Material Science & Engineering

Acoustic Emission Testing

63_mBefore acoustic emission testing, oil storage tanks could only be checked for leaks by visually inspecting the inside tank floor. Most companies are usually required to have this done every five years. To do this, all oil in the tank would have to be drained. Following drainage, the whole tank would have to be sandblasted. Inspectors could then go inside the tank and check the floor for damage. This type of damage testing had several draw backs. All the oil that was in the tank upon draining would have to be disposed of; it could not be reused in any way. The price of this procedure could range from 15 to 20 lakh depending on the size of the tank. On top of the high price, the tank itself would be offline and unusable for about 3 months.

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Automatic Weld Inspection

20For the year 2000, welding expenditures in the U.S manufacturing, mining and construction industry was about $34 million. In order to test these welds in a non-destructive manner, nearly half a million radiographs are being produced every year. General Manager-Operations wanted a team at the imaging lab to develop new methodologies to identify defects in welds for analyzing the radiographs.

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Induction Welding Case Study

19For the year 2000, welding expenditures in the U.S manufacturing, mining, and construction industry were about $34 million.In order to test these welds in a non-destructive manner, nearly half a million radiographs are produced every year. Mr.R.J.Pardikar, Senior Deputy General Manager for the Quality/NDT division at the company, wanted a team at the Centre for Nondestructive Evaluation (CNDE) lab, Indian Institute of Technology (IIT), Madras to conduct a feasibility study of the possible Nondestructive testing methods applicable to the problem or develop new methodologies to identify defects in induction pressure welds.

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Lorn Manufacturing Case Study

lornmanuThe Lorn Manufacturing case study details the dilemma Jim Russell faced after losing three fingers in a horrible accident that occurred while he was cleaning a lap winder in an industrial plant. Who is responsible? Did Russell fail to follow procedure while performing his maintenance duties, or is it the manufacturer’s fault for not following proper safety guidelines when designing the machinery? Find out the jury’s verdict and learn about engineering ethics.

Students use this case study to develop an understanding of the following key objectives:

  • Implementation of safety procedures in a manufacturing plant
  • Application of codes and standards in professional environments
  • Qualifications engineers must have to serve as expert witnesses
  • Proper communication skills in a professional environment, such as a manufacturing plant

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