinery, Mining &Crushing, Offshore & Marine, Steel Works
Contact: +90 312 267 18 80
•
Molding
Pattern is the physical model of
the casting part and it is made from
wood ,polymeric material and
aluminum. There is a part in factory
called Modelhane which the models is
made there..
Melting and Pouring
AKDAS uses induction furnaces ,
Inductotherm branded and there is a capacity of
45 tones at once . The site of melting is a special
part of factory designed for this action and there
are some horizontal cranes transfering the
molten metal to pouring area.In Akdas foundry 2,
the furnaces are at the capacities ;
10tones, 2x9tones, 3tones, 5tones and
2x1.5tones.
[email protected]
Heat Treatment
I have observed something related to
annealing and heat treatment in METE403 at the
summer school and that was a big opportunity that
I could see this treatment in details. Heat Treatment
is a group of industrial and metalworking processes used
to alter the physical, and sometimes chemical, properties
of a material.
The available processes in AKDAS are,,
normalizing, stress relieving, tempering,
selective hardening, differential hardening, and
quenching.
Quality Control
AKDAS controls the quality of its products in many
ways for having the best level of quality and confidence :
•
There is a great laboratory including a lot of testing
machines like tensile test,compression test , Charpy
impact test. The results are printed and sent to
customers.
•
Beside the Lab, the firm has Ultrasonic Test, Magnetic
Particle Test, Liquid Penetrant Test units in the factory.
Figure1: pattern
•
•
At the second part the core is made
usually from sand and placed into a
mold cavity, so the free space between
the core and mold-cavity surface is
what eventually becomes the casting.
Finally,the molding box is prepared and
it consists of all operations necessary
to prepare a mold for receiving molten
metal.
Figure4:TTT-diagram
Figure6: Magnetic Particle Testing
Figure2: Molten metal in the pot
References
Figure5: A product is taken from furnace
Figure3: Induction Furnace
1.
www.akdas.com.tr
2.
www.ndt-ed.org
3.
Callister, W.D. (2007). Materials Science and Engineering
4.
www.industrialmetalcasting.com
DOĞUKAN GÜR
EKSTRAMETAL Casting and Machine Industry
Prof. Dr. Amdulla Mekhrabov
EKSTRAMETAL is one of the well known companies in the field of grey and nodular cast iron parts production and
machining of them mainly for the tractors, wind mill energy systems, railway industry, construction, machine
manufacturing, ship building and hydraulic industry.
PRODUCTS: GREY CAST IRON, NODULAR CAST IRON
Güner Uğraş
Phone : +90 312 267 05 56
+90 312 267 05 59
E-mail : [email protected]
Processes:Melting,Core Making , Moulding , Laboratory , The Pattern Shop
Week 1
Week 2
Week 3
Week 4
On the first week of the summer
training, certain amount of time was
spent on the melting process ,usage of
thermocouples ,preparing specimens
for laboratory and Casting.
On the second week, Moulding room and
core room are visited. we see how cores
are produced by different methods and
observe the moulding procedure.
On the third week we observe the non
destructive testing methods for 3 days and
after these observations we perform two of
them for 2 days. Which are Ultrasound
Testing and Magnetic Testing.
The last week we operate in the laboratory of the
foundry in order to determine strength,
composition, impact response, hardness and
microstructure of the specimens.
These operations are done in the laboratory.
Mechanical Testing
•impact testing
•tensile test
•indentation
Spectrometry
Metallography
An addition to these tests we are also make the
regular test for mould sand.
For the melting process:
Examples for
types of cores
in Ekstrametal.
•We put pig in to the furnace
•We put scrap (steel) after that
•We put Carbon into the furnace
•We put runner into the furnace
•We put any other element ( such as
molybdenum, S, Cu
,Mangan,magnesium)
a) Melting
b) Preparing Specimen for
Laboratary
c)Casting
There are many types of cores The selection
of the correct type is depends on :
•production quantity,
•production rate,
•required precision,
•required surface finish,
•type of metal being used,
Moulding process
Moulds are used
for keeping liquid
metal till
solidification is
done. Wrongly
designed mould
can cause:
•Cracks,
•Voids,
•Irreversible
problems,
Representation of
Ultrasonic test
(UV).
Ultrasonic test is used for detecting
internal flaws or to characterize materials
and also used for measuring the thickness
of materials. Advantages of UT:
•High penetrating power
•High sensitivity
•Greater accuracy
•Estimating size , shape and orientation of
the defect
Computer aided
Brinell Hardness
machine is used
for measuring the
hardness of the
specimens that
are casted.
Spectrometry is used for
calculating the composition
of the specimens.
Specimens come from
induction furnaces to give
appropriate feedbacks.
Representation of
magnetic testing
Magnetic test is used only for materials that
have good magnetic properties.
Steps of magnetic test:
•Applying Ultra violet light to material
•Applying the magnetic penentrant
•Applying the magnetic flux
•Observing discontinuities
.
Spectrometry
Brinell Hardness
machine
Metallography is the most important
examination in the laboratory. We can
observe the manufacturing processes and
even sometimes its composition.
Grinding and polishing machine
References:
1:http://www.ekstrametal.com
2:http://www.ndt/ed.org
.
Mehmet Orhan TAŞ
Medaş Casting Machinery Industry and Trade Inc.
Prof. Dr. Rıza Gürbüz
MEDAŞ Casting has been established in February 2007 in Ankara. The company has a foundry in 9000 m2 open, 7000 m2 closed, a total of 16000 m2 area, the production rate has been
planed as 1500 tons/monthly production capacity with the variety of 1kg up to 9000kg single pc casting capacity. Production is taking place with continues plc controlling mixers with
the resin type of moulding.
PRODUCTS: • CAST IRON • Cr-Ni STEELS • NODULAR CAST IRON • Ni HARD – Ni RESIST STEELS • ALL TYPES OF CARBON STEELS
• TOOL STEELS • Mn-STEELS • STAINLESS STEELS • Cr-STEELS • LOW ALLOYED STEELS
GENERAL MANAGER : EMRAH ATAÇ
Tel: 0533 654 15 17 email: [email protected]
Week 1
Week 2
Week 3
Week 4
training, certain amount of time
was spent on the production line.
Melting and casting processes
observed in detail.
On the second week, patternshop and
foundary
facilities
were
visited,
working on the field, more idea was
gained about the process flow in the
company.
In the labrotary, certain test were done on
the products in order to understand more
about the mechanical properties of the
finished products. Medas has its own lab
equipments, however for NDT analysis,
they use the Government Place
(KOSGEB)
The last week was spent in the heat treatment
facility and computer simulation labs. In the
heat treatment facility different processes are
taking place in order to fulfill the claimed
mechanical properties by the customers. These
processes are;
Furnaces:
•Type:
Melt & hold type induction furnaces
Laboratory:
•Melt Capacity : 2 laddles each with 5 tones
capacity
(totaly 10 tones)
- Tempering
• Mechanical Testing
4tones /hr
- Austenizing
- Impact test
- Homogenizing
- Tensile test
Most of the mechanical properties are controlled
by applying these processes.
- Hardness test
• Spectrometry
• Metallography
• Spectrometer : Spectro type specromaxxm (nitrogen
channel- 0.002%-0.4%sensıtıve)
Moulding system
•Mixer type :
• Portable Hardness Measurement Unit : Hartip 3000
type 200-960hld measurıng level wıth sensıtıve %
0.5
done with plc
controlled
continuos mixers
• Inverted Metallurgical Microscope
enlargement capasity
•Mixer capacity :
1 qnt 20tones/hr
1 qnt 3tones/hr
: 100x & 1250x
• Sample polisher : Double disk d:200mmx250mm ;
100-500rpm
Image 2 – Moulding Facility
Image 4 – Some of the Products
In MEDAŞ, for modeling “Solidworks” and for transport
simulations “Nova Flow” are used. It is also possible
to see the flow speed of the liquid, the thermal
modulus and temperature at an arbitrary point during
the simulation run on Nova Flow. Also the simulation
can be paced up or slowed down in order to obtain
optimum flow velocity.
• Charpy Test Machine : Model fit 300 en
12tones/hr
• Mechenical Test Machine (%elg) : 5 tones capasity
(model: tst-5t)
•Sand system:
alpha-set
resin
sand system
Image 3- Employee taking hardness values of a
finished product
Labratory Equipment:
Image 1 – Induction Furnaces
•Reclamation unit :
- Quenching
Figure 1 – The Flow Chart of a Casting Process
• Magnetic Test : Sentinel - mpa2l
• Ultrasonic Test : Goverment place (kosgeb)
References:
[1] www.medasdokum.com
[2] Provided Company Documents on paper
[3] Met E 302 Principles of Solidification Lecture Notes by Ali Kalkanlı
Medaş Casting Machinery Industry and Trade Inc.
Cemre Çiftçi
Prof. Dr. Cevdet Kaynak
MEDAŞ Casting & Machinery, established in 2007 in Ankara.
PRODUCTS
The company has9000 m2 open, 7000 m2 closed, a total of
• CAST IRON
16000 m2 area. the production rate 1500 tons/monthly capacity :
• Cr-Ni STEELS • Mn-STEELS • Cr-STEELS • Cr-STEELS • TOOL STEELS
with the variety of 1kg up to 9000kg single pc casting capacity.
• ALL TYPES OF LOW ALLOYED STEELS
PRODUCTION PROCESSES
MELTING
FURNACES
.
• Melt & hold type induction furnaces are used
• Melt Capacity : 2 laddles each with 5 tones
capacity (totaly 10 tonnes)
• Ni HARD – Ni RESIST STEELS
CLEANING AND HEAT TREATMENT
Molding System
•Mixing is done with
Cleaning refers to all operations necessary to the
removal of sand, scale, and excess metal from the
casting. The casting is separated from the mold and
transported to the cleaning department. Burned-on sand
and scale are removed to improved the surface
appearance of the casting.
plccontrolled continuos
Mixers
•Sand system:
alpha-set resin sand
Figure 3 : Molding System
Figure1 : Induction Furnace
• NODULAR CAST IRON
The mold material and
the core combine to form
the mold cavity, the void
into which the molten
metal will be poured and
solidified to produce the
desired casting.
HEAT TREATMENT IN MEDAŞ
Normalization, tempering, quenching and stress relief
treatments could be done in heat treatment department
.
Figure 4 : Molding Panel
SCRAP
ADDITIVES
MELTING
CHEMICAL ANALY. &
TEMPERATURE
CONTROL
Figure 2 :Melting Process
FASTEN
MOLD
CASING
Melting:
The preparation of molten metal for casting
is referred to simply as melting. Melting is
done in a specifically designated area at
Medaş with induction furnaces and the
molten metal is transferred to the pouring
area where the molds are filled.
Raw mateial used in cast iron
production:
Pig iron
Steel scrap iron
Return materials
FeMn block
FeCr Block
FeNi
SOLIDIFICATION
MOLD OPENING
PHYSICAL
CONTROL
GENERAL MANAGER : EMRAH ATAÇ
Tel: 0533 654 15 17 email: [email protected]
CASTING DEFECTS
• Metallic projection
• Inclusions
• Casting cavities
• Incorrect dimension and shape
In order to detect casting defects, the quality tests imust be
done.
QUALITY CONTROL & LABORATORIES
spectrometer : (nitrogen channel- 0.002%0.4%sensitive)
portable hardness measurement unıt : hartip 3000
type 200-960hld measuring level with sensitive % 0.5
inverted metallurgical microscope :100x & 1250x
enlargement capacity.
sample polisher : double dısk d:200mmx250mm ; 100500rpm
charpy test machine : model fit 300 en
machenical test machine (%elg) : 5tones capacity
(model: tst-5t)
magnetic test : sentinel - mpa2l
ultrasonic test : goverment place (kosgeb)
Figure 6 : Heat Treatment Processes in Medaş
SURFACE FINISHING
After finishing all metallurgical processes and cutting the
feeders and extra parts, the products are sent into
machining hall for last surface finishing processes.The
main work done here is lampooning.
Figure 8: examples of the final products
CUTTING FEEDERS
NORMALIZATION
References:
Figure 5 : The Flow Chart of a Casting Process
Figure 7: lampooning Machine
[1] [2] [3] [4] [6] [7] [8] retrieved from www.medasdokum.com
[8] summer pactice notes
[9] Met E Melting & Casting Lecture Notes
[10] turkdokum.com
[11] Callister, W. D. (2007). Materials Science and Engineering
Summer Practice METE 400 or Fall 2012/2013
Student’s Name: Noureddine Chatah
Name of the Organization: ETİ ALÜMİNYUM A.Ş.
Name of the Student’s Advisor: Prof. Dr. C. Hakan Gür
Eti Aluminium Plant is an integrated primary aluminium production plant which converts aluminium ore into metallic aluminium by processing the
aluminium ore and after shaping it with casting, rolling and extrusionThe main bussiness of this Company is producing and selling Bauxite, Aluminum
Hydroxide, Aluminum Oxide, Primary Aluminium and Rolled products. Eti Aluminyum A.S. consist of Aluminum facility located in Seydisehir/KonyaTurkey
Bauxite Mining
Alumina Production
Seydişehir Alumina Plant
whose installed capacity is
200.000 tons of Alumina per
year, consists of six main
production units.
Although it has various compounds,
bauxite ore is used in Aluminium
production. Bauxite is the general
name of the aluminium ore which
consists of Al2O3 n H2O mineral
forms.
The production of bauxite ore is
made through open-pit mining. The
bauxite to be processed for alumina
production, has to be composed of
minimum 40% Al2O3 , maximum
15% SiO2, so that the modulus of
silica (Al2O3 / SiO2) has to be
minimum 7. Depending on the
chemical and mineral compounds
of the bauxite used for the primary
aluminium production, nearly 2 tons
of aluminium is produced from of 45 tons bauxite and, 1 ton aluminium
from 2 tons of alumina.
These are;
• Raw material preparation
• Autoclaves-Red Mud
• Decomposition-Hydrate
• Vaporization
• Calcination
• Aluminium Sulphate
Liquid Aluminium
Production
Casting Department &
Laboratory
The Casting Department is capable to produce
76.000 MT/year cast products by using the
Liquid Aluminium from Aluminium Factory and
also some Scraps from several sources. The
cast products are in forms of Slab, Billet, T-Bar
and Standard ingot and different alloys can be
produced according to the clients’ requests.
The next step in aluminium production is
converting the alumina into metallic
alumininium by means of electrolysis.
Primary aluminium is obtained by solution,
decomposition and reduction of alumina in
molten cryolite and aluminium fluorur bath
named as electrolyte at 960-970 0C and
with high current (100-400 kA); the
aluminium metal is neutralized. As a result
the molten aluminium is accumulated on
the floor of the electrolysis cell. During the
process oxygen is produced by
decomposition of aluminium fragmentation.
The main labs in ETİ ALÜMİNYUM A.Ş. Is
Metallographic Laboratory and X-Ray
Laboratory, Chemical Laboratory, and
Mechanical Testing Laboratory. The main
purpose of these labs is to make regular check
on the products produced daily and whether they
have the required properties. Moreover to
enhance the quality of the products.
References:
Light Metals 2002 edited by Wolfgang Schneider
http://www.etialuminum.com
http://www.alcoa.com
Summer Practice MetE 400 Fall 2012/2013
Hüseyin HIZLI
Turkish Aerospace Industries, Inc. – TAI
Prof. Dr. M. Kadri AYDINOL
Located in Akıncı-Ankara, TAI is the centre of technology in design, development, manufacturing, integration of aerospace systems, modernization and after sales
support in Turkey. TAI is also engaged in the design and manufacturing of structural components with leading international aerospace companies. Capabilities of TAI
can be classified as design, composite, metallic ,and surface treatment and coatings. For example, Automated Fiber Placement machine, Precision Milling Machine,
Real time X-Ray, and Automated Ultrasonic Scanning Systems, forming and mechanical milling of complex sheet metal panels, Automated Riveting Machine, etc.
Contact person in TAI is Ferhat SONAT whose phone number is ‘’03128111800/8158 ‘’and email is ‘’[email protected]‘’.
Week 1 and 2
Week from 3 to 6
Week from 6 to 9
Week 9 and 10
Since I have done my summer
practice as Co-op student, my
internship was different than others.
It has lasted 10 weeks, and so I
was working as an real engineer.
Therefore, approximately 2 weeks
of my intership was about research
and preparing study material about
materials for newly accepted
engineers. In these two weeks, I
have had an opportunity to observe
how metallurgical and materials
engineers are working together with
other engineering departments and
what kind of responsibilities they
are. Since I was in Co-op program,
engineers in R&D department
asked me to search and learn
some
important
facts
about
materials. In two weeks, I, briefly,
have done:
In the following three weeks, I was
asked to conduct non-destructive
testing for Airbus A350 XWB, A400M
and ANKA which is Turkish unmanned
aerial vehicle. I have done those tests
mostly with the help of Ultrasonic
testing which I have learnt from MetE
388 course and from Ferhat SONAT.
After conducted tests, I was asked to
write an report about results. Some test
specimens can be seen from below
pictures.
After
spending
three
weeks
by
conducting non-destructive
testing, I
have started to do destructive testings
like tensile testing, compressive test, 3point bending test,etc. Most of the
materials
were
composite
since
composite structures are using in
aerospace industry with increasing
amount. Most interesting tests were those
conducted under subzero and high
temperature for metals, and those
conducted for composites after putting
them into air conditiner for a year.
In my last two weeks, I have spent my time in
clean room which composites are made up and
physicochemical test laboratory. In chemical
laboratory, TMA, TGA, DSC, DMTA, ARES,
HPLC Polymer analysis of composite materials,
resins, adhesives, etc. are performing. At the
end
of
these
analyses,
manufacturing
parameters are specified. In clean room, I have
observed how composite panels are made from
prepregs.
• Research about SCC, SPF and
Welding specifications.
• Study material preparation about
Aluminum, Steels, Titanium and
Corrosion.
Rib of ANKA after static tests. With UT, delaminated areas
are founded as seen in white dashed area. There were 12
more specimens tested with UT.
Ramp qualification for
A350XWB panels are
inspected by using
conventional Ultrasonic
Testing way by using
Omniscan MX which is
Phased array ultrasonic
inspection device. As
seen from picture, there
is no defects on the
ramp region. After
experiment, a test report
is written and sent to
Airbus company in
Germany,
and
test
system accredited.
Instron 8502 and 8802 hydarulic machines used in testing.
With 8502, subzero and high temperature testings are
done, and with 8502, fatigue tests are done. Fatigue crack
growt tests are done in Instron 8502. Other than these
machines, there is one drop weight test machine and one
impact test machine in mechanical laboratory.
References
[1] www.tai.com.tr
Summer Practice METE 400
2012/2013
(13.08.2012-14.09.2012)
KADİR VOLKAN ALKAN
MITAS BOLT
VEDAT AKDENİZ
Company name:
No: 113P.K. No: 9 Gazi / ANKARA
[email protected]
MITAS Energy and Metal Construction Inc
Phone: (+90 312) 296 20 00
Contact person: Reşat LARÇIN
Company location: Eski Güvercinlik Yolu
Fax: (+90 312) 296 29 99
[email protected]
Week 1
Week 2
At first week my stuff help me to observe the
facilities.
At second week, i saw the galvanising plants. There
are 4 galvanising plants in the facility called Galva
0, Galva 4.5 , Galva 12.5 , Galva 14.
He gave me some information about process
about hot to galvanise steels.
Main Area of Business
Energy Sector
Telecommunication Sector
Lighting Sector
Automotive Sector
Galvanising
Week 3
At third week , I spent all of my time in laboraties
Fasteners
Services
Steel Structures
Grating
Special Poles
Packing and Shipment
Week 4
..
At the final week of my summer practice, i read the documents the
engineers in facility gave to me and observed the detailed
galvanizing process and see the physical and mechanical behavior
of galvanized products
The ungalvanised and galvanised productes tested in the
I spent my first week in the open (park) area of
the facility. He showed me the Galva facilities,
white area, black area and the other parts of
facilitiy.
My staff and workers gave me some information
about the galvanising plant.
laborities
.
Also I observed the management connections between workers,
engineers and managers to see how things done in a facility
Tensile tests and hardness tests were made according to
At the white park area there are galvanised
products and workers are packaging them for
shipment. After the final tests done in white
park by controllers the finished products are
shipped from the facility
standards
My staff is the sheff of Galva 4.5, Galva 14. so I was
interested in the two plants.
.
References
1. http://www.mitaşgalvanising.com.index.php
2. http://www.galder.org.tr
3. http://www.galvanizeit.org/
İlksen Barış Bademci
Akdaş Döküm Sanayi ve Ticaret A.Ş
Assoc. Prof. Dr. Arcan Dericioğlu
Akdaş has 34,200 m2 closed and 52,000 m2 open area in two fpundry factory and one machining manifacturing plant operates in three. Akdaş is one of the largesr plants in Turkey with a
capacity of 42 tons of liquid metal casting plants and annual production is 18000 tons of 65% from more exports.
Contact Person: Çağrı ERKAN ([email protected])
Week 1
Week 2
Week 3
Week 4
MODELING and MOLDING
MOLDING
MELTING AND POURING
CLEANING AND FINISHING
Sprue pins are positioned. One on the
back of the pattern and one on the
other side. After molding is complete,
the pattern is removed with a spike.
Induction furnace: The liquid material is
poured with care down the hole in A
current is passed through a water cooled
coil near or the upper sprue pin and it
spreads into the mold and left
around the charge for cooling. Eddy
currents are produced in the charge
material in response to the coil current.
Heat is generated thorough ohmic
heating in the material.
Modeling is done with solid works
software.Prototype is made of
wood or styrofoam.
Wooden sample is placed onto a
sufrace and the center of
casting
mold.
Sandbox
constantly pressed durıing
process to prevent cracks in
mold.
flat
the
ıs
the
the
Casting sand is shaken thorough a
sieve. Surface is flattened
The liquid material is
poured with care
down the hole in the
upper sprue pin and
it spreads into the
mold and left for
cooling.
CNC (Computer numerical control) is a machine
with a computer attached to it.In modern CNC
systems, end-to-end component design is
highly automated with computer-aided design
(CAD) and computer-aided manifacturing (CAM)
programs.
References
1.Documents given by AKDAS
2.www.cnc.com.tr
3. www.industrialmetalcasting.com
Ümit BAĞIŞLAR
TAI
F. Arcan DERİCİOĞLU
TAI ( TURKISH AEROSPACE INDUSTRY, INC.)
Fethiye Mahallesi, Havacılık Bulvarı No: 17
06980 Kazan-ANKARA / TÜRKİYE
Tel : +90 312 811 1800
Fax: +90 312 811 1425
Week 1
Main Areas of TAI
Marketing:
Procurement:
Human Resources:
[email protected]
[email protected]
[email protected]
BANU AKTİMUR
[email protected]
0-312-811-18-00/2568
Week 2
•
Visiting the clean room and getting
some information about this room
from workers
•
Learning the compaction process
•
•
•
Learning the moulding methods of
composite materials
Learning the working principles of
Automated fiber placing machine
•
•
•
Getting some information about
materials that use in the composite
materials
Puting into practice that the theoritical
knowledge of moulding
•
Learning the necesarry properties that
composites should have after prepration
of composite
•
•
Learning kinds of fabrics
Visiting clean room and learning how to
prepare prepreg
Fixed and Rotary Wing Aircraft Manufacturing
Product Development
Aerostructures
Modification, Modernization, Systems Integration and After Sales Support
Maintenance, Repair and Overhaul
Information Systems
Week 3
Getting information about the woking
principles and facilities in TAI
•
–
–
–
–
–
–
Week 4
•
Visiting the autoclave area
•
Visiting the tooling area
•
Learning the working principles of
autoclave and cure oven
•
Learning the tooling process
•
Learning necessary conditions for storage of
composite materials
•
Doing some experiment for the Saritsu Project
•
The aim of the Saritsu Project is to use compostie
materials in inner body of airplane instead of
aliminium
•
Learning the painting, coating processes of
composite materials
•
Getting some information about the firs t airplane
produced by Turkey: Hürkuş
Visiting the modification areas of
airplanes
Learning the testing processes
autoclave
Hürkuş
turna
automated fiber placing machine
şimşek
Kind of fabrics
obtaining prepreg
the usage areas of composite materials in airplane
References
1.
http://www.wikipedia.org
2.
http://www.tai.com.tr/en/capabilities/composite
Summer Practice 400 Fall 2012/2013
ÖNDER ERKUL
GÜRAL PORSELEN
MEKHRABOV AMDULLA
Contact Person in the Organization ;
Company Location:
Company Name:
HERİŞ SERAMİK VE TURİZM SAN. A.Ş.
GÜRAL PORSELEN FABRİKASI
ADDRESS
:
TELEPHONE :
FAX
:
ESKİŞEHİR YOLU 5.KM 43100 KÜTAHYA
( 0-274 ) 22 50 300
( 0-274 ) 22 50 316
Name
:
Hüseyin Ekmekçioğlu
- Porcelain production for daily use at houses and hotels
Job
:
R & D Manager
including plates, cups, bowls, vases and decorated products
E-mail :
[email protected]
- In the first week of the summer practice, i was in the press
part of the factory.
- In the second week of my summer practice, i spent my time
in the roller forming and glazing parts of the factory.
- In the third week of my summer practice, i was in the foundry and
ovens parts of the factory .
- In Güral Porselen Company, %70 of the production of
porcelain is made by isostatic presses. Almost all of the circular and
non-circular plates and large plates are made by presses.
- In porcelain production, roller forming method is used for
the production of cups, bowls and similar products.
- Foundry method is usually used when the manufacturing process
cannot be used for the previous methods because of the difficulty and the
inefficient production. Larger plates or small complex shaped should be
produced by foundry method.
- In this process, some amount of mud is prepared at dryer and
this mud is then passed from dryer and taken into the molds. The
molds that are used for this process changed after 120-150 uses since
they finished their service life.
- Glaze is a layer or coating of a vitreous substance which has
been fused to a ceramic object through firing and oiling. Glaze can serve
to color, decorate, strengthen or waterproof an item.
Main Area of Business :
- In this method, the mud used for production should have high
solid particle rate and lower viscosity. To be able to make this kind of mud,
distributors which increase the fluidity of the mud should be used. Foundry
muds should have fluidity and optimum thixotropy.
In the last week of my summer practise i was in the quality assurance and
decoration parts of the factory.
In the quality department of the factory, the products which all the
processes are applied checked before the packaging. All the products are classified
according to the quality of them.
- I observed the seperation of the products according to their qualities.
There are three classes of quality; first quality, second quality and third quality
products. First quality products are usually exported to different foreign countries
and they must satisfy international parameters for quality. Second and third quality
products are sold at factory outlets with low prices.
- After the selection, first quality products are taken to the decoration
process whereas low quality products usually packaged without decorating.
Why porcelain products are glazed?
- I observed the presses that consist of hydraulic, pneumatic and
electronic systems. They work with high hydraulic pressures (270300 bars). The air pressure that used in these machines is 6 bars.
- Porous and in micro level uneven surface of porcelain body
coated with a glassy layer which is nonporous and has flat surface
- For old roller methods 5 workers needed for 5000 products in
a shift but in presses only 1 worker needed for 6000 products.
outside so that it can be more hygienic and easy to clean.
- In the press unit of the factory there are 2 types of presses and
total of 10 press machine. 8 of these machines have 2 heads
whereas, 2 of them are one headed which gives total of 18 press
head. The types of presses are called DORST and NETZSCH
the possibility of decoration of the surface
- Aesthetically nice and smooth looking and also enhancing
- Increasing the toughness of the product
- Increasing the surface hardness
- Corrosion to the external effects
- Also i observed the processes applied in the ovens. The products
have some humidity in them before the drying process. After retouch
process porcelain products dried at the biscuit ovens where the temperature
is about 900 °C. After the biscuit ovens, glazing process is applied to the
products. Then products need to be dried again but this time applied
temperature is about 1350 °C. With this last process, products get the
necessary toughness, and after the glazing process fired products get the
white color. Color of the product is very important for the sales and this
color is the result of the glazing process.
- Pressed products have crust around them when they first
leave the press machines. Then these crusts are cleaned by retouch
machines with emery and sponge processes and pressing process is
finalized.
-
The basic raw materials for porcelain production are: kaolins,
quartzes and feldspars
Güral Porselen satisfies the ISO 9000:2000 quality document.
Moreover, all raw materials and the foreign subcontractor companies
have all been chosen very carefully and are all under continuous surveillance.
In the decoration part of the factory, plates and other products are
covered with an adhesive decoration layer.
References
1. http://www.guralporselen.com.tr/
2. http://www.porcelana-kristoff.pl/en/o-nas/wytwarzanie-porcelany.html
3. http://en.wikipedia.org/wiki/Porcelain
Summer Practice METE 400 2012/2013
Zekican Sıvışoğlu
Baran Steel & Galvanizing Co.
Prof. Dr. Abdullah ÖZTÜRK
The company was established in the 70’s in a 200 m2 workshop. Driven for success and thanks to the skill and support of our workforce, we soon became a
well known company in the steel structure fabrication sector. As the demand grew, Baran Steel and Galvanizing expanded and move to bigger premises. By the end of
the 80’s a building devoted to hot dip galvanizing was added to the facilities.
As soon as ISO9000 quality management system was introduced in Turkey. Baran became one of the first companies to implement it and receive the
certification.
In the years that followed, we update our equipment with CNC technology and renewed the lines upgrading both our capacity and the quality of our services.
Today, Baran Steel and Galvanizing operates in a 9000m2 indoor and a 15000 m2 outdoor area with a steel structure fabrication capacity of 36000 tons and
40000 tons of galvanizing, featuring a wide range of products such as overhead power transmission lines, substation structures, modular masts, monopoles, lightning
poles and any kind of tubular steel structures and telecommunication lattice towers.
Saray Mah.
Dağyaka Cad. 4, Kazan Merkez/Ankara, Türkiye Tel:0312 815 5352
WEEK 1-2-3-4
GALVANIZATION
Galvanization is the process of applying a protective zinc coating to steel or iron, in order to
prevent rusting. The term is derived from the name of Italian scientist Luigi Galvani.
Although galvanization can be done with electrochemical and electro deposition processes, the most
common method in current use is hot-dip galvanization, in which steel parts are submerged in a bath
of molten zinc.
Hot-dip galvanizing is a form of galvanization. It is the process of
coating iron, steel or aluminum with a thinzinc layer, by passing the metal through a molten bath of
zinc at a temperature of around 860 °F (460 °C). When exposed to the atmosphere, the pure zinc (Zn)
reacts with oxygen (O2) to form zinc oxide (ZnO), which further reacts with carbon dioxide (CO2) to
form zinc carbonate (ZnCO3), a usually dull grey, fairly strong material that stops further corrosion in
many circumstances, protecting the steel below from the elements.Galvanized steel is widely used in
applications where rust resistance is needed, and can be identified by the crystallization patterning on
the surface (often called a “spangle”).
References
1.
Baran Çelik ve Galvaniz
Handbook
2.
www. barancelik.com.tr
Serkan YILDIZ
Tusas Engine Industries, Inc.
Prof. Dr. Macit OZENBAS
TEI is a joint-venture company established in 1985 with the partnership agreement signed by Turkish partners (53.78%) and General Electric (USA) (46.22%). TEI’s Turkish partners are TUSAS-Turkish Aerospace Industries INC., Turkish Armed
Forces Foundation and Turkish Aeronautical Association. Their mission is To build a permanent aircraft engine industry in the country providing products and services which will develop technological basis of aviation and space industry and
their vision is To be a worldwide, high quality and competitive main aircraft engine manufacturer
Contact: Aydemir GUNAYDIN, Senior Special Process Engineer
Phone: 0 222 211 24 65
E-mail : [email protected]
Week 1
Special Processes
Laser Cutting and Drilling
Week 2
Special Processes
Plasma Spray Coating
The Plasma Spray Process is basically the spraying of
molten or heat softened material onto a surface to
provide a coating. Material in the form of powder is
injected into a very high temperature plasma flame,
where it is rapidly heated and accelerated to a high
velocity. The hot material impacts on the substrate
surface and rapidly cools forming a coating.
Laser cutting is a fairly new technology that
allows metals and some non metallic materials
to be cut with extreme precision if required.
The laser beam is typically 0.2 mm in
diameter with a power of 1-2 kW .
Week 3
Week 4
Non-Destructive Testing
Non-Destructive Testing
Fluorescence Penetrate Inspection (FPI)
Fluorescence Ultrasonic Inspection
This process is used to detect small defects in areas such
as aerospace engineering where extra precision is
needed. Because of its sensitivity to such small defects,
FPI is ideal for most metals, which tend to have small,
tight pores and smooth surfaces.
The ultrasonic inspection method is used for either the detection of
subsurface flaws and irregularities in castings, forgings and
welds, or for thickness gauging when only one side of
component is accessible. Ultrasonic inspection uses sound
waves of short wavelength and high frequency to detect flaws or
measure material thickness.
Radiographic Inspection
Magnetic Particle Inspection (MPI)
Magnetic particle inspection is a method for detecting
cracks, laps, seams, voids, pits, subsurface holes and
other surface discontinuities in ferro-magnetic materials.
Magnetic particle inspection can be used only on ferromagnetic materials such as iron, steel. It can be applied
to materials in any process for billets, finished or
semifinished, assembled or disassembled.
In radiographic inspection systems, a beam of high-energy
radiation, such as X-rays, is transmitted through a test object to
be inspected, and a corresponding image of the test object is
formed using various image-processing techniques. A flaw,
defect or structural inhomogeneity in the test object is detected
by examining the image generated.
References
1 - www.tei.com.tr
2 - www.twi.co.uk
3- www.tmi.org
Semih YORULMAZ
BORUSAN MANNESMANN
Prof. Dr. Yavuz Ali TOPKAYA
Turkey's leading steel pipe manufacturer, Borusan Mannesmann has started its business in 1958 as the first enterprise of Turkey's leading industrial power, the Borusan Group.
Borusan Mannesmann provides many products such as gas pipes, water pipes, general-purpose pipes, boiler pipes, construction pipes and profiles, industrial pipes and profiles,
large diameter pipes used in infrastructure projects such as water, gas, and oil transmission lines, and also concrete pump pipes, oil pipes and sprinkler pipes. Ender ÜNLÜ was
responsible for me in the factory who is quality manager of Borusan Mannesmann Halkalı Factory .
(E-mail: [email protected]
Contact Number: 0 212 411 35 40 or 0
533 618 6975 )
Week 1-2-3-4: General process table is shown below.
Sheet Slicing Unit
Jigsaw Unit
Heat Treatment
Phosphate Coating
Pointing
Cut-to-length
SLICING
Quality
Cold-rolling Unit
Sheet Annealing
Pipe Annealing
E/C Test
COLD ROLLING
ER Welding Machine
Control
Department:
Mechanical testing of ordered pipes are
carried out to understand whether they
have required mechanical properties or
not.
The project which I carried out
on it:
I worked on galvanization of steel,
factors effecting galvanization quality
and Sandelin effect on galvanization in
quality and control department.
Final Control
WELDING
Tensile Test Machine
Microhardness
Metalographic test is also carried out on
produced pipes to understand that
whether there is any defect in welding
like crack or segregation.
ANNEALING
PHOSPHATE COATING
POINTING MACHINE
References
ASM Hand Books
www.karyt.com
www.borusan.com
www.borusanmannesmann.com
POINTING
DRAWING
www.galvanizeit.org
Summer Practice Mete 400 Fall 2012/2013
Omid Chalabi Zonouzi
Borusan Mannesmann Boru
Prof. Dr. Rıza GÜRBÜZ
In 1958, Borusan Group has decided to enter the steel industry and with that decision they initiated Borusan Mannesmann which was aimed to manufacture steel pipes
for various needs. Basically the pipes they manufacture consist of water and gas pipes, industrial pipes and profiles, special pipes, boiler pipes, square and rectangular
profiles. The factory in Istanbul has an area of 58,000 m2 with a pipe manufacturing capacity of 925,000 tons per year. The Metallurgical engineer who was responsible
of me was Osman SERDARLI ( Email: [email protected] , Contact No: 0555 310 89 50)
Quality Control Department
All Weeks
Below the procedure carried out for manufacturing pipes are provided.
1.Sheet Slicing unit
7.Phosphating
2.Jigsaw Unit
8.Heat Treatment
3.Cold Rolling Unit
9.Edging and Straightening
4.Sheet Annealing
10.Cut-to-length
5.Electric Resistance Welding
11.Eddy Current test
6.Pipe Annealing
12.Final Control
Time spent here consists mainly of
metallographic analysis on microscopic
level. Below are some of the microstructural
images gathered from Met-Lab showing the
possible errors occurred during the welding
process.
Insufficient Press
Curvature
Sheet Slicing discs
Cold Rolling
Overlay
Straightening
ER Welding
Edging
After the procedures mentioned above , the pipe is sent to quality control
department to be sampled and tested for any errors or defects in its
microstructure
1) Determining non metallic inclusion content of
steels.
This study involves information gathered from
ASTM E45, DIN 5062, JIS G055 norms.
In all those norms classification, measuring
methods and sampling polishing parameters are
given and compared. One thing they all have in
common is that inclusions are classified as four
types: A type Sulfide , B type Alumina, C type
Silicate, D type Globular Oxide
Plastering in Burr
Slit
Pipe Annealing
Projects Carried Out
This department carries out tension test on
pipes and also chemical analyze. In tension
test the yield strength and amount of strain
till fracture is recorded to be used in pulling
A
B
C
D
---------------------------------------------------------------2) Estimating depth of decarburization in steels
Methods are as follows:
• Screening
• Micro scopical
• Micro indentation Hardness
• Chemical Analysis
• Spectrometric
Microstructural view of
decarburization
References
www.borusanmannesmann.com
Summer practice report, O.C.Zonouzi, 18.10.12
Ezgi Onur
AKDAŞ Casting and Steel Industries Incorporation
Prof. Dr. Şakir Bor
AKDAŞ Casting and Steel Industries Inc., established in 1982, produces high tonnage casting products. Having built its fifth plant, AKDAŞ produces 50000 tons of
casting annually 75% of which are exported. The main production is for automotive, cement, energy, mining, machine production and marine industries.
Ankara Chamber of Industry 1st Organized Industrial Zone, Ankara-Ayaş State Road 25th km. Sincan / ANKARA AKDAŞ-1 Batı Hun Street No: 1, AKDAŞ-2 Türkistan Street No: 4
Contact Person: Çağrı Erkan (HR) e-mail: [email protected], phone: + 90 (312) 267 18 80
Week 2
Week 3
Week 4
casting
Modelling workshop and maintanence
and repair department were visited.
Destructive
and
non-destructive
testing departments were visited.
White and nodular gray cast iron and
steel
casting
operations
were
observed.
Sand molding, polystyrene molding
processes, sand separation unit and
and also full-mold castings were
observed.
Metallographic examinations, impact
testing, hardness measurements and
tensile tests were conducted.
Welding and grinding workshop and
also computer aided modeling room
were visited.
Week 1
Throughout
this
week
workshop was visited.
Most of the steel and cast iron parts
produced for mining and machine
production were examined.
Ultrasonic, magnetic particle and
liquid penetrant inspections were
observed.
Casting defects were examined.
Surfaces of some castings were
inspected and the tolerance levels
were studied.
Charge calculations were done by the
interns using spectral analyses of
the samples taken from the furnaces.
In this unit different types of sand,
resins and sand mixtures were
examined.
Sand molding
and sand mixer
calibration was done by the interns.
Magnetic particle, ultrasonic and liquid
penetrant tests were also carried out
by the interns.
Welding and grinding operations were
observed. Shot peening of different
parts was carried out comparing the
hardness values at each step.
Rather than new products
•
surface finish and
•
product repair were examined.
Using basic solid modeling programs
knowledge
•
some casting
redrawn and
drawings
•
casting simulation analyses were
conducted.
Reference
•
AKDAŞ Operating Instructions
were
Summer Practice METE 400 Fall 2012-2013
Eren İNCİ
TAI (Turkish Aerospace Industry)
Prof. Dr. Şakir BOR
•Turkish Aerospace Industries, Inc. (TAI) was established by Turkish and US partners in 1984 for the co-production of F-16 aircraft in Turkey. As a result
of the acquisition of foreign shares Turkish shareholders, the company was restructured in the year 2005 and TAI became Turkey's center of technology
in design, development, modernization, manufacturing, integration and life cycle support of integrated aerospace systems, from fixed and rotary wing
air platforms to UAVs and satellites.
•TAI, which ranks among the top hundred global players in aerospace and defense arena, based its business on five strategic pillars as shown below:
Aerostructures Group, Aircraft group, UAV systems, Space systems, Logistics.
•TAI-Turkish Aerospace Industries,Inc.Fethiye Mahallesi, Havacılık Bulvarı No:17 06980 Kazan-ANKARA / TURKEY.
•Contact person : Banu AKTiMUR (0312) 811 18 00/2568
Week 1: Briefing
Week 2: Clean Room1-Autoclave
In the first week of the summer
practice, there were given
brifings related to summer
practice purpose, general
information about TAI and
projects and works that TAI has
by education department and
some engineers.
In clean room, some parts of the air
craft are made. Here, temperature and
moisture are at certain value. Carbon
fiber laying up is the main technique
that applied at clean room. Other
steps are like that ;
In this clean room, working
environment is more sensetive than
clean room 1. Here, rather than
hand laying up, machines are used
to lay up carbon fibers on tools. In
this clean room, some parts of the
JSF-F35, Sikorsky and A400M are
made.
Week 4: Non Destructive Testing (NDT)
TAI gives highest priority to have defectfree product. To do that non destructive
testing is used to analyze the defects or
imperfections in the products. TAI uses
Ultrasonic testing as non destructive
testing.
JSF-F35
Some important projects;
HÜRKUŞ
Week 3: Clean Room 2
Cutting prepregs by CNC ply cutter
Laying up on tool
ANKA
Ultrasonic Testing
ATAK
BOEING
A400M
Molding in autoclave
Vacuum bag
Elevator part of the SIKORSKY
References
1)
2)
3)
Inner parts of the autoclave
http://www.tai.com.tr
Banu Aktimur
https://www.google.com.tr/imghp?hl=en
&tab=wi
Mustafa Çağdaş AKKOYUNLU
KOSGEB Ankara Sincan Hizmet Merkezi Müdürlüğü
Advisor : Assist. Prof. Dr. Hüsnü Emrah ÜNALAN
•
With the aim of Supporting Small and Medium Size Industries, KOSGEB helps these enterprises to have scientific and technological
innovations swiftly with a view to ensuring that they operate effectively. KOSGEB provides both financial and technological support for
SMI’s.
Contact Person in the Organization : Yusuf Ziya KAYIR
E-Mail : [email protected]
Tel : 05325029534
Week 1
Week 2
Week 3
Week 4
Chemical Spectroscopy Lab.
Mechanical Testing Labs.
Some Company visitations are made
Chemical analysis of the samples
that are sent by the SMI’s to
KOSGEB are made and the results
are given to the companies in a
report.
Metallography Lab. And Foundry
Development Center
Tension, Hardness and Microhardness
tests are conducted here again for the
investigation of the samples that are
sent by companies to KOSGEB.
Mostly Cast Irons are sent here for the
metallographic examiation. All steps in
the preparation of a sample for
metallographic investigation are
conducted in this lab. by the technician
and then the sample is examined under
an optical microscope to observe the
microstructure.
 Akpınar Döküm
Tension Test
of a nondogbone
shaped sample
Chemical analysis of the samples
are done by the use of two
different spectrometers, one is
GNR and the other is of the brand
ATLANTIS. The spectrometers are
calibrated and then the samples
are burnt in the process to
determine chemical compositions.
Hardness and microhardness tests are
also studied in the 2nd week. Micro
hardness test is for the samples that
are too thin or small to be examined by
classical hardness test indentators.
Preparation of the samples for the tests
are also conducted in this laboratory
by KOSGEB technicians.
Microstructure
of a gray cast
iron with
graphite flakes.
(Pik döküm)
This company produces cores and molds for
melting and casting operations. The design
process in the factory is briefly explained during
the visit.
 Emek Boru
Emek Boru has the
capability to produce
spiral welded steel pipes
according to ISO 9001
and API Q1 quality
assurance standards and API 5
L Monogram. The used
Below are the procedures that are
conducted in the foundry development
center in KOSGEB
 Melting, molding, core making, fettling,
cleaning, heat treatment technology,
 Analyses of casting defects and their
preventation.
 Process control in foundries
 Foundry layout and selection of foundry
equipments
 Training of foundry personal
 Adaptation of new technologies to small
and medium size foundries
raw material here is hot rolled
sheet iron.
 Akdaş Döküm
The organization has a production capacity of
annual 10000 tons. High-low alloy and plain
carbon steels, stainless steels, wear resistant
manganese steels, Ni-hard, white casting irons
and gray nodular cast irons are produced
according to standards by experienced personnel
References
http://www.scielo.br/scielo.php?pid=S180683242006000100008&script=sci_arttext
http://www.wmlee.co.uk/sggrey.html
http://www.emekboru.com.tr/uretim/
Mustafa Mert Arslan
Turkish Aeronautical Association
Assist. Prof. Dr. H. Emrah Ünalan
Turkish Aeronautical Association (Türk Hava Kurumu - THK) is a non-profit organization with an aim of increasing public awareness
and participation in aviation related activities and the national body governing air sports in Turkey. The association was founded with the
name Turkish Aeroplane Society (Türk Tayyare Cemiyeti) by the directive of Mustafa Kemal Atatürk on February 16, 1925.
NDT
(Non-destructive
Testing) Workshop
• Magnetic Particle
Inspection
• Eddy Current Inspection
• Ultrasonic Inspection
• Liquid Penetrant
Inspection
Electric Board Workshop
Fuselage and Flight
Line
There are several airplanes in
the TAA but I mostly dealt with
the “NAC6 Fieldmaster”
airplane.
Fabric Coating
Workshop
Avionics Workshop
All communication and navigation
devices located on an aircraft are
called avionic devices.
• Communication Devices
• Navigation Devices
• Contributory Avionic Devices
• ILS (Instrument landing
system)
• GPS (Global Positioning
System)
• IFF (Identification Friend or
Foe)
Antonov AN-2 airplanes were
coated with fabric.
Hydraulic Workshop
In this workshop hoses
airplanes are produced.
for
Some instruments, used for testing
indicators, are introduced. Some of
them are pitot tube tester, compass
tester, torque meter, alternator tester,
RPM tester, high tension load tester. If
there is something wrong with the
tested indicator, a new indicator is
wanted from material control chief
administrator ship in order to use in the
airplane.
Tire Workshop
Landing
gears
are
important
components of an aircraft since an
aircraft may have an accident due to
the damaged landing gears although it
does not have any problem in the air.
According to the size of the damage,
necessary overhauling operations are
done; also tires may be replaced
completely.
References
http://www.thk.org.tr
Recep Buğra Atasoy
Nurol Technologies Inc.
Registration Advisor: H. Emrah ÜNALAN
Nurol Technologies Inc. has been established in 2008 for one of the biggest needs in order to provide advanced ballistic armor solutions and
production for Turkey's defense industry. The company is providing advanced ballistic armor solutions by Turkish engineers' knowledge and
experience, without any foreign partner or consultant.
Engineer: Adem Atilla Bostan (Production Meneger)
Composite Armor Products
Protective vests:
Land and Air Vehicles
Protection:
Ceramic Plates
Alumina (Al2O3) :
Hardness, thermal
shock resistance and
chemical corrosion
resistance
Silicon Carbide (SiC) :
High
mechanical
strength high oxidation
resistance and high
thermal shock resistance
Boron Carbide (B4C) :
High
fusion
temperature,
high
hardness, light weight
and excellent resistance
to chemical materials
Tungsten Carbide (WC)
: Tungsten Carbide with
its excellent erosion
resistance and high
hardness
Fiber Rainforced Polymers
UHMWPE
Glass Fibers: lightweight, extremely
Very tough material, with the highest impact
strength of any thermoplastic presently made. It
strong, and robust material, raw
materials are much less expensive
Carbon Fiber: extremely strong
material, strength is much higher then
glass fiber.
Kevlar: Kevlar is a well-known
component of personal armor. Its
tensile strength is extremely high.
is also highly resistant to corrosive
chemicals with exception of oxidizing acits;
has extremely low moisture absorption and
a very low coefficient of friction; is selflubricating; and is highly resistant
to abrassion, in some forms being 15 times
more resistant to abrasion than carbon steel.
References


http://www.nurolteknoloji.com
http://eippcb.jrc.es/reference/BREF/cer
_bref_0807.pdf
EYÜP CAN DEMİR
TUSAŞ-TÜRK HAVACILIK VE UZAY SANAYİİ A.Ş
TAI is Turkey's center of technology in design, development, modernization, manufacturing, integration and life cycle support of integrated aerospace
systems, from fixed and rotary wing air platforms to UAVs and satellites [1]. The Company has a modern aircraft facility furnished with high
technology machinery and equipment that provide extensive manufacturing capabilities ranging from parts manufacturing to aircraft assembly, flight
tests and delivery.
Banu Aktimur ([email protected])
)
Week 1
Almost 4 days,
conferences are given
about the rules of the TAI ,
Foreign Object Damege
(FOD), production
processes and important
places of the TAI. Last day
students were distributed
to their depertmant.For
METE students, it was
composite depatment.
Week 2
Engineer gave important
information about the
composite technology. After
geting information, firstly
clean room was invastigated.
Laying out of the composite
on the molds are done in here.
There are some restriction for
clean room, it should be clean,
it should not see sunlight
because epoxy on the
composite can be
degenerated. Besides,
temperature is fixed at 22 C.
Week 3
After laying out the composite
material it should be cured in the
autoclave . Polymerization
reactions is needed to get high
mechanical properties. According
to special recipes given by foreign
engineers some cylic firing
processes are applied. Important
parts of the Boeing, Airbus, F-35
are produced by this method [2].
Week 4
Last week, all production processes like
metal sheet forming, painting,
assembling , CNC machines, chemical
machining , mechanical testing place ,
heat treatment processes were
investigated. It should be noted that
there is no continious production in this
fabric. According to special orders ,
modernizations and manufaction
aerospace systems are done.
Roughting deparment was also
surveyed in this week. Trimming
of the excess part of the
composites was observed here.
References
1.
www.tai.com.tr
2.
TAI documents
TAYFUN DURMAZ
Eti Alüminyum A.Ş.
Prof.Dr. Yavuz Ali TOPKAYA
Eti Alüminyum A.Ş. is only liquid aluminum producer of Turkey
by fused salt eletrolysis method. Eti Alüminyum Facilities have
400000 tons/year capacity to treat bauxite with Bayer Process
and 65000 tons/year capacity to produce aluminum products.
Eti Alüminyum A.Ş. produces aluminum ingot, T-ingot, billet,
slab, alloyed ingot, hot rolled sheet, cold rolled sheet and folio.
Moreover, this facility commercializes aluminum hydrate,
alumina, aluminum sulfate and vanadium sludge.
Week 1
Week 2
Week 3
Week 4
• First week, Alumina Plant that
contains
Raw
Material
and
Manuplating Plant, Wet Milling Unit,
Preheating Unit, Autoclave and
Hydrate Unit, Evaporation Unit and
Calcination Unit hasbeen visited.
• Second week, Aluminum Plant has
been visited.
• This Plant is main part of the
factory because the purpose of this
plant is to convert alumina to
aluminum by fused salt eletrolysis
method..
• During
electrolysis
process,
Soderberg electrolytic cell is used.
• Third week, Casting Department
has been visited.
• In this plant, liquid aluminum is
transformed to last products such
as slab, billet or ingot by casting
process according to cunsumer’s
desire.
• Last week, we have been in
Laboratories.
• We have examined the composition
of products in Alumina and Aluminum
Laboratories, mechanical properties
in Mechanical Testing Laboratory and
microstructure
in
Metallography
Laboratory.
• The main product of this plant is
alumina (Al2O3) which is used in
Aluminum Plant.
References
1. http://www.etialuminyum.com/
2. http://www.lme.com/
3. http://www.world-aluminium.org/
4. http://www.alueurope.eu/
• Moreover, Eti Alüminyum A.Ş. has
Anode Paste, Chemical and X-Ray
Laboratories.
Contact Person
Salih Çiftci
Tel: +90 332 582 30 30 / 3377
[email protected]
Gamze Gül
Gulermak Ind. Cons. & Co. Inc
Prof. Dr. Rıza Gürbüz
Gulermak Ind. Cons. & Co. Inc was founded in 1958 by Vildan Güleryüz in Gölbaşı- Ankara. From 1976 to today, the company has been serving as
an incorporated company. Company has 14000 m2 closed-work shop production area, 28000 m2 open-container area and 2600 m2
administrative building area.
GENERAL MANAGER : Abdullah Eraslan
email: [email protected]
Several projects of company : industrial facilities, dams, high ways, thermal stations, rotary furnaces, underground railway systems and light rail systems.
Week 1
training, certain amount of time
was spent on labor-worker’s health
and job safety-security.
Week 2
Week 3
Week 4
On
the
second
week,
general
presantation about the works done in
the quality control department were
performed.
On the third week, these departments were
seen.
The last week was spent in the Technical Office.
Pre sanding
Department
CNC cutting
machine
Since the
business area of the
company is heavy industry Safety
is the most important criteria.
Importance of the preparation and
conservation of the quality files;
testings operations and testing reports
were emphasised. And nondestructive
tests applied were examined.
CNC Press Machine
Manufacturing
Department
Technical office is a department which is
interested in manufacture of projects. Technical
drawings are prepared and sent to the machine
shop in order to manufacture Project.
The other missions of technical office are:
Proper material selection
Teaching of how to manufacture the project
Lathe Department
Here are the examples of some of the
tests; penetration, magnetic and
ultrasonic test aparatus, respectively.
Informing to foreman
The adjustments of time and workers for
projects
Painting
Department
References:
[1] www.gulermak.com.tr
[1] www.gulermak.com.tr
S.Kaan Gürel
FNSS DEFENSE SYSTEMS INC.
Prof. Dr. Mahmut Vedat AKDENIZ
FNSS Defense Systems Inc. is a leading manufacturer and supplier of armored combat vehicles and weapon systems for the Turkish Armed
Forces and Allied Armed Forces. FNSS is a Turkish based joint venture company between Nurol Holding of Turkey and BAE
Systems.While 51% of this joint venture belongs to Nurol Group, 49% of it is owned by Bae Systems
Contact Person: Haldun Olgun (Business Development Manager)
E-mail: [email protected]
Phone Number: 0312 497 4660
Establisment of FNSS has aimed to design, develop, and produce the Armored Combat Vehicles(ACV),and weapon systems for Turkish and
its allied armies by using of welding and machining processes
Week 1
Marketing Department provides advertising,
promotions, assisting universities, and
supporting charitable institution in order to
protect the brand equity of FNSS. Moreover, it
organizes advertiser fairs and also attend fairs.
This department organizes the website of the
company, and gives advertisements and
announcements in electronic form. It also
organizes some competitions and sponsor to
some competitions as well. Development of job,
protection of brand equity, and purchasing are
main responsibilities of marketing. Over-all,
marketing department manages all of the
company by use of process management
techniques.
How a company should be managed and there is
how kind of an atmosphere in management
departments are observed. Also how managers
and directors act as and how they spend their
time. Additionally, process management and
development is taught by industrial engineers.
Week 2
Machining, research and development
departmants are observed briefly. In
machining part, the unwanted metal from
a workpiece in the form of chips is
removed for getting a product of desired
sizes and also shapes by machines which
use CNS codes.Tool geometry, work
hardening and temperature of
environment are all calibrated while this
process was applying.
Research and Development department consists of four main units.
These are design, electric and electronic, materials and ballistic, and test
and analysis.
Design: All projects are designed.
Electric and electronic: This unit determines where
electric and electronic are necessary, and fulfill them to necessary parts.
Materials and ballistic: This unit determines all
requirements of materials and ballistic , and fulfill them to necassary
parts.
Test and analysis: this unit determines all requirements of analysis and
test, and apply them to necassary parts.
All signed projects starts by doing design. Design prints are technical
pictures. According to these pictures, necessities are supplied by
purchasing or manufacturing engineering. Designer engineer use a
drawing program, which is called CATIA, and SMARTEAM program is
used for engineering configuration management
Week 3
Week 4
Welding is one of the two main processes
along with machining in FNSS for
manufacturing. Welding engineers work with
the machining engineers in the manufacturing
engineering office. The most of the parts of
vehicles are joined each other by welding
processes. Before applying welding process,
all parts are put in chemical baths, such as
ridoline bath. By using this, silica extracts
from the aluminum surfaces. The reason why
this process is used that silica has much
higher melting temperature because it is
ceramic.
There most common used welding processes
in FNSS are TIG,MIG and MAG welding.
Quality Control tries to minimizing defects that is
appeared from other processes. Some tests are
applied for this;
Macro and Micro tests: It is applied by using
microscope.
The structure and content of a material or weld are
known.
Penetrant testing: For determining cracks and
porosities which are in welded area of the material
Tensile testing:
The duraiblity of metals can be determined from this
test.
TIG WELDING
MIG WELDING
MAG (Metal Active Gas) welding requires
the use of an active gas CO2 is commonly
used shortening of MAG welding gas
(difference from MIG)
References
1-Summer Practise Report
2- www.fnss.com.tr
3- www.welding engineer.com
4- www.safetyculture.com
5- www.transportation.anl.gov
Timuçin Koray GÜZELDEREN
MAHLE
Prof.Dr.Vedat AKDENİZ
MAHLE Konya A.S. , 2. Organize Sanayi Bolgesi Evrenkoy Caddesi, Nr. 2, Selcuklu 42300 Konya, Contact Person: Mustafa AYAZOĞLU / Human Resources GSM: +905414791993
e-mail: [email protected], Company information: Automotive Supply Industry ; manufacturer of components and systems for combustion engines and its periphery1.
Week 1
Week 2-3-4
Week 2-3-4
Job Health and Security department,
Foundry processes are observed for 3 weeks.
Technical maintenance department,
The units visited and processes observed are given
Planning department, Quality Control
below.
Week 2-3-4
department and Material Analysis Laboratory
are observed.
Liner, Piston Pin and Piston Ring Production ;
CNC Machines and coating processes are also
observed.
Liner Cutting Machine
Heat Treatment Furnace
Air Cooling After Shell Casting
Liner Storage and Air Cooling Area
Average Production Capacities of MAHLE Konya Factory for 1
year:
- Cylinder Liners : 500.000
- Piston Pins : 500.000
- Piston Rings : 425.000
Properties of Products
CNC Machines
Surface Coating Baths
Induction Furnace
Short Cenrifugals and Liner Racks
Shell Mould Production
Shell Moulds Before Casting
-Shell moulds are made by heating the silica sand in the
Production Line
negative steel moulds. Then they are packed on euro
pallets before casting.
-Liners which are casted in long centrifugal casting
benches are cutted in liner cutting machines to obtain
right height before goes into production line.
Material Analysis Laboratory
Quality Control End Product
Long Centrifugal Casting Bench
Shot Peening
-Some specific liners are taken into heat treatment
-Gray cast iron alloys are smelted in induction furnace
furnaces to obtain desired properties.
analysis laboratory by taking chill specimens
by induction heating. Composition is controlled by
-Both shell casting liners and centrifugal casting liners
from all charges in the furnaces.
taking chill specimens from furnace and casting is
are air cooled to obtain desired hardness profile.
-Some specific liners are surface coated in
done into shell moulds or centrifugal moulds.
-After air cooling and shot peening, liners are taken to
coating baths.
-Liners are taken to the shot peening machines after
storage room before goes into CNC production line.
-Quality control department is controlling all
air cooled to room temperature. Shot Peening is done
products in every step from foundry to packing.
to eliminate residual stress in liners.
-Alloy
composition is controlled in material
Engine Liners
C
Si
Mn
P
S
Fe
2,80-3,70
1,60-2,60
0,60-0,90
0,40-0,65
0-0,12
Rest
Hardness [HBW30] 190-250
Piston Pins
C
Si
Mn
P
S
Cr
0,14-0,19
0,15-0,40
1,0-1,3
Max 0,035
Max 0,035
0,8-1,1
Hardness (HB30) 159-262
Piston Rings
C
Si
Mn
Ni
Cr
Cu
S
P
Fe
Cu+Ni
2,40-2,80
1,80-2,40
1,00-1,40
13,5-17,00
1,00-1,30
5,00-7,00
Max 0,1
Max 0,1
Rest
%20
Hardness HBW 2,5/187,5 120-150
References
1. http://www.mahle.com
Summer Practice METE 300 or 400 Fall 2012/2013
İlkay Sezin KEMAHLI
Robert BOSCH RBTR
Prof. Dr. İshak KARAKAYA
BOSCH RBTR is located in Bursa/TR, and it is one of the leading companies in diesel injection systems. Nozzles and
injectors for gasoline and diesel systems are being manufactured.
Nurşen Dağlı (e-mail [email protected] +90 224 219 2184)
,
Week 1
Carbon coating and DLC
training for 3 days.
Carbon coating labs are
visited.
Week 2
Metallography and R&D labs are
visited.
Heat treatment experiments of the
nozzles were performed in a smallsized furnace.
Week 3
Week 4
The hardnesses of 80 nozzles are
measured with a Vickers Hardness
measurement device by myself.
.
Electroslag Remelting Process’s feasibility
research on the materials that BOSCH uses
Presentation preparation according to the
findings.
Presenting the work and data found to the
Research and Development Center’s
engineers.
.
X 80
The coating machines and
preprocesses were being
explained and observed.
The experimental set is
prepared. Times and
temperatures are determined.
The hardness data were
evaluated.
The first experimental process
took for 3 days.
665
660
655
650
645
640
635
630
625
620
615
610
605
600
595
590
585
580
575
570
10 h
15 h
10h_brake
15h-brake
8h
References
[1]http:/www.republicspecialmetals.com/remelt.html
240
290
340
390
[2] http://www.directindustry.com
Kerem Cengiz KILIÇ
TOFAŞ
TOFAŞ receives 15% share from national automobile market with spectacular five processes – press (shaping), body (welding), painting,
assembly and suspension. TOFAŞ manufactures FIAT Doblo, Linea, Fiorino (Citroen Bipper, Peugeot Partner and Opel/Vauxhall
Combo). Contact Person: Mr Ömer İNCE ([email protected], 0-224-261 03 50)
Week 1
Week 2
During the first week
orientations that are
related to
•
•
•
•
•
FIAT’s automobile
manufacturing history
History and products of
the company
TOFAŞ’s production
lines
New automobile
technologies
Job safety rules in the
company
Week 3
I performed my internship in
press and die shops. During
the second week I tried to
understand some concepts
which are
•
•
•
•
Designing, assemblying
and repairing of die sets
Material procurement
Technological systems
Forming of steel sheets
3D
analysis at
die shops
Week 4
In the third week I had a
chance to visit both body and
painting shops. I observed
some operations such that
•
•
Spot welding by robotic
machines
Phosphating, cataohoresis
coating, under and final
paintings
Robotic
welding
machine
At the final week of the summer
practice, assembly and suspension
shops were visited. Moreover, some
basic methodologies which are
•
•
•
Just-in-time (JIT)
Total productive maintenance
(TPM)
World class manufacturing
(WCM)
were introduced.
Assembly shop
were taken.
Crossbar
feeder
Undercoat
painting
References
http://www.tofas.com.tr/ and Mr Ömer İNCE
Ömer Faruk KOÇ
Componenta Döktaş/Orhangazi-Bursa
•Componenta Corporation is a family business that was established in 1918 in Finland. This company
is casting most of parts for automotive. In October 2006 Componenta acquired 55% of the shares and
votes of Döktas Dökümcülük Sanayi ve Ticaret A.S., a Turkish listed iron and aluminum casting
component manufacturer. Componenta and Döktas together form the second largest independent
European supplier of casting components and advanced solutions. Later Componenta has increased
its holding of Döktas up to 92.6%. In June 2008 the name of Componenta's Turkish subsidiary
was changed. The new official name is Componenta Dökümcülük Ticaret ve Sanayi A.S., unofficially
called Componenta Turkey.
•Atilla EVSEN Health Security and Education Responsible.
[email protected]
Phone number: 05524096530
•Main area of business in Componenta Orhangazi is mainly Gray and Spheroidal iron casting and partly the Compacted
Graphite iron casting. These casting methods are used for manufacturing the basic parts for heavy trucks and automobiles.
To illustrate, these parts are mainly; engine blocks, differential carriers, caps, differential cases, brake drums, brake discs
and so on.
Week 1
Week 2
Week 3
Week 4
Pattern Preparation Unit:
Sand Preparation and Core Making:
Melting Production Unit:
Fettling Unit:
•
•
•
In the third week we have been in the
melting production unit.
•
In the final week we have been in the last
stage of the process in the Fettling unit.
•
There, raw material is melted And
according to the customers’ wish
sphero treatment is executed (molten
metal is mixed with Mg).
•
Fettling unit’s main job is to make the half
product by means of some different
operations a finished product and send them
to storage depot.
•
After treatment molten metal poured
into the moulds.
•
There defects, runners and rises are
removed. Some last surface polishing and
cnc procedure is executed.
•
•
First week pattern preparation
unit has been visited . There
patterns are produced and
outside company sent patterns
are examined.
Additionally, there is another job
for the pattern production that is
when a change of defect occurs
in the core, its pattern sent
back to the pattern pruduction
center and neceserray changes
are made under the supervision
of the engineers.
Also, all patterns are kept in the
pattern production unit. There is
a huge depot for this storage.
•
Second week sand preparation and
core making process has been
observed.
In casting process sand has an
important role; mold is produced
from sand and core is also
produced from sand to give the
cavity inside the product.
•
After sand preparation core making
process begins and sand is filled to
the core pattern and pressed.
•
At the end of the process cores are
painted an sent to melting unit.
References
1.
Componenta handbook
and documents given
from the company.
2.
http://metallurgyfordumm
ies.com/wpcontent/uploads/2011/06/
ADI-microstucture.png
Semih KURDOĞLU
Turkish Patent Institute
Advisor: Prof. Dr. Kadri AYDINOL
The Turkish Patent Institute established on June 4 ,1994 in Ankara, has hereby been established, as an independent legal entity with a special budget being attached to the Ministry of Industry and Trade to be liable under special judiciary provisions for matters not provisioned by this
Decree-Law, with the objective of supporting the technological development in Turkey and of establishing and protecting of industrial property rights, as well as providing the public with the worldwide information on industrial property rights, thereby supporting the cultivation of a
competitive environment and the development of research & development activities.The vision of the instute is the Turkish Patent Institute provides effective protection and widespread usage of industrial property rights ensuring that Turkish industry and technology plays a leading role
in global competition. It strives to be a leading institution in the world of industrial property.
Person in the Organization: Salih BEKTAŞ
e-mail:[email protected]
Phone No: 03123031070
Week 1
PATENTS/
UTILITY MODELS
What is invention?
The invention is defined as the solution to a
specific technical problem. The concept of
'invention' forms the basis of the patent law. The
inventions are protected through the patent /
utility model certificate for the purpose of
encouraging the invention activities and the
attaining technical, economic and social
progresses by means of application such
invention to the industrial sectors.
Week 2
TRADEMARKS
Week 3
INDUSTRIAL DESIGN
What is a trademark?
What is industrial design?
A Trade Mark is a label that can be affixed over products or
packages and is designed in order to distinguish products or
services of an enterprise from products or services of another
enterprise and may contain personal names, special words,
shapes, letters, numbers and any symbols that can be
produced and copied by any means.
How many types of Trade Marks exist?
An invention is considered know in technology if it has
been made public by written or oral description, usage
or another way anywhere in the world before the date of
patent application. Moreover; an invention is accepted
as not known in technology when it is developed by a
professional technologist and is invented by a way
which is not evidently borrowed from any known
technology.
Shared Trade Mark
It contains of symbols used by a group engaged in a production, trade or
service administration. Shared Trade Mark is used to distinguish
products or services of a group administration from products or services
of another administrations.
Guarantee Trade Mark
Guarantee Trade Mark is a sign used to guarantee the common features,
production methods, geographical sources and quality of many
enterprises that are economically connected to an enterprise that owns
the guarantee Trade Mark which uses it for all its products and services.
Commercial Trade Mark
This is a sign that is used to distinguish products manufactured and/or
traded by an enterprise from products of other enterprises.
Trade Mark of Service
This is a sign used to distinguish services provided by an enterprise from
What is utility models?
services provided by other enterprises
What is patent?
New; An invention is considered new if it has not been
described publicly in Turkey or any other country or has
not been in use locally or inside country.
Usable in industry; An invention is considered usable in
industry if it possesses features that are useful for any
branch of industry including agriculture.
Which inventions are not included in
the Utility Model class?
Scientific theories and findings, mathematical methods,
Plans, methods and rules for mental, trade and game
activities,
Literature and art works, scientific works, creations of
esthetic quality, computer programs,
Systems for collecting, editing, presenting and
transmitting information which do not have technical
aspects,
Surgery and healing methods for human or animal
bodies, and diagnosis methods for human or animal
bodies.
.
The signs on the trademarks
It is not a must to use the symbols such as ®, TM,
SM or similar symbols and they do not provide
additional protection. In addition, use of such
symbols may be the proper way to inform the others
of the fact that the said sign is a trademark and to
warn the violators and the imitators. TM symbol
shows any sign that is a trademark while ® is used
when the trademark is registered. For service marks,
SM symbol is used.
Is registration of a trademark a must?
Although registration of a trademark is not a must,
registration is the most significant means of
evidence on the trademark and of the hindrance of
the trademark violations. Therefore, registration of
the trademarks in the countries where commercial
activities are established is highly recommended.
It is combination of various elements and features
that can be perceived by human senses such as
drawings, figures, shapes, colors, textures,
materials or elasticity which are applied to a
product, a part of a product or a decoration over a
product and put altogether.
Product; is an object made by industrial or manual
way, not including computer programs or half
conductive topographies, and may be a
combination of parts put together as sets, tackles or
packages and may be presented with multiple
objects and carry visible graphic symbols and
typographic characters.
Advantages of Design Registration
Industrial Design application is evaluated by the Turkish Patent
Institute the same date hour and minute when applied. Turkish
Patent Institute will decline Design registration applications of
other companies made after you in case their design is the same
as yours or indistinguishably resembles your design.
If the same design as a new one has never been presented
publicly in any place of the world, then this design is accepted as
new. If a design is different in only few small details then it is
accepted as the same and the next owners application will be
declined.
The right of usage of a registered design is only valid in the
country where it was registered. A product that belongs to a
registered design cannot be used by other companies. If the
company which owns the registered design can prove that their
design is being forged, it can seize the forged goods or stop the
service of forging company. The company may also apply to the
Court for compensation for moral and material harm.
Any registered brand can be sold, transferred by inheritance,
license for usage may be given, can be presented as a mortgage or
compensation.
Week 4
GEOGRAPHICAL SIGNS
The geographical sign is an industrial property right describing a product
originated from any region or attributable to any region due to its quality,
reputation or other characteristics. Any product, fruit, stone, mine of any
region may be different from those in the other regions or any
carpet, pileless carpet, fabric, tile etc may have attained reputation for
whatsoever is the reason. Use of the name of the region with such
products may be perceived by the consumers as their distinctive features
from those with similar nature. The consumers may prefer the products
sold through the
name of such regions in lieu of the other products due to the fact that they
rely on the name of the region. In this context, the geographical signs are
dimensioned in the manner that they are shaped, packaged , purchased and
sold through the traditional knowledge and they are the signs of guarantee
evidencing the quality of the product , traditional production method and
geographical origin.
What is designation of origin?
Designation of origin” indicates a name of a product, the quality or
characteristics of which is essentially or exclusively due to the inherent
natural and human factors of a place of which the geographical
boundaries have been defined. All of the steps for production, processing
and preparation should take place within the defined boundaries.
Some examples are Eskiþehir Meerschaum, Çelikhan Tobacco, Aegean
Cotton. Such products are not manufactured outside their respective
regions. It is because the products acquire their characteristics only in the
region they are made available.
Whar is the geographical indication?
The product may be manufactured in any other location provided that at
least one of the product characteristics to which a geographical indication
is linked to the defined boundary should be originated from the said
region. Some examples are, Isparta Carpets,
Damal Doll, Siirt Blanket. The nature, quality, reputation and other features
of such products may depend on the natural raw materials or human
factors which all belong to the specified location.
References
1.
http://www.tpe.gov.tr
2.
http://tr.wikipedia.org/wiki/Türk_Patent_Enstitüsü
3.
http://www.mtppatent.com
Ertuğrul Kütük
ASELSAN / Macunköy Facilities
Student’s Advisor : Kadri Aydınol
As a developer of state of the art Land, Air, Naval and Space technology, ASELSAN is Turkey’s leading defense industry company. ASELSAN has attached the utmost importance to R&D
activities as well as the advancement of technology, and endeavors to achieve its goal of increasing its share in the international market by taking part in international projects.
For the last four years, ASELSAN sustained its position in the world as being in the list of Top 100 Defense Companies.
Address : Mehmet Akif Ersoy Mahallesi 296. Cadde No: 16, 06370 Yenimahalle / Ankara, Türkiye
Name of the engineer : Kadir ÇITAK
Phone : +90 (312) 592 30 51
Fax
: +90 (312) 385 19 00
Week 1
Week 2
Week 3
Week 4
Orientation for the interns was
given by Aselsan directors and
engineers about the company’s
purposes, visions, operations
and history. Also, course for
the work safety was given by
the responsible directors.
The Brazing processes are learned
in the related department that
belongs to REHIS. Some of the
components of radars are bont and
tested in this department. Small
components are exposed to torch
brazing, and relatively bigger
Aliminium components are joint
with putting thin Aliminium sheets
between the masses and placed in
the furnaces.
In same department, radons are also
produced, fixed or tested. Radons
are the covering frames of radars
and radar components. They are
exposed to the environmental tests
including rain, salt, pressure and
temperature.
With the permission of the directors, Printed
Circuit Boards Department and Plating
Department were also seen in this week.
PCBs are designed, produced, chemically
cleaned in cleanrooms and acid baths and
prepared for the service for Aselsan’s
products.
Plating Department is responsible for the
plating copper materials with Nickel or
Gold with respect to the purpose and area
of usage. The aim is to protect the surface
from outside and in some conditions, to
give the electrical or chemical property.
- Plating Bath
References
- Torch Brazing
•
www.abbottfurnace.com/technology/brazingfundementals
•
www.marineinsight.com
•
www.tekniklab.com.tr
•
Blogs.indiium.com
•
Electronics-lab.com
- Printed Circuit Board (PCB)
Dağhan Oral
Nurol Machinery & Ind. Co. Inc.
Prof. Dr. Kadri Aydınol
Nurol Machine Division is founded in 1978 in Ankara and has undertaken large-scale projects in steel construction and machinery production. . After a while Nurol Co. involved to the defence industry while continuing
its mentioned capabilities and established its plants in Sincan Ankara Industrial Zone. Following this aim, the company had been reconstructed in 1991 with the aim of meeting the requirements of Turkish Army Force,
local and foreign defense contractors in the defense industry. Until today, it has carried out several important projects in an indoor area of 17.000 m2 on a land of 50.000 m2, with its 226 qualified and experienced
personnel. The products of Nurol , i.e. Armoured wheeled vehicles, personal carrier, combat vehicle, support vehicle, evacustion vehicle, recovery vehicle, etc. , armored subsystems like canon system, machine gun
turret, TOMAS and shelter systems. During my practise, my responsible engineer and chief was quality assurance engineer Gökçe Göksu. ( e-mail :[email protected] , phone number : 05333991202 )
Week 7,8,9
Week 1,2,3,4,5,6- Quality Control Department
Production Planning Department
Since Nurol Machine Division is performing in the defense industry and producing
his product according to customer demand, there is no continuous production at the
firm. If there is a bid, company determines a unit price to sell their product. Then if
company wins the bid, it starts to production according to demand. Therefore, in the
company there is no long term decision about the market needs and market demand.
Company can not do any forecast about the demand quantity. But in the short term
production planning department and quality control department has some decisions.
Production Planning Department makes some decisions especially about the
production schedule and requirements about the production. During my practise , I
spent not too much time on production planning, Ar-ge and Production departments.
My first priority was quality assurance department and NDT.
Fig.6. Production Flow Chart
Testing and Inspection Capabilities of Quality Control Department;
 Testing Field for below vehicle performance tests:
•
•
•
•
•
•
•
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60% vertical slope
30% vertical slope
30% right/left horizontal slope
Pool for 1,5 m. water pass test
Forward/backward 35 cm. obstacle pass over test
110 cm. trench pass test, 50 cm. trench pass test
12 m. vehicle suspension system performance test
Rain test
Test equipment for vehicle oil and cooling fluid temperature and flow rate
X-Ray NDT system
Liquid penetrant NDT system
Ultrasonic NDT system
CMM 3D measurement system
Portable hardness measurement system
Data measurement and analysis system for environment temperature conditions
Weight measurement equipment
Various length measurement equipment
Various pressure measurement equipment
Various temperature measurement equipment
Flow rate measurement equipment for liquids or gases
Paint and coating thickness measurement equipment
Surface roughness measurement equipment
Noise level measurement equipment
Fig. 1. EJDER 6X6 Armored Wheeled Vehicle [2]
NDT SECTION
Fig.2. ACE II Shelter System [2]
Fig.3. TOMA Model 2500 [2]
On this section, X-ray beams are used and filmed on KODAK Mx-125 industrial photographic paper in order to define whether the welded region is suitable for standards or not. This NDT technique
is the most common and useful technique in Nurol Machinery Division. There are two X-ray sources brand name “Balteau CF5 Radiographic Equipment.”(Fig.5). Radiography section was working on
the welding of aluminum fuel tanks in order to ensure there is no imperfections such as discontinuity or other welding defects. Since aluminum parts were welded , MIG/MAG welding was used on
these armored fuel tanks which means Metal-Inert-Gas / Metal -Aktiv- Gas. The gas that used on these welding is Argon. On the other hand the possible errors in these parts can be exampled by
discontinuity, porosity, spatter , scattered porosity( Appendix), gas cavities, etc. (Fig.4). On my summer practise , I worked on the armored fuel tanks of armored combat vehicles on NDT section. More
specifically, on radiography section, I made the quality control of the aluminum tanks’ welded regions.
Fig. 7.
Production Area [2]
References
1.
n.d.). Department of defense standard practice. Radiographic Reference Standards And Radiographic procedures
for partial-penetration aluminum welds, Retrieved from http://www.everyspec.com
2. (n.d.). Retrieved from www.nurolmakina.com.tr
Fig. 4 -
Some of important possible errors in welded regions [1]
Fig.5
-
Balteau Radiographic Equipment [3]
3. (n.d.). Retrieved from www.balteau.com.
Ekin SOLAK
BMC
BMC (British Motor Company), one of the Turkey’s leading commercial vehicle manufacturers active in all commercial vehicle segments, was established in 1964, in Pınarbaşı–İzmir, on 200.000 square
meters area. The Company has a production capacity of 22,000 engines and 21,500 vehicles per year. BMC has founded its own foundry with important investments besides its engine, chassis, and axle production centers.
BMC Foundry serves all automotive sector in Turkey and in the world with its superior technology and high production capability of 21,800 ton Per year. Parts such as engine block, and cylinder head are being cast in BMC
Foundry since 1975. The Mould Shop in BMC Foundry has an exceptional place in the Turkish casting industry with its advanced technical capabilities, and expertise manpower.
Contact Person : Ali ASLAN (Assistant Manager in Education Department)
Phone : 0(232)477 18 00 – 6720
Mail : [email protected]
Week 1
Week 2
Week 3
Week 4
Patternshop
Molding
Melting
Quality Control
Casting period starts in patternshop.
First of all, technical drawing of the object, which
is drawn by BMC itself or other companies,
comes to the patternshop. It is examined here
and a pattern is made according to that technical
drawing. Pattern making is the art of making an
original pattern or form which will be used to
make a mold.
A pattern is a form made of wood, metal
or other suitable material such as wax,
polystyrene or epoxy resin, around which molding
material is packed to shape the casting cavity of a
mold. The pattern is constructed to casting design
with the addition of: (a) shrinkage allowance, to
compensate for contraction of liquid metal during
cooling; and (b) an allowance called taper or
draft, on the vertical sides of the pattern to
facilitate the removal from the sand or other
molding medium.
For long production runs metal pattern
equipments are particularly well suited. Metal
patterns and core boxes are more costly
compared to wood patterns, but also more
abrasion resistant, stronger, and dimensionally
stable under changing humidity. They can be
fabricated for use with automated high-pressure
molding equipment, can be made to high
dimensional tolerances, and can be used for a
large number of castings before pattern repair or
rework is necessary.
There are several types of molding, but sand
molding is the one that is using in BMC. Sand molding
is one of the most versatile of metal-forming processes,
providing great freedom of design in terms of shape,
size, and product quality.
In foundry of BMC bonded sand molds are
using. In system of foundry, in order to obtain the
molding sand; silica sand, bentonite and seacoal are
mixed in the mixers with some water addition. BMC
make their molds both by using automatic machines
and also by using workers. After obtaining the green
sand, for serial production castings, whose size also
should be small within a limit, molds are filled by using
jolt-squeeze molding machine. Molds are consisting of
two parts, which are called cope and drag. Joltsqueeze molding machine fills these cope and drag in
regular turns.
BMC uses induction furnaces for melting process
of ores that will be used in casting. Induction furnaces
have gradually become the most widely used means for
melting iron and, increasingly, nonferrous alloys as well.
The key to the ready acceptance of this type of furnace
has been its excellent metallurgical control coupled with its
relatively pollution-free operation.
Currently, induction furnaces are available in a
wide variety of sizes. There are two classifications of
induction furnaces: coreless and channel.
However, for limited number of production or
bigger sized castings molds are filled by workers by
using hands and some hand tools. Since hand-made
molds are not as pressed as molds squeezed by
machine, there is a probability to spill of the sand. In
order to prevent this probability, CO2 gas is blown
inside of the sand along the holes that was made with
some big needles. The gas blown in sand makes it rigid
and tight; as a result it does not spill when turned over.
Coreless
Channel
There are 2 induction furnaces in BMC with a
capacity of 6 tons. Each of these furnaces can prepare 6
tons liquid metal (approximately 14500C) within an hour. In
order to obtain the proper liquid metal, which should meet
the needs of the properties of casting parts, charge
materials are supplied into the furnaces. These materials
are mixture of pig iron, residuals of castings, steel and
alliage, which can be ferrochromium, ferrosilicon, copper,
ferromolybdenum and ferromanganese. Charging amount
of the materials is very important because these charge
materials are placed in furnaces according to the intended
chemical analysis of the casting object.
Quality control is the last section of the foundry of BMC,
however it is one of the most important sections, because it is the
place where castings are controlled whether they are being produced
properly or not; and also whether the technical drawings, which come
to the foundry at first, are appropriate and logical or not. These
controls are being done not only at the end of the whole process but
also during the process. There are several controls under the title of
quality control. These are;
•Entrance control
•Sand laboratory
•Spectroscopy
•Metallography
•Measurement
•Last control
Entrance control : This control is done for checking the technical
drawings in order to see whether they are right or not. Another usage
of this control is to check any kind of casting part that BMC purchased
from other companies.
Sand Laboratory : Sand laboratory has just one aim, which is checking
the properties of the sand that used in both mold and core making
Spectroscopy : Spectroscopy is a electronic machine that can analyze
the chemistry of a material, in other words, it does chemical analysis of
a given sample. It is especially used during arranging the ratio of
charge materials.
Metallography : Metallography is the study of physical structure and
components of the metals by using optical microscope. In BMC,
tensile test samples are taken according to the weekly schedule. After
the tensile test is done, a little part is taken from the broken part. It is
first grinded then polished. Afterwards, it is examined under the optical
microscope.
Measurement : Measurement examination is done in order to check
the casting objects in right dimensions.
Last control : This is done when all the processes are over. It is not a
detailed control, rather it is done by naked eye whether there are any
defects on the castings or not.
References
1) www.bmc.com.tr
2) ASTM Metals Handbook Vol.15 – Casting
Hüseyin Doğukan YAĞBASANLAR
TEMSA
Prof. Dr. Yavuz TOPKAYA
TEMSA Adana, Yolgeçen Mahallesi, Turhan Cemal Beriker Bulvarı, No : 561, 563 01323 Seyhan / Adana / Türkiye , Contact Person: Bülent Köprülü/ Human Resources Phone No: +90 322 441 02 26
e-mail: [email protected], Company Information: Automotive Company; manufactures and distributes Temsa brand buses and coaches in domestic and international markets,
and represents Mitsubishi and Komatsu as their distributor in Turkey
Week 1
Week 2
Week 3
Week 4
Job Health and Security department,
Planning department,
Quality Control department,
Material Laboratory,
R&D department,
Production lines are observed.
ATOS surface scanning compares the experimental and
Before
After
Heat deflection temperature test determines the
theoretical dimension of the sample.
temperature at which the plastic samples
The pressing test is done to control the welding
deform under a specified load (10 MPa). The temperature
stitches of the samples.
values are different for 3 stations because dimensions of
the samples are not same.
Resin transfer method
Hand lay-up
LK 3D measurement device can measure the distance between
The results of the tensile test are observed that
any two points at 3 dimensions, and determine a hole and
the composite produced by resin transfer
transfer the hole to the computer screen.
method (RTM) is stronger than the composite
After the chassis assembly is finished, welding
Muffule furnace separated resin and fiber from each
produced by hand lay-up.
process of side, front and back panels are done to the
other; so, fiber ratio of the sample can be determined.
chassis in body welding.
References
http://www.temsaglobal.com.tr
Gözde ÇAMBEL
MITAS Energy and Metal Construction INC.
Assist. Prof. Dr. H. Emrah ÜNALAN
MITAS was established in 1955 in Ankara. The main fields of the company were determined as energy transmission lines, lighting poles,
GSM poles, advertisement poles, bolt and nut production, and hot-dip galvanizing. MITAS carries out these activities in its total 82,000 m2
manufacturing facilities, of which 42,000 m2 is indoor.
Contact person: Özgün KELEŞ (Lattice tower Galvanizing Manager )
Telephone: 0312 296 28 03 e-mail: [email protected]
Week 1
•
•
Galvanisation is the process
of applying a protective zinc
coating to metal, in order to
prevent rusting and galvanic
corrosion
Although galvanisation can
be done with electrochemical
and electrodeposition
process, the most common
method in current use is hotdip galvanizing, in which steel
parts are submerged in a bath
of molten zinc.
Week 2
PROCESS STEPS IN HOT-DIP
GALVANISATION
• Jigging,
• Surface Pretreatment,
• Rinsing with water,
• Fluxing,
• Drying,
• Galvanisation,
• Post-treatment (If passivation is
needed),
• De-jigging,
• Finishing and Detailing,
• Logistics to the installation site
Week 3
GALVA 12.5 FURNACE
Galva 12.5 plant,, is a facility where
generally jobbing materials and
polygon poles are galvanised, with a
monthly capacity of 5000 tons. The
plant incorporates fully automatic,
PLC-PC controlled and
programmable material transport and
process systems. It is equipped with
3 black (un-galvanised) material
loading stations and 2 white
(galvanised) off-loading stations.
Week 4
QUALITY CONTROL PROCESSES
•
Tensile test , Charpy impact test and
chemical composition test are done
before the production is started.
•
Coating thickness in zinc coated materials
is inspected by means of electronic
micrometer. In addition, average
thickness is also determined by acid
peeling test.
•
Bending test is applied in order to
determine whether brittleness has
occurred in the products as a result of
galvanising process
Figure 6: examination of coating thickness
Figure 2: Jigging
FİGURE 5: Galva 12.5 Furnace



Figure 1: Galvanization process
figure 4:Drying
Figure 3: surface pretreatment

Furnace dimensions (L x W x D): (12.5m x
1.55m x 2.5m),
Operating Temperature: 430-450°C,
Liquid Zn alloy in the furnace is;
(12.5x1.55x2.4 (usable depth in meters) x
6.57 (density of liquid Zn))
=> 306 tons of liquid Zn alloy
Figure7: tensile test machine
References
Retrieved from http://www.mitasgalvanising.com/index.php?l=en
Retrieved from http://www.galvanizeit.org/
Abdurrahman Özdemir
MITAS Energy and Metal Construction INC.
Assoc. Prof. Dr. Caner DURUCAN
MITAS was established in 1955 in Ankara. The main fields of the company were determined as energy transmission lines, lighting poles, GSM poles, advertisement
poles, bolt and nut production, and hot-dip galvanizing. MITAS carries out these activities in its total 82,000 m2 manufacturing facilities, of which 42,000 m2 is indoor.
Contact person: Reşat Larçin (Manufacturing Manager, Galva 14)
Week 1
Week 2
Galvanised steel is steel that has
PROCESS STEPS IN HOT-DIP
GALVANISATION
• Jigging,
• Surface Pretreatment,
• Rinsing with water,
• Fluxing,
• Drying,
• Galvanisation,
• Post-treatment (If passivation is
needed),
• De-jigging,
• Finishing and Detailing,
• Logistics to the installation site
been coated with zinc in order
to prevent rusting / corrosion.
Sometimes the galvanising
process is referred to as hot
dip galvanising. The zinc forms
a barrier against corrosion in
that the steel underneath does
not come into contact with
Telephone: 0312 2962000
e-mail: [email protected]
Week 3
(Galva 14 Plant)
Week 4
(Quality Control)
Its dimensions are 14m x 1.8m x 2.2m.
•
Tensile Test
•
Charpy Impact Test
•
Chemical Composition Test
•
Electronic micrometer inspection
•
Acid Peeling Test
•
Bending Test
•
Hammer Test
Generally jobbing materials and
polygon poles are galvanised in this
plant with a monthly capacity of 5000
tons.
water / moisture in the air.
Figure7: Electronic Micrometer
Figure 3: Jigging
Figure 8: Test Hammer
Figure1: Hot Dip Galvanising
Figure 6: Galva 14
Figure 2: Rust
Figure4: Surface Pretreatment
Figure 5: Drying
References
•
www.mitastower.com
•
www.technologystudent.com
Furkan ÖZDEMİR
Componenta A.Ş
Assoc.Prof.Dr. Caner DURUCAN
• Componenta is a major casting solutions provider in Europe. With local presence in key markets,Componenta serve customers by providing
them solutions, from engineering to component .
• Products: Grey Iron, Spherodized Iron, Compact Graphite Iron Components in Orhangazi,Bursa
• Contact Person in the Organization: •Atilla EVSEN,Health Security and Education Responsible. [email protected], 05524096530
Week 1
Melting Production Unit:
• Metal with scrap and return
is melted according to the
desired composition.
•Raw material is prepared
according to component
• Chemical Analysis And
Week 2
Moulding Production Unit:
Week 3
Core and Pattern Making:
Week 4
Fettling Unit:
• Sand Molding is applied in the
foundry with 6 horizontal and
2 vertical molding lines.
•After sand preparation core
making process begins. Sand is
filled to the core pattern and
pressed.
•Fettling unit’s main job is to complete
the half product with mechanic
applications like cutting and grinding
and sending them to storage depot.
•At the end of the process, cores
are painted an sent to melting
unit.
•Defects, runners and risers are
removed .Last surface polishing
and CNC procedure is executed.
Material Types
References
•
http://www.componenta.com/
•
Componenta Handbook and Documents Given From the Company.
•
http://www.themetalcasting.com/articles/2008/08/cast-irons-an-overview.html
Erhan ÖZEN
Turkish Patent Institute
Advisor: Prof. Dr. Cemil Hakan GÜR
The Turkish Patent Institute (Türk Patent Enstitüsü) (TPE) is an intellectual property organization with a special budget being attached to the Ministry of Industry and Commerce of the Republic of Turkey. Established on June 24, 1994 in Ankara as an independent legal entity, it is liable under special judiciary provisions with the
objective of supporting the technological development in Turkey and of establishing and protecting of industrial property rights, as well as providing the public with the worldwide information on industrial property rights. As mentioned under the Vision of the institute, "The Turkish Patent Institute provides effective protection and
widespread usage of industrial property rights ensuring that Turkish industry and technology plays a leading role in global competition. It strives to be a leading institution in the world of industrial property.“
Contact Person in the Organization: Salih BEKTAŞ
e-mail:[email protected]
Phone No: 03123031070
Week 2
TRADEMARKS
Week 1
PATENTS/
UTILITY MODELS
What is a trademark?
What is patent?
Patent, granted to the inventor for an invention, is one of the
industrial property rights and it grants the right to prevent the
production, utilisation or sale of the invention by others without
permission of the inventor.
What is utility model?
The utility model is a system which provides protection of the
novel not only in Turkey but also all through the world and
industrially applicable inventions. The procedures for the
issuance of a utility model certificate are much more convenient
than the patent certificates in terms of time and expenses. It has
been considered that the simple and inexpensive procedural
proceedings for utility models may encourage especially the
small and medium scale enterprises (SMEs) and research
institutions to make an invention and apply such inventions to the
industry. Besides, particularly today, there exists a risk for the
imitation of the inventions realised by the small and medium
scale industrialists by the competitors in almost the
same manner. Even if an invention is small and modest, the
issuance of the utility model certificate for such an invention will
serve as protection of the SMEs and their perpetuation
economically.
Novelty
Inventive Step
Industrial
Applicability
Methods and the
products resulted
from such methods
Chemical substances
Search
Examination
Publication
Protection Period
Patent
+
+
+
+
+
Utility
Model
+
˗
+
˗
˗
+
+
+
+
20/7 years
The trademarks are protected mainly through registration. Registration
of a trademark makes available a sound protection against particularly
disputes arising from similarity or identical aspects, which may lead to
confusion. Many people consider that registration of the
commercial title and the commercial company into the trade registration
offices mean simultaneous protection of the trademark. This is
the most common misperception. It is important to comprehend the
differences between the commercial titles and the trademarks.
Commercial title is the full name of your company e.g. “Abc Kimya
Sanayi Anonim Şirketi” etc and identifies your company. Such titles
generally end with “Ltd. Co.” or “Corp.”, which defines the legal
structure of the company. The trademark is the sign, which makes your
product/products different than others. Any company may have various
trademarks. For example; “Abc Kimya Sanayi Anonim Şirketi”
may use different trademarks for the different products marketed by the
said company. Such trademarks may not only be similar with the
commercial title (e.g. “ABC”) but also a totally different wording than
the commercial title (e.g. XYZ).
• Registration of a trademark shall grant the holder of the said
˗
˗
˗
+
10 years
SEARCH
EXAMINATION(1-3 times)
The Patent Certificate
20 years
Protection of the trademarks
What rights are acquired through
registration of the trademark by the
trademark holder.
PATENT APPLICATION WITH EXAMINATION
Positive Report
Trademarks are the signs of the goods and services provided by any
enterprise to make them distinct from those provided by other
enterprises. Words, letters, numbers, drawings, pictures,
figures, colours, logos, labels and a combination of these used
specifically for the purpose of distinction of such goods and services
may be accepted as trademark.
Negative Report
Refusal
with Examination
trademark the right of sole use of the trademark and protect
unauthorised use of such trademark.
• It grants the right of unauthorised use of any mark which may distort
the distinctive character of any registered trademark, provide unfair
advantage through the creditability of any registered trademark, or lead
to any confusion with respect to the similar or identical goods and
services which fall within the scope of the trademark registration.
• Any registered trademark may be assigned to another, inherited to the
successors, licensed for utilisation rights, pledged or denominated as a
guarantee.
• The trademarks not yet registered cannot enjoy the rights and
protection through the law pertinent to registration and protection of
trademarks.
Week 3
INDUSTRIAL DESIGN
Week 4
GEOGRAPHICAL SIGNS
What is an industrial design?
What is a geographical sign?
The industrial designs are any product or pieces of such products which
accompany us in our daily lives and facilitates our lives; the patterns,
ornaments which make our lives colourful and address our senses. The glass
out of which we drink water, the introductory posters of a movie, the
patterns on our clothes, calculator, keyboard , chair, jacket, car, traffic
plates, watch, thermometer, toys, the page-setting of the date book, glasses,
bags etc are the examples to this. So, the design can best be expressed as the
entirety of the various features such as lines, colour, texture, shape, sound,
elasticity, material or other characteristics perceived by the human senses of
the appearance of the whole or part of a product or its ornamentation.
What is the scope of the rights for
designs, how does registration protect ?
The holder shall have the exclusive rights through protection of industrial
design by registration. The third parties cannot produce, market, sell, import,
or enter into contract, use the same for commercial purposes or with hold
the registered designs without permission of the holder of the design rights.
What is the novelty in designs?
If the design has not been made available to the public in the world prior to
the application date or the priority date, such a design shall be deemed to be
“new”. If the designs differ only in immaterial details, they shall be
considered as identical. To make available to the public shall cover of all
actions of sale, use, publication, publicity, exhibiting, or such similar
activities. If a design for which protection is claimed has been made
available to the public during the twelvemonth period preceding the date of
the filing of the application by the designer or his successor in title or by a
third person having their approval, such disclosure shall not affect the
novelty.
What is an individual character?
A design shall be understood to have an individual character if the overall
impression it creates on the informed user is significantly different from the
overall impression created on the same user by any design.
What is priority right?
It shortly means the priority rights. Depending on the previously made
proper applications for the design registrations abroad or on the exhibitions
for this specific purpose, the Applicants will hold priority rights to make an
application in Turkey for the same design within six months as from the
date of first filing.
The geographical sign is an industrial property right describing a product originated from
any region or attributable to any region due to its quality, reputation or other
characteristics. Any product, fruit, stone, mine of any region may be different from those
in the other regions or any carpet, pileless carpet, fabric, tile etc may have attained
reputation for whatsoever is the reason. Use of the name of the region with such products
may be perceived by the consumers as their distinctive features from those with similar
nature. The consumers may prefer the products sold through the name of such regions in
lieu of the other products due to the fact that they rely on the name of the region.
What is the superiority of the geographical signs over
other industrial property rights?
The superiority of geographical signs over other industrial property rights is that it
protects not only a manufacturer who applies for the registration of a geographical sign
but also all those people manufacturing under same conditions. Because geographical
signs have some sort of anonymity, a kind of local, regional, country wise generality , the
rights provided through such signs cannot be attributed to an individual or individuals.
Why the registration of a geographical sign is
required?
The registration of any geographical sign is made due to two reasons :
1. Protection of the quality of the product which is the subject of the geographical sign
and provision of the production according to the known speciality.
2. Provision of the benefiting from the protection of the manufacturers and the region
for which geographical sign is granted, through registration in the first priority. The
consumers may prefer such products due to their reliance on the region and the products
which are sold under the name of such region. Therefore it is beneficial for the people of
the region to protect the name of the region which has become the symbol of quality for
any given product as a geographical sign. A geographical sign adds dynamic marketing
power to the product and functions as the regional or social development tool through
its anonymous possession force. It is especially an important means for rural
development. One of the aims and benefits of the protection through geographical sign is
to prevent misleading the consumers by using the wordings on the geographical signs on
false products which fail to attain the necessary characteristics. Thus it assists in the
protection of the consumers.
References
1.
http://www.tpe.gov.tr
2.
http://tr.wikipedia.org/wiki/Türk_Patent_Enstitüsü
Zeynep ÖZTÜRK
TÜBİTAK MRC
Prof. Dr. Cemil Hakan GÜR
TÜBİTAK MRC Materials Institute is a
scientific research & development and
technology center in the field of materials
technologies.
ELECTRON MICROSCOPS
AND ATOMIC FORCE
MICROSCOPS
LABORETORIES
HRTEM, SEM, and AFM were
introduced and sample imagings
were observed at each of them.
Sample preparation steps were
represented and experienced.
HRTEM(JEOL JEM 2100 LaB6):
Imaging of the crystallographic
structure of a sample
at an atomic scale
is done.
Contact Person: Dr. Özgür DUYGULU
INVESTMENT CASTING AND
TITANIUM TECHNOLOGIES
LABORATORY
Three main investment steps consist of
wax injection, ceramic mold making
and casting were told and shown.
In the laboratory stainless steel / cobalt
base implants, non-porous
complicated shape aluminum castings
are being studied and developed.
Research on investment casting of
titanium and its alloys is also initiated.
Some small titanium pieces had been
casted and were on display.
Electron microscope, ceramic, investment
casting and coating & corrosion (sol-gel)
laboratories were subjects of the summer
practice.
CERAMIC LABORATORY
There are wide fields of activity in ceramic
laboratory, such as Al2O3 based
engineering ceramics, forming and
shaping techniques, recycling and
managing of industrial solid wasted,
glass and glass ceramics, archeological
ceramics, cement, porous ceramics,
natural raw materials, ceramic filters and
nozzles, electronic ceramics.
Extrusion and slip casting which are
forming and shaping techniques and
cement were told and experienced.
COATING AND CORROSION
LABORATORIES (SOL-GEL)
Using recent nanotechnological advances within
the nanostructured materials, the project group
provides technical solutions to the surface
problems and develops coatings for functional
applications via sol-gel techniques. Sol-gel is
one of the techniques for the formulation of
functional coatings allowing to operate at low
reaction temperatures with evaporation losses,
small volumes, homogeneous mixtures, low
viscosity solutions. These advantages of sol-gel
technique enable the formation of powders,
gels, films and membranes.
Figure 1. HRTEM result
SEM (JEOL JSM 6335F FEG) & Low
vacuum SEM (JEOL JSM-6510LV
SEM ): Surface
morphology of
samples can be
investigated.
Figure 2. SEM result
AFM is a surface examination
technique. In addition to
topographic
imaging, z-height
and roughness
information can be
obtained too.
Figure 3. AFM result
Uncoated
Figure 6. Extruded cordierite ceramic filters
Figure 4. Investment casting route[1]
Coated
Figure 8. Functionalisation of Denim and Gabardine
Textiles by Hydrophobic and Crinkle Speciality
Coatings
References
1. http://www.custompartnet.com/wu/images/in
vestment-casting/investment-castingsmall.png
Figure 5. Investment casting and Titanium
casting products
2. http://www.mam.gov.tr/ME/index.html
Figure 7. Optimization and research of
production of İznik china [2]
3. TÜBİTAK MRC Materials Institute Catalogue
Summer Practice II METE 400 Fall 2012/2013
Muhammad Ichsan
PT MULIA JAYA MANDIRI
Prof. Dr. MACİT ÖZENBAŞ
Oil Tools Fabrication and Repair Facilities, Manufacturer of Casing & Tubing Accessories, Thru Tubing Intervension Services
Balikpapan, Jl. Sultan Hasanuddin No. 22 RT.48 Karang Joang Kec Balikpapan Utara 76127
Phone: +62-542-7208690 ; email : [email protected] ; website : www.muliajaya mandiri.com
Week 1 : Introduction
Week 2 : Manufacturing
For the first week during
my
summer
practice,
there was only brief
introduction
about
company, safety in factory
and also the engineer
explain about types of
steel that used in the
factory
with
their
properties too.
Manufacturing process start
with cutting the material
and
then
shaping
its
through the CNC machine.
Most process goes through
CNC Lathe machine and
CNC Milling machine during
this shaping.
Week 3 : Quality Control
Quality control consist of
hydrostatical test , and
measuring accurate size of a
products.
After
every
manufacturing process, the
engineer measure the size of
the product .
Week 4 : Finishing and Packaging
Finishing include the painting
process of an product, since
painting is the cheapest and
easiest way to pretend the
corrosion
Reference
www.muliajayamandiri.com
Biadelma Nanda Illiandi
Construction and Building Materials Laboratory at Syiah Kuala University
Advisor : Prof. Dr. Abdullah Öztürk
Syiah Kuala University (UNSYIAH) is the oldest and the largest national university in Aceh Province of Indonesia. It was founded on September 2, 1960. This institution has up to 131 laboratories for
students, professors, and also for community service. The summer practice program was conducted under a supervisor whose name is Dr. Ir. Abdullah
([email protected]/+62811687767) and he is the head Construction and Building Materials Laboratory. A new building material for the people in that area is being developed in the
laboratory and it is called Batafoam. In the 5 different process to produce this material, only three main raw materials are needed. This material has several advantageous properties to be applied to the
buildings, houses, and schools in that developing city.
Week 1
During the first week, all about the
laboratory was introduced directly by
the head of Construction and Building
Materials Laboratory. Moreover, an
overview about the production of the
lightweight foamed concrete, or
specifically Batafoam, was explained. I
was also introduced to a master
scholar who is studying his graduate
program at this institution.
Week 2
Week 3
In the second week, we focused to
understand thoroughly about the
production process of the Batafoam.
Starting from introduction to the raw
materials, the equipment, and finally
the five main production processes.
During the third week, from the production
process we moved to study the superior
properties of the Batafoam. This is done
by consulting to the professor in the
laboratory who has conducted various
experiments about the Batafoam. `
Raw Materials
Superior Properties
Low
Density
Cement
Water
Foam
Proportioning Process
Batafoam
Batafoam can be interpreted as a
concrete in which there are air
bubbles
are
distributed
and
dispersed homogenously in the
concrete mass. The surface structure
of Batafoam resembles the usual
structure of concrete which is
generally porous.
Mixing Process
Week 4
A Perfect
Heat
Insulator
An
Excellent
Sound
Absorber
Transportation Process
Long
Durability
Casting and Placement
Process
Has Self
Levelling
Ability
• The overall weight of the load can
be reduced by third.
• Suitable for the low quality soil
construction area.
• Cannot dissipate heat from the
inside of the room to the
outside, or in other words, it can
make the temperature constant.
In the fourth week, we started to focus on the
application of the Batafoam. The method to
install this material in a construction of a
building and its time efficiency is explained by
the supervisor.
Based on the superior properties that have
been possessed by this lightweight foam
concrete, the Batafoam, this material attracts
some contractors. And they have applied it to
some existing buildings in the Province of
Aceh. These buildings which use the
Batafoam instead of ordinary red brick in their
construction in Banda Aceh, namely Lab
School Unsyiah (Picture), the houses which
are the donations for the earthquake and
tsunami victims, and official building.
• Unlike the conventional concrete
which tends to reflect the sound,
this foamed concrete generally
absorbs the sound.
•Batafoam that has been casted on 10
years before only had 75% of the cement
hydration. Thus, the development of the
strength can be expected to continue
taking place by the hydration.
• At the time this foamed concrete in
the form of cement paste, they will
fill overall the gaps and vacancy in
the molds in the casting process
Lab School Unsyiah
References
Curing Process
Surface Structure of Batafoam
Quick
Installation
•The comparison of dimensions
between Batafoam with the ordinary
red brick is 1:8. Then the installation
time of Batafoam to a building
construction is more than five times
faster..
Abdullah.(2010). Lightweight Concrete as Alternative Construction Material. Research Report to Directorate General of Higher
Education of Indonesia.
Abdullah and Surya B. (2007). Development of Foamed Concrete as Construction Material. Seminar on Research Result, Batam,
Indonesia.
Gambhir M L. (2004). Concrete Technology 3rd Edition. The McGraw-Hill Company: New Delhi.
Zulfian, Abdullah, Fahridhal. (2010). Determination of Sound Absorption Value in Foamed Concrete Wall Panels for the
Environmentally Friendly Alternative Panel. Journal of Chemical and Environmental Engineering, page 7-12: Syiah Kuala University.
Mustafacan Kutsal
Arçelik A.Ş. R&D Centre, Materials Technologies Laboratory
Advisor: Prof. Dr. Hamdullah Mekhrabov
•
Arçelik A.Ş. R&D Centre, Materials Technologies Laboratory has been working on developing processes, new materials and enhancing these technologies for all
household appliences on Arçelik’s catalog.
•
Contact Person: Alper Yeşilçubuk, PhD., Project Group Leader.
Tel: (0216)585 8565 E-mail: [email protected]
Week 1
Week 2
Week 3
Week 4
The subject of the project that had
been conducted is determined as
«Lead-free solder alloys and
enhancing their properties by
microalloying
with
transition
metals».
Three ternary alloy samples;
To observe whether Fe microalloying did
enhance or worsened the properties, a
simple test is done for all the alloys.
The wetting angles were obtained by a costum
made contact angle device.
An intensive literature review was
done about the alloys that are used
by the global market leaders and
the alloys used in Arçelik
products.
Sn-Ag-Cu ternary system was
selected as the alloy system of
concern,
since
several
compositions of this system (Sn3Ag-0.5Cu and Sn-1Ag-0.5Cu) are
being used in electronic parts of
Arçelik products.
Furhermore, a brief patent review
was done for the lead-free alloy
compositions and for microalloyed
lead-free solder compositions.
•
SAC 305 (Sn-3Ag-0.5Cu)
•
SAC Eutectic (Sn-3.5Ag-0.9Cu)
•
SAC 205 (Sn-2Ag-0.5Cu)
and three Fe microalloyed samples
•
SAC 205-1 (Sn-2Ag-0.5Cu-0.05Fe)
•
SAC 205-2 (Sn-2Ag-0.5Cu-0.1Fe)
•
SAC 205-3 (Sn-2Ag-0.5Cu-0.2Fe)
were produced by the apparatus in the
below figure.
The apparatus consists of a quartz tube
as container, a silicone tap and two
copper pipes that is planted on the
silicone tap.
From the literature, it is known that wetting
is an critical property that affects a
solder alloys reliability[1]. It is also
known that electronic cards that are used
in Arçelik products have copper
substrates. Thus, wetting angles of all
six alloys, ternary and microalloyed, are
determined
just
by
melting
and
solidifiying tiny pieces of solder on
copper plates as seen in the figure
below.
Each alloying constituent was weigthed
in a presicion balance and was put into
the quartz tube. Before the melting
process, argon gas is given inside the
tube via one of the copper pipes to
obtain a cleaner athmosphere. The
argon gas reimained flowing during the
melting, also.
The results shows that SAC 305 has the best
wetting angle among ternary alloys.
However, SAC 205 with %0.1 Fe has the best
wetting angle among both microalloyed and
ternary alloys (SAC 205 has worser wetting than
SAC 305).
Hence, this proves that microalloying can
enhance certain properties of lead-free solders.
44
43
42
41
40
47
39
46
38
45
37
44
205
205-A (%0,5 Fe)
205-B (%1,0 Fe)
205-C (%2,0 Fe)
43
42
References
41
40
305
Eutectic
205
[1] Abtew, M., & Selvaduray, G. (2000). Lead-free solders in microelectronics. Materials Science and
Engineering Reports R, 27, 95-141.
Sena OKAY
INM-Leibniz Institute for New Materials
Prof.Dr.Ali Kalkanlı
INM is mainly a science based institute, however,
some projects are handled collaboratively with the
industry by different research groups.
•
The main mission is to make a pilot production from a
molecule.
•
Week 1 & 2- INM and CVD/Biosurfaces
Group & Project
•
•
Research Groups and Fields in INM; Functional
Surfaces, Metallic microstructures, Nanotribology,
CVD/Biosurfaces, Biomineralization, Nanomers, Nano
Cell Interactions, Nanoprotection and Optical
Materials are the basic research fields in the institute.
The topic for the internship project was
determined as “The Optimization of the
DLC device” by changing only the time
parameter and sample preparation was
done.
LITERATURE REVIEW
Diamond-like carbon (DLC) films are
metastable, amorphous, hydrogenated
or non-hydrogenated forms of carbon
material, which may contain microcrystalline phase of diamond with
significant sp3 bonding.
DLC is a semiconductor with a high
mechanical hardness, chemical
inertness and optical transparency
together with attractive tribological
properties which is processed by
Plasma Enhanced Chemical Vapor
Deposition (PECVD)
Water droplet
•
•
First Argon (Ar) gas (200 sccm) was sent
to the chamber to activate the ions and
the process starts. [2]. Acetylene (C2H2)
(350 sccm) was chosen as hydrocarbon
and tetramethylsilane (abbreviated as
TMS) (250 sccm)- the chemical compound
with the formula Si(CH3)4 –was used for
the middle layer for adhesion.
e-mail: [email protected]
Week 5 & 6 – Transmissivity Measurements & Discussion
The contact angle measurements were
performed by using Krüss Drop Shape
Analysis DSA II device and related software.
Water droplets were used for measurement.
•
Figure 2. The experimantal device
(CVD-Piccolo/Domino by Plasma Electronics)
Dr. Cenk Aktaş – CVD/Biosurfaces Group Leader
Week 4- Contact Angle and Thickness
Calculations
Week 3- The Experiment and Coated Samples
Adjustment to the institute and the
CVD/Biosurfaces research group
Contact Person:
Glass Surface
Figure 3. The
example for contact
angle (56 degrees)
The thickness measurements were
performed by using the device 3D
profilometer Surfcom 1500 SD3 by ZEISS.
•
Table 1. Contact angles
Time (min)
The experiment was started with 2
minutes coatings and followed by 4
minutes, 6 minutes and 15 minutes. After
15 minutes in order to see the difference
more obviously the time were increased
10 by 10 until 1 hour is reached.
Contact
angle
(degree)
15
40.15
25
48.54
35
52.79
45
53.68
55
74.47
2
4
6
15
25
35
45
55
Figure 1. The schematic sketch of the
PECVD device working principle (retrieved
from www.springerimages.com)
15 min coated sample
6 min coated sample
55 min coated sample
Thickness (nm)
2 min coated sample
800
600
400
200
160 190
116
0
0
10
%T
(15 min)
%T
(25 min)
%T
(35 min)
%T
(45 min)
%T
(55 min)
500
63.6
48.19
37.28
37
36.05
550
74.3
65.92
59.62
59.34
57.12
600
81.75
76.2
70.61
70.21
69.46
650
87.44
82.99
78.61
78.43
80.18
700
91.67
87.5
86.15
86.22
84.24
DISCUSSION
Increasing with time, some adhesion problems started
to occur after 35 minutes.(Fig. 5-6)
453.7
631.5
Problematic region
Figure 5.Adhesion problems
(35 min coated)
•
y = 15.933x + 78.099
R² = 0.9963
1000
Wavelength
(nm)
Thickness
(nm)
116.0
160.0
190.0
282.1
453.7
631.5
807.1
963.8
Thickness vs time graph
1200
Table 3. The transmissivity data
Table2. Thicknesses
Time (min)
963.8
807.1
For the transmission measurement, UV/Vis – NIR
device was used.
•
Problematic region
Figure 6.55 min coated sampledirect contact with the metal
holder
Thickness increases with increasing time. When the
coatings above 15 min are discussed, it is easy to see
the linear increment between these samples with a
rate around 17.7 nm/min.
282.1
20
30
time (min)
40
50
Figure 4. The thickness vs time graph
60
References
[1]Gupta,P. (2003). Synthesis, structure and properties of nanolayered dlc/dlc
films. (Master's thesis). Louisiana State University, LA
[2]N. Mutsukura and K. Miyatani, Diamond Relat. Mater. 5, 342 (1995).
[3](n.d.). Retrieved from http://www.inm-gmbh.de/en/about-us/
AHMET DURSUN
ERKUNT TRACTOR INC.
PROF. DR. AMDULLA MEKHRABOV
Erkunt Tractor Inc. is a member of the ERKUNT group which isthe second largest casting and machining company in Turkey.
Dilek EKEMEN ([email protected])
With two foundries and a machining plant, Erkunt Inc. provides 6 sigma quality casting and machining products for agricultural tractor and automotive industries.
Week 1
Week 2
Week 3
Week 4
• 
• 
Visiting Metallurgy Laboratory
•  Visiting other parts of the factory
•  Preparing and presented a final
presentation
• 
Hardness Testing
•  Observing Flexible Manufacturing
System (FMS)
•  Visiting Ar-Ge department
•  Visiting Model Workshop
•  Observing products
• 
• 
Orientation about summer
internship
Having a training about job
security
Having a training about fire
safety
• 
General information about
factories
• 
Visiting factories
• 
• 
Observing Microstructures
Checking reports of materials
•  Visiting Casting Factory
References:
http://www.erkunttraktor.com.tr
http://www.armatrac.com/products.php
My Erkunt Traktör Presentation
0312 592 10 41
0312 592 10 47
Buket Arslan
ASELSAN
Prof. Dr. Mehmet Kadri AYDINOL
•
ASELSAN is the center of advanced technology to meet the electronic product and system
needs of Turkish Armed Forces in the most favorable price-time-quality conditions so as
to minimize external dependence, to lead the development of national defense industry
Brazing
Types of Brazing:
•Torch brazing
•Furnace brazing
•Silver brazing
•Braze welding
•Cast iron ‘’welding’’
•Vacuum brazing
•Dip brazing
•
Contact Numbers for the Organization:
0312 592 10 41
0312 592 10 47
Cleaning processes
Process of Brazing
• The surfaces should be cleaned carefully
Torch brazing:
Case: How the filler thickness
affect strenght?
Pre-cleaning stage:
Advantages of Brazing :
• It's easy to learn.
• You can join virtually any dissimilar
metals.
Three types of torch brazing;
• The bond line can be very neat in
appearance.
-manual torch brazing
-automatic torch brazing
• Joint strength is strong enough for
most non-heavy-duty use applications.
Disadvantages of Brazing :
• A badly brazed joint looks similar to a
good joint, and can have a VERY low
strength.
•The metal used to bond the two parts
may be different in color than the parts
being bonded. This may or may not be a
problem.
• Long-term effects of dissimilar metals
in constant contact may need to be
examined for special applications.
•Since the filler material melts at a
relatively low temperature, brazed parts
may not be put in an environment which
exceeds the melting point of the filler
metal.
-machine torch brazing
• It is best used in small production volumes or in
specialized operations
• Manual torch brazing is a procedure where the heat
is applied using a gas flame placed on or near the
joint being brazed.
• Machine torch brazing is commonly used where a
repetitive braze operation is being carried out.
Ultrasonic cleaning stage:
• Acetone (99% purity) is performed
• Effective on the pieces which have
complicated geometry
As an estimated conclusion if the filler materials
thickness increases, the strenght of the brazed
material will increase. However, it is valid only up to
some certain thickness value.
• Automatic torch brazing is a method that almost
eliminates the need for manual labor in the brazing
operation, except for loading and unloading of the
machine.
Vacuum brazing:
• Temperature uniformity is maintained on the work
piece when heating in a vacuum, greatly reducing
residual stresses due to slow heating and cooling
cycles.
• Vacuum brazing is often conducted in a furnace
References
Aselsan. (n.d.). Retrieved from http://www.aselsan.com/Default.aspx
Brazing. (n.d.). Retrieved from
http://www.stanford.edu/group/prl/documents/html/brazing.htm
What is brazing?. (2013). Retrieved from http://www.wisegeek.com/what-isbrazing.htm
Cansu SAVAŞ
Turkish Aerospace Industuries
•
Designing, development, modernization and manufacturing aerospace systems.
•
Banu AKTİMUR
Tel: (0312) 811 18 00/ 2568
Week 1
Week 2
Week 3
Week 4
Internship Orientation
• Briefings:
 History of TAI
 Working area of TAI
 Main products of TAI
 Work safety and health
care in TAI
 Facilities, technologies
and services .
 Aim and vision of TAI.
• Buildings:
 Cemical Building
Helicopter Facility
10th Building
Clean Room no:1
Clean Room no:2
Composite
lay-up
and
honeycomb sandwich panel
making were observed.
Carbon fiber laying machine
kevlar and glass fiber were
observed.
• Composites:
• Carbon fiber laying Machine:
Autoclave
Lay-up composites are cured under
certain pressure and temperature at
furnace called autoclave.
Tooling
Scrab composites and resin is cut
of at tooling.
Testing
Finished parts are tested at NDT
machine which uses water for testing
 Ply Cutter is used for
forming carbon fiber fabric.
 It is applied on desired
shapes by the workers.
 Vacuum back is applied to
remove any gas bubbles
between layers and then it is
sent to the autoclave.
• Honeycomb:
 Honeycomb is applied
between two metal sheets.
 For
big
and
detailled
patterns machine is used.
• Glass Fiber:
 It is used for inside parts
because of its low durability.
• Kevlar:
 It is used for
the parts
which
work
under
high
pressure.
New test part was done by interns
to see which material is good and
which procedure is easy to do.
Autoclave
NDT machine
References
Honeycomb
Carbon Fiber
Glass Fiber
Carbon lay-up
Machine
1)www.tai.com.tr
2)www.aero-mag.com
3) www.ccm.udel.edu
CANSU BİLGİN
HÜSNÜ EMRAH ÜNALAN
TUSAŞ ENGINE INDUSTRIES, INC
TEI is a joint-venture company established in 1985 with the partnership agreement signed by Turkish partners (TUSAS-Turkish Aerospace Industries INC., Turkish Armed Forces Foundation and Turkish
Aeronautical Association)(53.78%) and General Electric (USA) (46.22%). Established with the aim of building assembly and testing capability of F110 engines of F16 aircrafts.
Responsible Engineer: Ergin Güngör , +902222112457
SPECIAL PROCESSES
Processes which alter materials’
metallurgical, chemical, magnetic
and electrical properties and can
only be observed by destructive
inspection methods.
•
Shot Peening
Chemical Milling
Shot Peening
EDM & Wire EDM & Stem Drill
Laser Cutting & Drilling
To cut and drill sheet metals
by using laser beam
•
Thermal Spray Coatings
Macro Etching
•
Black Oxide Coating
To avoid corrosion
•
Blue Etch Anodizing
To detect segragations in titanium forgings
Alkaline Cleaning & Titanium
Cleaning
•
•
Nickel & Chrome Plating
Metallography Laboratory
Destructive testing and inspection of special
processes
o
Visual Inspection
Sermetal, Glass Bead and Dry Lube Coating
inspections: thickness of the coating, surface
roughness, discoloration, crack inspection
Blue, Macro Etch inspection
o
Optical Microscope Inspection
Spot Weld, Seam Weld and Thermal Spray Coating
Coupons,
Shot Peen Media, Casing inspection and
measurement
o
•
To remove dust, grease and burrs
Mechanical Properties Inspection
Macro, Micro, Cross-Hatch Cutter, Hoffman
Hardness;
Buckling, Bending, Tensile Test;
Sieve Test
To avoid erosion and corrosion
Heat Treatment
For solution strengthening,
•
To observe casting flaws by chemical
etching
To remove metal, drill holes or make
contours and cavities by using electric arc
•
Brazing
Chemical welding method for non-weldable
parts
•
To thin the desired features of the part by
etching in an acid solution
•
•
To enhance the abrasive, thermal, electrical,
corrosive or wear properties
To relieve residual stresses
by producing compressive
stress
•
SPECIAL PROCESSES
SPECIAL PROCESSES
QUALITY CONTROL
o
Corrosion Test
Nickel coating corrosion test in salt cabinet
Laser Cutting
aging, stress relieving
o
•
Metallographic Sample
Preparation
Cougar Helicopter
F-16
•
Ultrasonic Testing
To detect inner discontinuities by using
ultrasound to penetrate the material
•
Eddy Current Testing
To find discontinuities on the surface or slightly below the surface of
non-ferromagnetic materials by using
electromagnetic principles
•
Fluorescent Penetrant Inspection
To detect discontinuities open to surface by
using florescent penetrant under purple light
•
Magnetic Particle Inspection
To find discontinuities on the surface or slightly
below the surface of ferromagnetic materials by
using electromagnetic principles and fluores
cent penetrant
•
Radiographic (X-Ray)
Inspection
To detect welding flaws by using X-rays
Chemical Laboratory
Tests and controls the chemicals and chemical
processes
Nato AVACS aircraft
NON-DESTRUCTIVE TESTING
References
http://www.tei.com.tr
http://www.turkmilitary.com/
http://icsp9.iitt.com/
http://www.emfinc.net/edm.htm
http://www.ndt-ed.org
ttp://gdgylaser.en
Doğa ULUTAŞ
GE Marmara Technology Center
Assist. Prof. Dr. Y. Eren KALAY
General Electric Marmara Technology Center was established in 2000 as one of the Global Sites of GE.
In 2007, GEMTC and TEI formed an alliance and Turkish Technology Center was opened.
Major operations in TTC are R&D, design and development for commercial aircraft engines.
Contact Person : Onur ATEŞ, onur.ateş@ge.com, +90 2626776072
Week 1
Week 2
Week 3
Week 4
Learning General Structure
of TTC;
Manufacturing Engineering,
Manufacturing Support Lean Lab
Team
Manufacturing Support Lean Lab Team
Manufacturing Support Lean Lab Team
Laser Assited Manufacturing
Metallography Laboratory
Ultrasonic Inspection
-Immersion Testing System is
-laser cladding process for rapid prototyping of
fully dense metal components
used to model ultrasonic testing
-cost savings and market advantage
Metallographic inspection is a very important and practical
method in order to evaluate microstructure of the
manufactured component.
procedure during manufacturing
-complex components can be manufactured
without using dies, tooling and they only need
little machining
Especially during designing of a process, metallographic
inspection gives very important information about the
weaknesses and strengths of the procedure.
-due to rapid solidification of the molten pool, fine
microstructure without segregation can be
obtained
When high temperature processes are designed major issue
is heat affected zone, heat induced cracks and pores,
growth mechanism of crystals and grain size.
1.Manufacturing Engineering
-Rotating Parts Team
-Manufacturing Support Lean Lab
Team
-Material Application Engineers Team
-Metal Coatings and Joining Team
2.Repair Technologies
welding, coating, robotic design
and non-destructive testing
3.Manufacturing Software
Technologies
provides solutions and manages
software tools for manufacturing
within GE
4.Design Technologies
Figure 1: Immersion ultrasonic testing of aerospace parts. Retrieved from :
http://www.bam.de/de/_pic_u_film/web/kompetenzen/abteilung_8/fg84/fg84_f
otos/fg84_ultraschall_tauchtechnikan
-Ultrasonic Inspection Software
CAD of 3D Part Designs, CAE
Finite Element Analysis of engine
parts and assembly
Figure 6: Robotic system used for laser cladding. [6]
Laser Welding
Laser beam welding uses a moving high-density coherent optical
energy source called a laser as the source of heat
References
Figure 5: Simulation of Ultrasonic testing retrieved from : http://www.ndted.org/EducationResources/CommunityCollege/Ultrasonics/Introduction/futuredire
ction.htm
D.C. Latia, Nondestructive Testing for Aircraft, Jeppesen Sanderson Training Products.
F. Lui et all. Microstructure and residual stress of laser rapid formed Inconel 718nickel-basesuperalloy,
Optics and Laser Technology, 43, 208-213 ,2011
K.G. Watkins, Achieving the potentail of direct fabrication with lasers, 3rd International Conference on
Laser net shaping, 25-38, 2001
Evrim Avcı
TUSAŞ Turkish Engine Industries
Asisst. Prof. Dr. H. Emrah Ünalan
TEI is an aerospace icompany with the history of a quarter of a century.
E-mail : http://www.tei.com.tr Phone : 0222 211 21 00
All types of non destructive testing techniques, special processes and fabrication processes shall be observed.
First 2.5 weeks
Second 2.5 weeks
MRO : Maintanence Repair and
Overhaul . The deparment is in
charge with the engine parts came
to maintanence to the company.
Although it is a new deparment it
received a prize from NATO.
Non destructive testing: materials both
coming to the company and produced
are examined through these
processes.
After the engine parts enter the
company they are cleaned,
inspected, and according to some
technical orders repair procedures
are specified for each industrial
part.
Products examined were mainly
engine parts such as high and low
pressure turbines, blades, mixing
ducts etc.
The processes observed are mainly,
Ultrasonic Testing
Magnetic Particle Testing
Radiographic Inspection
Fluorescent Particle Inspection
Eddy Current Test.
Among these only ultrasonic inspection
and radiographic inspection gives
information related with the inner
stages of the part. Other methods
expose the surface defects. i.e. Using
radiography the defects of a welded
zone could be inspected.
third 2.5 weeks
Special Processes : Special processes are
done to prolong the life span of the
products.
Processes observed are mainly,
 Shot Peening
Nickel and Chrome Coating
 Electro Discharge Machining
 Electro Chemical Milling
 Plasma Spray
Sermete Coating
 Stem Drilling
 Macro Etching
Forth 2.5 weeks
Quality Control Department :
 Testing and release or rejection of all incoming
raw materials, packing materials, in-process /
intermediates and finished products
 Maintaining testing records as per standard
procedures for raw materials, packing materials,
in-process / intermediates and finished products.
 Calibration of laboratory instrument /
equipment.
 Preparation of standard volumetric solutions
and maintain standardization record.
 Maintain Labeling procedure at all the stages
and records.
Besides the engineers, operators are mainly
doing visual and dimensional inspection which
also requires an adequate level of technical
drawing readings.
Laser Cutting
 Heat Treating
Figure 4 : Shot Peening
Figure 7 : Technical Drawing
Figure 6 : CMM machine
Figure 2 : Magnetic
Particle Inspection
References
Figure 1 : Major Assemblies of the Engine
Figure 3 : Eddy Current Testing
Figure 5 : Plasma Spray Coating
http://www.tei.com.tr
EZGİ ÖNAL
KOSGEB,SİNCAN OSB.
ASSOC. PROF. DR. CANER DURUCAN
Ankara 1.Organize Sanayi Bölgesi 7.Sokak Dökümcüler
Sitesi KOSGEB SİNCAN ANKARA 06935
Tel: 312-2670285 Fax: 312-2670288
[email protected]
KOSGEB helps small and medium size enterprises in finding their
problems and finding or suggesting solutions which are
acceptable for enterprises to yield products of better quality
which cost lower.
AKDAŞ DÖKÜM
WEEK 1 AND WEEK 2: MECHANİCAL
TESTS AND ANALYSIS
Picture1. The spectrometer for
chemical analysis.
One of the primary aims in mechanical property
tests is to determine conformance or nonconformance to specifications. The data may thus
serve as an index of the quality of a product in
comparison with the data obtained from other
sources. Such data may also be used to compare
a given material with other materials and in
conjunction with other factors, may assist in the
replacement improvement of a material.
Manufacturers frequently use tension testing data
for control of manufacturing methods, as well as for
a guide in developing new materials
WEEK 3 AND WEEK 4: VISITED
FACTORIES
The organization has a production capacity of
annual 10000 tons. High-low alloy and plain
carbon steels, stainless steels, wear resistant
EMEK BORU
The production of spiral welded steel pipes with
qualified material and outstanding quality with
the raw material as hot rolled sheet iron.
manganese steels, Ni-hard, white casting irons
and grey, nodular cast irons are produced
according to the standards.
Five main mechanical testing is done in KOSGEB;
1. Tension
2. Compression
Picture 5. Products of Emek Boru taken from
http://www.emekboru.com.tr/
Picture 7. Molten metal to use for casting taken from
http://www.akdas.com.tr/dokumhaneler.html.
3. Bending
4. Hardness
5. Micro hardness
Picture 6. Controlling after shaping the pipes.
REFERENCES:
http://www.emekboru.com.tr/
http://www.akdas.com.tr/dokumhaneler.html.
Picture2 , 3 and 4. Tensile , compression and bending
testing machine from left to right.
Picture 8 and 9. Mold prepared for casting and the riser
Fırat GÜLER
İskenderun Iron & Steel Company
Assist. Prof. Dr. H.Emrah ÜNALAN
Web: http://www.isdemir.com.tr
Company name: İskenderun Iron &Steel Company
Company location: Karayılan Town 31319 ISKENDERUN/TURKEY
Responsible Engineer:Eriş Durmuşoğlu
Phone: +90 (326) 758 4040 (Santral-PBX)
Fax: +90 (326) 755 1184 - 758 5351 - 758 3838
Phone: +90 (326) 758 3082
ISDEMIR being commissioned with 1,1 million tons/year steel bloom production capacity in 1975, reached to capacity
of 2.2 million tons/year with 1. plant extension in 1985. At ISDEMIR facilities being established with the intention of
producing long products like pig iron, bloom, billet, construction steels in international quality standards; production is
made with coke- sinter –blast furnace – steel mill – continuous casting and hot rolling processes. Besides the domestic market,
products, lead by Middle East countries, are exported to European, African and Asian countries.
Ladle Metallurgy
Iron Ore
Pellets
Blast Furnace
Sinter
Limestone
Scrap
Electric
Furnace
Slab
Oxygen
Week 1
1) Harbor
Slag
Molten Iron
Coke Ovens
Required improvement on the existing harbor is made to load products (billets, slab,
wire, rod and pig iron) which will be sent to domestic and foreign markets and to
unload raw materials required by increase in productions. In this content, dredging
works of 19 meters water depth to accept the ships up to 180.000 DWT at Dock No.1
started in 2005 and completed in 2008. Water depth of Docks No3.& 4. has
increased to 13.5 and 13 meters by dredging. Two new cargo cranes which each
have 55 tons capacity are erected at the Dock No.5. A new slab & coil stockyard
(picture 2) erected on the cargo mole between Docks No.3.4.&5. Today, İsdemir
harbor has 2 unit 50 tons unloading cranes, 5 unit 15 tons cargo cranes, 4 unit 10
tons cargo cranes and 2 unit 55 tons cargo cranes. These properties of İsdemir
harbor make it one of the biggest harbors in the Mediterranean Sea.
2) Sintering Plant
Ore preparation facilities have open stock area which has a capacity of 750.000 tons,
160.000 tons capacitated pellets stocking pool, 2x40.000 tons blending yards and
other stocking yards. There are 4 stocker/reclaimer machines on open stock area
and 4 stockers on blending yard. Ground and screened ore fines are mixed with
limestone, dolomite and coke breeze with certain amounts to prepare sintering
blend. Then it is heated up to 1100-1200 with the coke gas to produce sinter. Sinter
that are coming out of sinter furnaces have dimension between 6-50 mm and finally,
they are sent to blast furnaces.
3) Blast Furnaces
Cold Strip
Pickling
Lime & Flux
Crushed
Coal
Hot Strip
The first mission of this unit is producing hot and liquid metal. İsdemir has four
blast furnaces, namely,Cemile, Ayfer ,Gönül and Dilek.
Week 2-3
Basic Oxygen
Furnace
Week 3-4Annealing
Continuous Casting
Steel Pant and Continous Casting
1) Desuplhurization:
The liquid (pig) iron from blast furnaces is transported in torpedo via railway to the steel plant. Torpedoes
have 320 tons capacity to carry liquid iron. They are carried to hot metal pretreatment facility
(desulphurization plant) to inject fluxes for desulphurization. Different fluxes are used for different levels of
sulfur; for example lime, calcium carbide and magnesium.
2)
4) Documents obtained from İsdemir
Coating
Rolling Mills
Rolling is called obtaining a finished product (coil, bobbin, and deformed
construction bar) by giving it a plastic form after passing the semi-finished
product heated up to the tempering temperature (billet or slab) through 2
cylinders (roll) turning around their axis.
There is a wire rolling mill in ISDEMIR having a capacity of 700.000 tones/year.
The semi finished (billet) product to be hot rolled are firstly heated up to the
tempering temperature of steel (1050-1200 °C) in proportion of the carbon
amount of steel in tempering furnaces. Natural gas is used in tempering furnaces.
Incase natural is not available, fuel oil can be used. The billet
Basic Oxygen Furnace (Iron to Steel Converter):
In steel plant there 3 BOF converters with capacity of 200 tons in İsdemir. Basic oxygen steelmaking (BOS) is
the most widely used process for producing crude steel from molten pig iron (hot metal). The process involves
blowing oxygen through hot metal to reduce its carbon content by oxidation.
Scrap is charged into converter
Composition of the steel after reactions:
before charging liquid iron to
•
C
: % 0.03-0.05
prevent the refractor in the
•
Mn : % 0.10
furnace from excessive heat
•
Si
: % 0.005
•
P
: % 0.012
shock caused by oxygen injection
•
S
: % 0.012
into 1300 ºC liquid iron.
•
O
:
600 ppm
Scraps are separated according to
•
N
:
25
ppm
their qualities and processed
in scrap yard. %10-15
scrap is charged into converter.
3) Continous Casting:
Reactions in BOF:
Continuous casting of steel is a process in which liquid steel is continuously
•
C+O
CO2 (gas)
solidified into strand of metal. Depending on the dimensions of the strand, these
•
Si+2O
SiO2 (slag)
semi-finished products are called slabs, blooms or billets.
•
Mn+O
MnO (slag)
Billet
Scrap addition
•
2P+ 5O
P2O5 (slag)
After adding scrap liquidDimensions……...100 mm x 100 mm – 160 mm x 160 mm
into converter
•
FeS+CaO
CaS+ Fe (slag)
iron is poured into BOF.Length……..……. 6-12 meter
(BOF)
Slab
Slab Thickness….225 mm
References
Slab Wideness…...700-2.050 mm
1) İsdemir website (isdemir.com.tr)
3) steeluniversity.org
Slab Length….… Max 12.000 mm (wideness =< 1600 mm)
…….Max 10.800 mm (wideness =>2.050 mm)
2) İsdemir photo album
Temper Rolling
Hasan Serkan AKKOÇ
AKDAŞ CASTING IND. & TRADE CO.
Prof. Dr. Yavuz Ali TOPKAYA
Akdaş, two foundries and one machining factory at three different sites, including a total of 34 200 m2 closed area and 52.000 m2 open area covered maintains its production activities.
Turkey's largest with a capacity of 44 tons of liquid metal casting plants, and 25,000 tons of annual production, 75% is exported to more than.
Akdaş, automotive, cement, construction, energy, food, machinery, manufacturing, mining and quarrying, crushing, and iron and steel sectors such as marine products.
Contact person in Akdas: Çağrı Erkan ([email protected])
Batı Hun cad. No 1 OSB-Sincan / Ankara
Week 1
Week 2
MODELING AND MOLDING
MELTING AND POURING
Solid Works
Nova Flow and Cast - Casting Simulation
Magma - Casting Simulation
Production Planning System
The charge is melted inside a rammed refractory
lining. A cylindrical water cooled copper coil
surrounds the outside of the refractory and produces
a magnetic field pulsating in the vertical direction
when supplied with power. Outside the coil there
are packets of magnetic laminations which provide
return paths for the flux, improving the power factor
and reducing the risk of flux linking with
surrounding metal work to cause stray heating,
06935 Türkiye
Tel: +90 312 267 18 80 - Fax: +90 312 267 18 88
Week 3
CLEANING AND FINISHING
All castings are trimmed and thoroughly
cleaned and inspected. Stock removal equipment
includes sprue cutter, band saw, abrasive cutoff
machines, plus back stand, wheel and disc
grinders. Surface cleaning equipment includes a
wheelabrator machine for casting finishing.
Week 4
QUALITY-CONTROL AND HEAT
TREATMENT
2 pieces of Spectral Analysis (OBLF RS 1000)
Charpy Impact Test (Pendulum Impact Tester PS30) - Temperature
range -40 / +70 ° C
Cash / Tilt Test (Universal Strength Testing Machine EU20)
Portable Hardness Testers (Poldi, EQUOTIP)
Ultrasound Devices (Panametrics Epoch LT, Krautkramer USD 10)
Magnetic Particle Mobile and Fixed Equipment
Liquid Penetrant Testing
Microstructure Investigation (Union Examet Digital Microscope)
Measuring and Control
If there is a mistake in casting it is found in ndt controls. After that
these products are fixed by welding. After welding heat treatment
are aplied for perfection
Liquid metal has put to the ladle for
casting. Then it flows to mold for final
product.
References
http://www.custompartnet.com/wu/SandCasting
http://www.akdas.com.tr/en/metod-muhendislik.html
http://www.hellotrade.com/non-ferrous-casting/cleaning-and-finishing-casting-services.html
Hasan SEZEN
Trakya Döküm A.Ş.
Prof. Dr. Abdullah ÖZTÜRK
Trakya Döküm is a world class ISO/TS 16949 certified Disamatic foundry producing cast and machined parts in all grades of ductile, grey and malleable irons destined for the automotive, white
goods, construction, hydraulics, electronics, machinery, railway and for some other different field of operations.
Contact: Birol BARUT e-mail: [email protected] Number: 0532 517 50 58
WEEK 1
Coreroom: Trakya Döküm produces its
own cores by its own core production
machines. Company has 3 different coremaking processes which are hot-box, coldbox and shell methods.
WEEK 2
WEEK 3
Pattern Design and Production: Trakya
Disamatic Routes: In these routes, pieces at
Döküm produces its own patterns into highly
equipped pattern shops of its own by needs of
the production. Patterns may be made of iron,
steel, poliurethane or bronze.
the interval 0.1-30 kg are casted. The produced
casting pieces’ maximum dimensions changes
due to the mass and design.
Hot box: Resin, sand and hardener are
mixed by the instructions to produce a core
that has the property wanted. The mixture
that has produced are transmitted into the
core box by blowing air and hardened by
roasting in 200-220̊C. Hardened cores are
ready after air cooling.
Cold Box: Into liquid phenolic and isocyanate
resins are mixed with sand and blown into
the core box. Core box is given
dimethylethylamine gas in order to harden
the core.
Shell: Sand is covered with phenolic resin at
125̊C and cooled. Sand is roasted into the
core box at 220-250̊C.
Methods
Price
Production
Painting
Hot –Box
Expensive
Normal
No
Shell
Expensive
Slow
No
Cold-Box
Cheap
Fast
Must
Table-1: Comparison of Core Production Methods
Sand Plant: To decrease the production
costs, sand is used again and again.Sand
plant gives the opportunity to recycle the
sand. After the usage in Disamatic lines,
cores are broken by vibration and the
possible metal parts are cleaned out in
three steps by the help of meshes,
centrifuging and magnetic impact. Then the
sand is washed to clean out other materials
inside. Cleaned sand is moved into the
bunkers. For the production of both patterns
and cores, old sand and new sand mixture
is used in proper ratio. To make new
patterns, old sand, new sand, bentonite as
cement, coaldust and water at 50̊C are
mixed in sand plant with a proper ratio to
get required tensile strength, gas
permeability, sand compressibilty etc.
WEEK 4
Laboratories: Trakya Döküm’s laboratory facilities;
•
Dimensional Laboratory
•
Metallurgical & Material Laboratory
2013 MK4A
2013 MK5A
230X
•
Sand Laboratory
Width(mm)
480
480
535
•
Fittings Laboratory
Length(mm)
600
600
750
Height(mm)
200
200
200
In these facilities Trakya Döküm has the opportunity to make
microstructure, failure or quality analysis.
Table-2: Pattern Dimensions
Figure-1: A pattern design and testing
Scrap Depots:The factory generally provides
its metal from its own scraps that come from
used runners, risers or defective products that
taken into scrap depots. They are taken from
all scrap depots by the help of electromagnetic
lifters to charge the induction furnaces.
230X
Width(mm)
360
360
410
Length(mm)
500
500
650
Height(mm)
250
250
270
Disamatic Process Flow:
•
In Disa 2013 MK4A mostly grey and malleable
cast iron production are made. Especially 1st
Disa Route is reserved for only the fittings
pieces’ production and 3 junker furnaces with 4
tones capacity are feeding this route.
•
In 2nd Disa casting route 2013 MK4A again grey
and malleable cast iron products are made. But
in this line, besides 3 junker furnaces with 4
tones capacity, 2 inductotherm furnaces with 5
tones capacity are also feeding this route.
•
a) More clear melting
b) High Efficiency
c) Low Refractory Abrasion
2013 MK5A
Table-3: Piece Dimensions
Inductotherm Furnaces: Heating occurs
basically by the usage of alternative current
and the created alternative magnetic field. The
magnetic field inside the induction furnace
provides quick heating and melting. Also this
magnetic field makes the molten metal inside
the furnace to mix naturally. Another point is,
the metal is not in contact with the heating
units. This case offers an environment to get
high quality and purity molten metals.
Advantages of the inductotherm furnaces;
2013 MK4A
•
d) Energy Saving
e) Natural Mixing
3rd route is casting grey and nodular cast irons
to Disamatic 2013 MK5A by the help of 1 ABB
pressurized automatic casting furnace with
usable 5 tones capacity. It is taking the metal
from 2 inductotherm furnaces with 5 tones
capacity.
4th and 5th routes are Disamatic 230X and it is
used for the casting of grey and nodular cast
irons. It takes these metals from 2 inductotherm
furnaces with 10 tones capacity and makes
casting with inductotherm automatic furnace with
5 tones capacity.
Figure-4: Microstructure analysis with an inverse microscope
Tempering Furnaces: Trakya Döküm is able to
decrease the hardness of malleable cast iron products from
300-350 Brinell to 150-180 Brinell to be able to do machining
process by the heat treatment applications.
Figure-5: A Tempering Furnace
Machining Department: Trakya Döküm makes
machining due to the disposition. 29% of all the production
are launched as machined parts and the aim is to increase
this percentage to 40%s.
Galvanization Department: The company delivers
the products as black or galvanize coated by the
instructions. Trakya Döküm makes coating by the limits of 70
μm mid-layer thickness and minimum of 500g/m² zinc
coating mass.
Figure-6: Galvanization Unit
References:
Figure-2: A view from Scrap Depots
www.trakyadokum.com.tr
•
Figure-3: An image from Disamatic Routes
Hüseyin Çıtak
Land Force Command 5th Main Maintenance Center
The facility gives service under Army Logistics Command. 5th Main Maintenance Center provides several benefits such as maintenance and renovation of the
helicopters and the aircrafts with their subunits technical assistance, oil analysis, material manufacturing and examination processes to state-or civil-based
organizations and corporations through revolving capital.
Responsible Engineer:Fahir Kubilay 03122526200
Non-Destructive Testing: Dye Penetrating- Magnetic Particle Testing- Ultrasonic Testing-Eddy Current Testing- Xray Inspection
Material Improvment Process:Shot Peening
DYE PENETRATING
MAGNETIC PARTICLE TESTING
ULTRASONIC WAVE INSPECTION
SHOT PEENING
Shot peening is a cold working process in which small spherical media called shot bombard the surface of a
part. During the shot peening process, each piece of shot that strikes the material acts as a tiny peening
hammer, imparting to the surface a small indentation or dimple. To create the dimple, the surface of the
material must yield in tension. Below the surface, the material tries to restore its original shape, thereby
producing below the dimple, a hemisphere of cold-worked material highly stressed in compression.
Figure4: Longitudinal and circumferential crack inspection
Figure1:Metal Parts With Penetrant Layer
This method is frequently used for the detection of surface breaking flaws in
nonferromagnetic materials.The subject to be examined is first of all chemically
cleaned, usually by vapour Phase, to remove all traces of foreign material, grease, dirt,
etc. from the surface generally, and also from within the cracks.
Next the penetrant (which is a very fine thin oil usually dyed bright red or ultra-violet
fluorescent) is applied and allowed to remain in contact with the surface for
approximately fifteen minutes. Capillary action draws the penetrant into the crack
during this period.The surplus penetrant on the surface is then removed completely
and thin coating of powdered chalk is applied.After a further period (development
time) the chalk draws the dye out of the crack,rather like blotting paper, to form a
visual, magnified in width, indication in good contrast to the background.
The principle is to generate magnetic flux in the article to be examined, with the flux lines
running along the surface at right angles to the suspected defect. Where the flux lines
approach a discontinuity they will stray out in to the air at the mouth of the crack. The
crack edge becomes magnetic attractive poles North and South. These have the power to
attract finely divided particles of magnetic material such as iron fillings. Usually these
particles are of an oxide of iron in the size range 20 to 30 microns, and are suspended in a
liquid which provides mobility for the particles on the surface of the test piece, assisting
their migration to the crack edges.
RADIOGRAPHIC INSPECTION
Figure6:Ultrasonic Testing Equipment
This technique is used for the detection of internal and surface (particularly distant surface)
defects in sound conducting materials. The principle is in some respects similar to echo
sounding. A short pulse of ultrasound is generated by means of an electric charge applied
to a piezo electric crystal, which vibrates for a very short period at a frequency related to the
thickness of the crystal. In flaw detection this frequency is usually in the range of one
million to six million times per second (1 MHz to 6 MHz). Vibrations or sound waves at this
frequency have the ability to travel a considerable distance in homogeneous elastic
material, such as many metals with little attenuation. The velocity at which these waves
propagate is related to the Young’s Modulus for the material and is characteristic of that
material.
EDDY CURRENT TESTING
Figure8:Principle of shot peening application
In most modes of long-term failure, the common denominator is tensile stress. Tensile stresses
attempt to stretch or pull the surface apart and may eventually lead to crack initiation. Because crack
growth is slowed significantly in a compressive layer, increasing the depth of this layer increases
crack resistance. Shot peening is the most economical and practical method of ensuring surface
residual compressive stresses.
Typical examples of premature failure which improved by shot peening:
Metal fatigue
Corrosion fatigue
Stress corrosion cracking
Intergranular corrosion
Galling
Spalling
Wear
Figure2:Penetration process of metal
Figure5:Working principle of X-ray radiography
This technique is suitable for the detection of internal defects in ferrous and nonferrous metals
and other materials.
Advantages of Radiography
• Information is presented pictorially.
• A permanent record is provided which may be viewed at a time and place distant from the test.
• Useful for thin sections.
• Sensitivity declared on each film. • Suitable for any material.
Disadvantages of Radiography
Figure3:Penetrant applied metal under UV light
• Generally an inability to cope with thick sections. • Possible health hazard.
• Need to direct the beam accurately for two-dimensional defects.
• Film processing and viewing facilities are necessary, as is an exposure
compound.
• Not suitable for automation, unless the system incorporates fluoroscopy with
an image intensifier or other electronic aids
• Not suitable for surface defects.
• No indication of depth of a defect below the surface
Figure7:Eddy Current Testing Equipment in 5th Main Maintenance
The main applications of the eddy current technique are for the detection of surface or
subsurface flaws, conductivity measurement and coating thickness measurement. The
technique is sensitive to the material conductivity, permeability and dimensions of a product.
Eddy currents can be produced in any electrically conducting material that is subjected to an
alternating magnetic field
The magnitude of the eddy currents generated in the product is dependent on conductivity,
permeability and the set up geometry. Any change in the material or geometry can be
detected by the excitation coil as a change in the coil impedance
Figure9: Shot peening equipment used in 5th main maintenence
REFERENCES
http://www.kkk.tsk.tr/internet/5ABM/en/index.html
http://www.turkndt.org/sub/makale/ornek/a%20brief%20description%20of%20NDT.pdf
http://www.metalimprovement.com/shot_peening.php
İhsan Anıl ÇIRAĞ
TIRSAN Trailer Ticaret ve Nakliyat A.Ş.
TIRSAN basicly produces containers to trucks. It is founded in 1977. TIRSAN has
%51 of the market in Turkey and the leading firm of the sector.
Light Curtainsiders&
Tarpaulins
Curtainsiders&
Tarpaulins
Low-Beds
Joining Processes
Welding: Tırsan uses welding at
bowsers and low-beds. It’s
done by melting the
workpieces and adding a filler
material to form a pool of
molten material that cools to
become a strong joint,
- Maximal
- MegaMaximal
-Maxima Curtainsider
- Fixed 3 Axles
- Maxima Tarpaulin
- Fixed 4 Axles
- Maxima w/ Mega Ch. Curtainsider
- 3 Axles w/ Lower Loading Platform
- Maxima w/ Mega Ch. Tarpaulin
- Extendable 4 Axles
- Stepdeck Tarpaulin
- Extendable 3 Axles
- Mega Curtainsider
- Extendable 6 axles Low-bed
- Mega Tarpaulin
- Extendable 8 axles Low-bed
- Maxima Coil Tranporter
- Flex Carrier
--Mega Light
Platforms
Riveting: Tırsan uses rivetering
at curtainsiders. Its done
by bolt which holds two other
pieces of metal together. Holes
are drilled or punched through
the two pieces of metal to be
joined.
- Platform
-Extendable Platform
- Mega Coil Transporter
-Heavy Duty Plartform
References
www.tirsan.com.tr
Mehmet Hazar Şeren
Alvimedica Medical Technologies
Prof.Dr. İshak Karakaya
Alvimedica is the first cardiology product manifacturer in Turkey. The company has been operating in Çatalca/İstanbul. Alvimedica
designs, develops and manufactures mainly cardiologic angioplasty balloon catheters, guidewires and SDS (Stent Delivery Systems).
Contact Person: Doğan Arpaçay (0 212 786 [email protected])
Week 1
In the first week period,
such orientations were
taken.These are;
- Safety rule in the
company
- Alvimedica’s short
production history
- Products of Alvimedica
- Production techniques of
Alvimedica
- New stents’ design and
improvement of stents
Week 2
Week 3
I performed my internship
production department of
Alvimedica. During second
week, I started to learn
production line of stents.
- Laser Cutting,Annealing
- Pickling, Deoxidation
- Electropolishing
- Passivation
- Inspection of stents
Stent at special
holder
CNC machine
laser cutting
Week 4
In third week, I produced a
new stent by myself.
Laser cutting
- Laser Cutting done by CNC
- Annealing done at 1150oC
- Polished in acid with 3.0V by
mixing of HF H2SO4 at 14min
- Passivated in acid with
different composition of acid
- Inspected by myself that
there is no problem at all.
Inspection in
Microvision
At the final week of my summer
practice, I presented my project
about the new stent material and
shape memory alloy “Nitinol”.
The details;
- Superelasticity(for radial stiffness)
- Shape memory(for deformations)
- Nickel-55.8wt%
- Superior fatigue life
- Produced like bone-structure
Nitinol Stent
High radial
Stiffness
References
www.alvimedica.com-Doğan Arpaçay
Mert ÖVÜN (ID: 1559764)
Organization: Turkish Patent Institute (TPI)
Advisor: Prof. Ali KALKANLI
Turkish Patent Institute is the governmental organization that is responsible for protection of inventions and intellectual
property rights. The institution undertakes the evaluation of the applications and operates with the purpose of contributing to
the development of Turkish economy and technology.
Contact person: Salih BEKTAŞ
Phone No: +903123031070
Week 1
Patents & Utility Models
Week 2
Trademarks
Week 3
Industrial Design
Week 4
Geological Signs
• Patents and utility models are
two different type of
certificates basically
protecting an invention.
• Trademarks serve for stating the
difference of the product of a
company from similar products of
other companies.
• Trademarks are particular for
products and they are not related
to the commercial title of a
company.
• Registration of a trademark
provides protection to the
company for the sole use of the
specific name for a product and
provides a legal right against
unpermitted use of that
trademark.
• Using internationally accepted
symbols such as ® and TM states
the fact that the sign is already
registered as a trademark.
However, these symbols are not a
must.
• Industrial design provides
improvement of physical
human/product interaction by
combination of artistic and
scientific techniques.
• The geographical sign describes a
product originated from or attributed to a
specific region due to its prominence.
• Geographical signs are different from
other industrial property certifications in
manner of protecting not only the
applicant, but also all other manufacturers
making production by fulfilling under the
requirements and conditions.
• The main difference between
patent and utility model is that
the application does not
require a so-called «inventive
step». However, it takes much
less time and investment
granting for utility model;
therefore, it is most suitable
for small and medium scale
enterprises.
• After the registration of an
industrial design, the applicant
holds the right and permission of
producing, marketing, selling
andimporting the product with that
design solely.
References
1)
2)
3)
4)
5)
6)
TPI Website, http://www.tpe.gov.tr
TPI (2007), “Patents/Utility Models”
TPI (2007), “Trademarks”
TPI (2007), “Industrial Design”
TPI (2007), “Geographical Signs”
Wikipedia, www.wikipedia.org
Mert ÖVÜN (ID: 1559764)
Organization: Turkish Patent Institute (TPI)
Advisor: Prof. Ali KALKANLI
Turkish Patent Institute is the governmental organization that is responsible for protection of inventions and intellectual
property rights. The institution undertakes the evaluation of the applications and operates with the purpose of contributing to
the development of Turkish economy and technology.
Contact person: Salih BEKTAŞ
Phone No: +903123031070
Week 1
Patents & Utility Models
•
•
Patents and utility models are
two different type of
certificates basically
protecting an invention.
The main difference between
patent and utility model is that
the application does not
require a so-called «inventive
step». However, it takes much
less time and investment
granting for utility model;
therefore, it is most suitable
for small and medium scale
enterprises.
Week 2
Trademarks
•
Trademarks serve for stating the
difference of the product of a
company from similar products of
other companies.
•
Trademarks are particular for
products and they are not related
to the commercial title of a
company.
•
Registration of a trademark
provides protection to the
company for the sole use of the
specific name for a product and
provides a legal right against
unpermitted use of that
trademark.
•
Using internationally accepted
symbols such as ® and TM states
the fact that the sign is already
registered as a trademark.
However, these symbols are not a
must.
Week 3
Industrial Design
•
•
Industrial design provides
improvement of physical
human/product interaction by
combination of artistic and
scientific techniques.
After the registration of an
industrial design, the applicant
holds the right and permission of
producing, marketing, selling
andimporting the product with that
design solely.
Week 4
Geological Signs
•
The geographical sign describes a
product originated from or attributed to a
specific region due to its prominence.
•
Geographical signs are different from
other industrial property certifications in
manner of protecting not only the
applicant, but also all other manufacturers
making production by fulfilling under the
requirements and conditions.
References
1)
TPI Website, http://www.tpe.gov.tr
2)
TPI (2007), “Patents/Utility Models”
3)
TPI (2007), “Trademarks”
4)
TPI (2007), “Industrial Design”
5)
TPI (2007), “Geographical Signs”
6)
Wikipedia, www.wikipedia.org
Mustafa GÖKTAŞ
Nurol Technologies Inc.
Registration Advisor: H. Emrah ÜNALAN
Nurol Technologes Inc. is the company of most modern, fully automated, flexible and varied production lines which is located in Ankara, Turkey.
Instead of classical armor systems, by the ceramic and ballistic composite products and also lighter, safer and more durable armor systems are
designed, produced ahelp of nano sized powder metallurgical techniques, advanced and improved. Engineer: Berna SERT (Laboratory Leader)
Types of Ceramics and
Production Methods in
Theory
Types:
Alumina (Al2O3)
Silicon Carbide (SiC)
Boron Carbide (B4C)
Tungsten Carbide (WC)
Methods:
Powder Preparation(Waxing)
Cold Press
Dewaxing
Presintering
Hot Press (Sintering)
Laboratory and Testing
Technical Equipment:
X-ray Diffractometer
TG-DTA
Lazer Particle Size Analyser
Universal Test Machine
Cutting, Grinding, Polishing and
Mounting Machines
…..
Testing and Quality Management:
Powder size analyses
Mechanical testing
Microstructure analyses
Mass loss analyses
Moisture analyses
Coercivity analyses
….
Observation of Production
Methods, Furnaces and
Autoclave
Initial preparation of powder
Preparation of material before
furnace and autoclave
Timing
Cleaning
Size measuring
Togethering with other composites
Packaging
Composite Materials
Processes:
Cutting machine
Lay up
Composite layers
Autoclave
Ballistic tests
Types of composites:
Polymer matrix composite
Ceramic matrix composite
Ceramic + Polymer Composites
References

G.S. Upadhyaya, 1998, Cemented Tungsten
Carbides, Noyes Publication.

http://www.nurolteknoloji.com
Oğulcan OTUZBİROĞLU
Erkunt Industry, Inc.
Prof. Dr. M. Kadri AYDINOL
•
Erkunt Industry Inc. was constructed as a pattern shop in 1953 by Mümin Erkunt and his partners. In 1955, name of the company was changed as “Erkunt Unlimited Company Senior Engineer Mümin Erkunt and His Partners”. Then, in 1959, investments for machining of the
casting products were started and as a result of this, it took the name of “Erkunt Industry Inc.” in 1960. The first Erkunt product which was exported was sent to Germany in 1980. In 1989, in order to develop machining capacity, high technology CNC (Computer Numerical
Control) machine investments were begun. Implementation of quality systems start with QS 9000 Quality Management System, TSE-ISO-EN 9001 and BS EN ISO 9002 Quality Management System. Now the company holds ISO/TS 16949 Quality Management System, ISO 14001
Environmental Quality Management System, OHSAS 18001 Occupational Health and Safety System, and Q1 Quality Award (Given by Ford Inc.). The main products that Erkunt produce are engine blocks, cylinder heads, power shifht group, oil panels, axle hausings, flywheel
and flywheel hausings, gear boxes, and transmission hausings.
•
Başak GÜLEKEN, production engineering and pricing management department, metallurgical and materials engineer. Her contact number is 0532 523 65 61.
Week 1
Week 4
Week 3
Week 2
week in production
In the third week, first half of the week was spent in
In the last week of the summer practice, casting factory which
and
engineering and pricing management. Basicly, main
production engineering and pricing management. Erkunt
is strongly related with metallurgical department was visited in detail.
employees was given to all interns. Then,
purpose of this this department is whether casting and
satisfies Gray Cast Iron requirement from the scrapes, gating
How cores are produced and dried, 3 molding lines and how cores,
responsible engineers from all departments such
machining processes are done or not . Generally,
and
runner systems of products and so on. Pricing
supports, and other axuillary materials are placed on mold, how
as casting factory, machining factory, quality and
metallurgical engineers are responsible for casting
management also had responsibility for arranging the prices
induction melting furnaces are works and how melted cast iron are
control,
processes
at
of the tools for machining, molds, and so on. Also I work for
poured to molds, how sand on casting peices are cleaned and how
machining processes. In this department, I could had
this purpose and take calculations for how much carbon,
gating systems and runners are cut in fettling shop. Also, in this
departments. Also, casting factory which İncludes
chance
program
silicon ,other ores are required for the processes. Also, With
week, generally I participate in the meeting at casting factory about
core room, melting room, molding lines and
’’Magmasoft’’ and works at gating system simulation of
other two interns, I try to solve machining problem of the
the scrapes. Every
fettling shop was visited and Machining factory
Perkins’s cylinder head. Also, I spent most of time on
engine support of the Wolksvagen Amarok. Second half of
possibility to remove as scrap are inspected by quality control
consists of turning, milling, drilling and honning
technical drawings of casting pieces. I learned which
the week, I had chance to visit pattern workshop. In this
engineers and argue about the failure analysis.
CNC
hole was constructed by casting and which of them by
department, core boxes are designed by using CAD and CAM
machining
programs.
In the first week of the summer practice,
general
briefing
about
production
performance
gave
machines
the
planning,
information
was
engineers in the casting
visited.
company
and
industrial
about
their
Furthermore,
and machine factory
I spend almost all
and
to
see
mechanical
the
process,
casting
how
engineers
simulation
technical
works
drawings
are
give some information about the processes done
interpreted and practice on different views of casting
in these factories. At the end of the week, all
pieces.
morning, scrap casting pieces and
interns was placed to their departments by
human resource department.
Figure 6. Induction Furnace and Melting
Figure 4. . Core Room (Casting factory)
Figure 2..Machining Factory
Figure 7. Fettling Shop
Figure 1. Casting Fact. (Molding Line)
References
1.
W. D. Callister, “Materials Science and Engineering: An Introduction”, John
Willey & Sons Inc., New York. , 2007.
2.
Retrieved October 1, 2012, from www.erkunt.com.tr
3.
Erkunt Intern Documents
Figure 5. Pattern Shop
Figure 3. Melting Shop (Casting Factory)
had
Summer Practice METE 300 or 400 Fall 2012/2013
Onur TÜREL
NANOGRAFI NANOTEKNOLOJİ BİLİŞİM İMALAT VE DANIŞMANLIK LTD. ŞTİ.
Prof. Dr. Amdulla Mekhrabov
Nanografi is founded as the first and only carbon nanotube manufacturer in Turkey, Mehmet BAŞÇİ
([email protected] and 0 312 210 13 00), Carbon nanotubes, advanced conductive thermoplastics and advanced conductive
thermoset materials produced and mechandised in Nanografi.
Week 1
Week 2
Week 3
Week 4
At first week, I mainly
researched about carbon
nanotubes through the
resources of the company
and through the internet.
In second week, I joined the drills
to produce carbon nanotubes.
First drill was unsuccessful due
to leakage on the connection
point of hydrocarbon gas pump
and quartz tube. Then this
location was covered with
polyesther.
After the production, quartz tube
was full of ferrocene residue that
was thick orange colored.
At 4th week we made a last drill and
produced carbon nanotubes.
This researched showed that
carbon nanotubes are
superior to common materials
known in more than one way.
Youngs
Modulus(GPA)
Tensile
Strength(GPA)
Density(g/c
m^3)
Multi Walled
CNT
1200
150
2.6
Single Walled
CNT
1054
75
1.3
SWCNT bundle
563
150
1.3
Graphite
350
2.5
2.6
Steel
208
0.4
7.8
Diamond
1000
200
3.5
Reference Sites:
www.nanografi.com
www.scientificamerican.com
To clean up the tube, we came to the
METU Metallutgical and Materials
Engineering labs and cleaned the
tube by using HCl solution.
This polyester zone prevented the
leakage and the next drill to
produce carbon nanotubes was
successful.
At the end of the 3rd week, I did
some translations of Nanocyl
products to Turkish for
merchandising it in here. These
translations can be found at
Nanografi webpage, under
products.
Then most of the people went to Eskişehir
for European Union Project meeting. The
project aimed for finding a material that
shows good mechanical properties and
thermal conduction and carbon
nanotubes is a good candidate.
When they were missing, I sen emails to
the given companies the translations I
made for advertisement purposes.
Reference: Mauro Giorcelli, «Growth and
Characterization of Carbon Nanotubes
by CVD Systems»
Elif Gamze Şahin
BARIS ELECTRICAL INDUSTRY INC.-ANKARA
PROF. DR. İSHAK KARAKAYA
Location of the Company: Esenboğa Havalanı yolu 23.km Akyurt 06750 Ankara/Türkiye,
Tel:0312398022 , [email protected]
Barış Electrical Industry Inc is mainly focused on fiber reinforced composite production. This area is a still expending area with many
applications all through the world. Some every day examples to composite products are automobile parts, ships, planes, safety equipments,
like helmet, and military equipments.
COMPOSITE MATERIALS
Composite materials have been gaining important
industrial and commercial applications world widely and
they were developed because they can offer unique
properties (lightweight, high strength and stiffness,
chemical and corrosion resistance, electrical and thermal
properties, etc.) which no single homogeneous structural
material could be found that had all the desired attributes
for
a
given
application.1.COMPOSITE
MANUFACTURING TECHNIQUES IN BARIŞ
1. Filament Winding
2. Resin Transfer Molding (RTM)
3. Hand Lay-up Process
4. Vacuum Bagging
5. Press Molding
2.QUALITY DEPARTMENT
Test Equipments in Barış:
1. DSC ( Differential Scanning Calorimetry ) Test
Equipment:
provides insight into critical physical properties of
materials by testing their response to heat.
2. TGA (Thermo-gravimetric Analysis) Test
Equipment:
Thermogravimetric Analysis (TGA) measures the
amount and rate of change in the weight of a material
as a function of temperature or time in a controlled
atmosphere
3. Universal Tensile and Compression Testing Machine(
INSTRON )
Universal Tensile and Compression Testing Machine in
Barış has a load capacity of 100 ton and cross head speed of
0.5-500 mm/min. It has also a conditioning cabinet to
observe material behavior in require temperature range
4.RESEARCH AND DEVELOPMENT DEPARTMENT
Research can be market research or performance
research. Market research, on existing prototypes or
markets, leads toward new products or upgrades that
meet consumer desires. In Barış Electrical Industry
Inc. R&D department follows these steps;
1.Research
2. Design
3. Testing (Pre- Production Prototypes)
4 Hazard analysis
5. Manufacture and Release:
CONCLUSION
In my summer practice in Barış, I have learned lots of
things about composite materials. It was good
opportunity for me to decide my future career by the
help of engineers. They are professions in their field
and also produce and finish difficult projects.
References
Figure 1. 3-axis filament winding machine
Figure 2. DSC, TGA and tensile machines
1.http://www.jjmechanic.com/process/index.htm
2.http://imtuoradea.ro/auo.fmte/files-2010v2/TCM/Adrian%20Petru%20Pop%20L1.pdf
3.http://www.rtmcomposites.com/whatrtm.html
ŞERİF ALİ AYDOĞAN
MERCEDES-BENZ TÜRK A.Ş
Assist. Prof. Dr. Hüsnü Emrah ÜNALAN
Mercedes-Benz Turk was established in Istanbul in 1967. In November 1990 the company name was changed to Mercedes-Benz Türk A.Ş. The company currently employs
2.800 personnel Mercedes-Benz Türk has recently increased its capital to TL. 155.000.000.000.000. The shareholders of the Company are DaimlerChrysler AG (66,91 %),
Overseas Lending Corporation (18,09 %), Koluman Holding A.Ş. (7,04 %), Türk Silahlı Kuvvetlerini Güçlendirme Vakfı (5,00 %) and Makina ve Kimya Endüstrisi Kurumu
(2,96 %). Mercedes-Benz Türk has sold approximately 36.000 buses, 50.000 trucks and 1.000 midibuses from ist own production in addition to 20.000 cars since 1989 when
the Company activated the importation of passenger cars. Mercedes-Benz Türk, currently produces intercity and municipality buses at Hoşdere Plant and light and heavy
duty trucks at the Aksaray Plant.
Hakan BELDEK
05322553288 [email protected],
Parts
production
and various testings are Week
made in
Week
3
4 materials test laboratory.
Week 2
Week 1
Orientation programme was
made. I was informed about
the processes in factory.
Various types of quality
systems are introduced.
Business safety are
emphasised. Parts of the plant
are toured.
In the second week, I was in
production and maintanance machine
or parts production .There were lots
of machine such as ;
CNC Sheet cutting machine,
CNC Laser machine
CNC Sheet bending machine
Sheet forming (Hydraulic press)
Pipe cutting (CNC Sawing
machine),
Pipe bending (CNC Pipe bending
machine)
In the third week, I was in material test
laboratory. It was so qualified
laboratory, there were lots of testing
methods such as martin-dale
abrasion testing, xenon testing,
tensile testing to metals and nonmetals materials, combustion
testing...
In the fourth week, I analysed
microstructures of failed specimens with
an optical microscopes. In addition to, I
attended a welding course. The content of
course was about MAG welding.
Furthermore, in order to better understand
how the processes are going on, I
attended KAIZEN workshop.
.
Parts Production
Body production
Paintshop
Assembly Line
Seats Production
Finish
References
Hakan BELDEK – Abdurrahman
ELVEREN – Şeyma SEZEN
AYDAN BOZDOĞAN
TÜRK TRAKTÖR A.Ş
Assist. Prof. Dr. Hüsnü Emrah ÜNALAN
Turk Traktor is the first founder of the automobile industry in Turkey. The company was established in 1954. Koç Group and CNH both shares the 37.5% share holds which are the two
partners of Turk Traktor. The rest 25% is open to public. Annual capacity of plant is 35,000 tarctors and 25,000 motors. In every 7 minutes, one tractor is produced in the plant.
Products of Turk Traktor Plant are mainly produced in three series: New Holland 56 series , New Holland TT series , New Holland TD series & Case JX series
Contact person: Asil Ege Büke , e-mail:[email protected] , telephone: +90 312 233 32 02
Week 1
During four days of first week, every
department of Turk Traktor made a
presentation to make us familiar with
the factory. The fifth day, everyone is
sent to their department to recognize
there. The department that ı did my
summer practice was ‘gear and heat
treatment’. During four-dayspresentation, thirteen departments
gave a speech which are;
-Human Resources and Quality Systems
-Production Planning and Logistic Management
-Production Engineering Department
-Assembly Production Management
-Entrance Inpection Department
-Body Production Department
-Technical Education and Documentation
Department
Week 2
Week 3
Heat treatment processes which are;
Gear line processes which are;
•
Normalization(used to soften metals and
relive internal stresses to refine the grain
size and microstructure)
•
Carburization(produces a steel
composition containing higher carbon on
some part of surface of steel)
•
•
Nitration(nitrogen diffusion produces
hard intermetallic compounds in the
surface)
•
Annealing(used for reduction of residual
stresses in large castings, welded parts
and cold-formed parts)
•
Sandblasting(used to clean surface of
metals)
were examined in detail.
Microstructures of materials which are exposed to
have heat treatment are examined.
Turning
Nitride Layer
Turned surface
Other departments which are
•
Grinding
•
Hobbing
Induction hardening(used to harden
surface of steel containing more than
0.35% carbon)
•
Week 4
•
production engineering,
•
body production and
•
assembly production
departments
•
Centring
•
Chamfering
•
Broach
•
Lapping
•
Buffing
•
Slotting
•
were visited.
-Indirect Purchasing Department
Assembly of fuel pump gear into motor body
-Direct Purchasing Department
-Spare Part and AfteR Sale Group Management
Slotting
-Treasury and Commercial Control Department
-Motor Production Department
-Gear and Heat Treatment Department
motor production,
were examined in detail
References
1.
http://www.trakmak.com.tr
2.
Turk Traktor Operation Papers
Taylan UZUNLAR
BOSCH Thermo Technique
Prof. Dr. Yavuz TOPKAYA
The Bosch Group is a leading global supplier of technology and services. According to preliminary figures, more than 300,000 associates generated sales of 51.4 billion euros in the areas of automotive and
industrial technology, consumer goods, and building technology in fiscal 2011. The Bosch Group comprises Robert Bosch GmbH and its more than 350 subsidiaries and regional companies in some 60
countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further
growth. Bosch spent more than 4 billion Euros for research and development in 2011, and applied for over 4,100 patents worldwide [1].
Günay GÜLSEVEN, who graduated from Metallurgical and Materials Engineering, METU, was my responsible engineer at Bosch Thermo Technique.
Week 1
In the first week of the summer
practice, general briefing about
the company, its shareholders,
location and employees was
given to all interns. Then, some
theoretical knowledge about
the safety, accidents and
manufacturing
flow
were
explained in order to increase
the efficiency of the summer
practice.
There
are
departments of first quality
control, product line quality
control and research and
development quality control
because Bosch Company is
very sensitive about quality of
products. During first quality
control, products which were
supplied from sub-industry
were checking.
Week 2
In the second week, I stayed at the
purchasing quality department
because purchasing quality is the
most related department for
metallurgical
and
materials
engineers. Therefore, I spent 20
days of my summer practice at the
purchasing quality department. In
this second week, product line
quality tests were done. During
product line quality, product
resistance, product life, and effects
of products on human health were
tested. During R&D quality control,
parts of new products were
controlled. If the product gets OK
after controls, mass production
starts.
Week 3
In the third week, ordered list of
parts using for central heating boiler
were made. Needed parts in that list
were supplied. Then, they were
prepared to be tested for different
type of tests such as electronic tests,
mechanical tests and chemical tests.
Types of mechanical tests are
hardness measurement, tension test,
shear test, compression test and 3D
measuring device. Impermeability
test were applied for some parts of
central heating boiler which contact
with water. If the tested part of the
central heating boiler passes the
test, then it refers as NFF (No Failure
Found). If it can not pass the test,
then it is sent to supplier.
Figure 2. Bakelite Coating Device.
Figure 1. Condensing Heat Boiler.
Week 4
In the last week of the summer practice,
computer programs, which are necessary
for checking all kinds of results about
products, were introduced. In addition to
these, detailed informations about central
heat boilers that are produced at Bosch
Company were given. At Bosch Company,
condensing central heating boiler and
conventional (non-condensing) central heat
boiler are produced. Bosch Company’s
Classic Condense wall-hung condensing
boiler is convincing thanks to numerous
advantages packed into the smallest
volume of space: it’s solar compatible; its
child’s
play
to
operate
via
the
multifunctional display; and it offers
perfect heating convenience [1]. On the
other hand, Non-condense heat boilers are
energy efficient and are subject to stringent
safety standards, you do not need
elaborate safety mechanisms on the tank.
Instead, underground lines bring the
natural gas directly to your home [1].
References
Figure 3. Impermeablity Test Device.
1) Retrieved September 22, 2012, from
http://www.bosch.com.tr/
2) Summer Practice Notebook.

Mete 400 - Department Of Metallurgical And Materials Engineering

Transcription

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