1. INDUCTION TRAINING
@
UNIVERSAL M/C’s LIMITED
COMPILED BY: PRITAM ROY

2. ACKNOWLEDGEMENT
• I would like to express my gratitudeand appreciation to all those who
gave me the opportunity to completethis report. A special thanks to Mr.
A. Dey ,whosehelp, stimulating suggestions and encouragement, helped
me to coordinate my projectespecially in writing this report.
• I would also like to acknowledgewith muchappreciation the crucial
role of the staff of Mechanical EngineeringDepartment, who gave me
the permission to useall required machinery and the necessary material
to complete this report.
• Last but notleast, many thanks go to the Vice President, Mr. S.
Mukherjee, Alom ExtrutionsLtd. who has given his fulleffort in guiding
me in achieving the goal as well as his encouragementto maintain my
progressin track. I would like to appreciate the guidancegiven by other
supervisorsaswell as the panelsespecially in this report that has
improved my technical skills by their commentand tips.
Pritam Roy

3. What is Anodizing and Powder Coating?
Anodizing is an electrochemical process that converts the metal surface into a
decorative, durable, corrosion-resistant, anodic oxide finish. Aluminum is ideally suited
to anodizing. Anodizing is a process used to increase the thickness of the natural layer
on the surface of metal parts.
For anodizing aluminium, extruded part is used as anode & pure aluminium as cathode.
DC current is supplied to the electrolytic solution in proportion to the anodizing surface
area.
ADVANTAGES:
 Anodizing is durable and will not flake, chip, or peel over time.
 Anodizing is easy to maintain. Only periodic cleaning of anodized extrusions with
a mild detergent and water to restore the original lustre.
 Ease of fabrication.
 Color sustainability, because of the sealing process during anodizing, helps to
keep your extrusions looking factory new for years to come.
Powder coating is a type of coating that is applied as a free flowing, dry powder. The
coating is typically applied electro statically and is cured under heat to flow and form a
skin.
ADVANTAGES:
 It does not required any solvent to keep the binder & filler parts in a liquid
suspension form which produces thicker coating without running or sagging.
 It creates a hard finish, smooth & texture free coating that is tougher than
conventional paint.
 Because no carrier fluid evaporates away, this process emits few volatile organic
compounds(VOC)

4. JIGGING / RACKING:
 The extruded profiles are clamped to the two hangers attached to a flybar with the help
of polymer clamps tightly. The clamps are of ‘C’ and ‘D’ type.
 Loose clamping results in reduction of current conductivity which further causes
uniform coating.
 Here visually defected profiles are rejected.
PROCESS BATH CHEMISTRY TEMPERATURE IMMERSION
TIME
CONSUMPTION RINSING
DEGREASING 40-60 ltrs. of
UNIKLEEN 437(50-
55) g/l per 1000
ltrs. bath volume
with DM water.
Max Al content:
4g/L
Ambient 2 to 10 mins
as per
requirement
Considering
normal drag out
approximate
consumption
will be (10–20)
ml/m2 of the Al
processed
IR water
(Iron
removed
water)
ALKALINE
ETCHING
30 to 70 kg NaOH
(70-80) g/L + (15 to
25) kg MSP 40
(additive) per 1000
ltrs. bath solution.
Al contect: (80-
100)g/L
45o C to 65o C 3 to 15 mins
(Depends
upon
required
finish)
Twice
with IR
water.
DESMUTTING (200-250)g/L of
nitric acid (65%
pure).
Ambient 10 mins IR water
then DM
water
ANODIZING (220-230) g/L of
conc. H2SO4. Al
content: (8-15)g/L
( 20 to 22)o C 30 mins Current density
is (150-160)
amp/m2
IR water
then DM
water
ELECTRO
COLOURING
SnSO4 (10-20) g/L
+H2SO4 (15-20) g/L
+ (12-16) g/L
MSPCAA(additive)
(18 to 24) oC (0.5 – 15)
mins
Average
consumption of
MSP CAA is (6-
8) g per sq.
meter of Al
processed

5. GOLD
COLOURING
ORFIX (Ferric
Aluminium
Oxalate) (18-22 g/l)
pH – 4.5 to 5.5
(45 to 50)OC
MID TEMP
SEALING
M-SEAL ( 3.5 – 5.5)
% wt/V.
(55 to 65)oC. 1min/micron DM water
SPECIAL
TREATMENT
30 to 40 ltrs. of
42oC Nitric Acid
and (60–70) kg of
MSP 28 per 1000
ltrs. Bath
Ambient (1-4) min (8-12) ml of
Nitric Acid and
(60-70) gm of
MSP 28 for
each square
meter of Al
processed
IR water
then DM
water
SPECIFICATION OF ADDITIVES:
 The use of MSP 40 eliminates hazardous fumes generated in etching bath resulting into
a clean & non toxic working environment.
 TT 100 additive is used to absorb fumes produced in the bath.
 MSP CAA additive is used to prevent formation of Stannic Sulphate which is deposited
under the solution & reduces Tin content in the bath. 12-16 g/l MSP CAA is used.
 Fe 100 – It helps to arrest the Hydrogen gas generation by forming a shield over the
caustic soda solution.
 MSP 28 solution produces a superior pickling action that removes almost completely
heavy extrusion lines and activated surface for subsequent operation.
 ORFIX is used in the immersion colouring process and produces a range of gold colours
from light to dark gold.
BATH TEMPERATUREMAINTENENCE:
 To increase the bath temp, thermo fluid oil is passed through pipe which is
kept inside the bath. The temperature of the oil is raised through a boiler in
which heat is generated by burning of diesel.
 To decrease the bath temp, cooling towers areused.

6. INSPECTION OF ANODIZED MATERIAL:
ANODIZING DEFECTS (VISUAL):
Iso PropileAlchohol is used to remove oil, adhesives for cleaning the surface
before inspection as defects are visual. Some defects are-
 Anodizing Mark
 Deep scratch
 Black corrosion
 White patch
 Corner bend, pitting etc.
 Any adhesives overlooked before degreasing prevents anodizing.
STANDARD INSPECTION CONDITIONS:
 Inspection should be done with naked or corrected eye with sample held at
900
views & at a distance of exact 1 meter.
 Daylight or other uniformdiffused background light with minimum
luminance 700 lux should be used.
There are two types of surfaces-
1. Class A (exposedarea): Surfacewith scratches longer than 10mmis
rejected.
2. Class B (unexposedarea): Scratches notmore than 50mm& two scratches
per surfaceareallowed.
DYE AND SPOT TEST:
In this process a solution containing 25m/lconcentrated sulphuric acid & 10 g/l
PotassiumFluorideis used to check whether the sealing is properly done or not. If
not, the solution gets absorbed on the surface.

7. PROCESS BATH CHEMISTRY TEMPERATURE IMMERSION
TIME
CONSUMPTION RINSING FUNCTION
DEGREASING/
ACID ETCHING
40-60 ltrs. of
UNIKLEEN 437(50-
55) g/l per 1000
ltrs. bath volume
with DM water.
Max Al content:
4g/L
Ambient 2 to 10 mins
as per
requirement
Etching degree
of 1 g/m2 is
beneficial for
chromating in
case of alloys
like
AA6060/6063.
IR water
(Iron
removed
water)
CHROMATING 50% DM water +
15ml/L
CHEMIDITE 14-7 A
(make-up) &
5ml/L CHEMIDITE
14-7 B
(maintenance).
25o C to 60o C 3 to 10 mins 8 – 12 ml of
CHEMIDITE 14-
7 B per 1 mm of
Al surface.
Twice
with DM
water.
CHEMIDITE
14-7 A acts
as a
catalyst to
get uniform
yellow
iridescent
conversion
coating
DEJIGGING:
 De-jigging the material for air drying.
POWDER COATING :
 Jig the materials.
 Apply powder coating as required. Two types of powders are used polyester and epoxy-
polyester. Powders are negatively charged by 60 KV current in a hopper and is sprayed
through a gun on the chromatized material.
DRYING :
 After powder coating, the coated materials are passed through a hot chamber in which
they are baked at 200o C for 10 mins. Then the temperature is gradually decreased. The
powders are melted here and stick uniformly on the material surface by creating a
strong bond with Al surface.
 Heat is generated by burning LPG with air in controlled manner. A blower is used to
supply air from atmosphere and another blower is used to pass the hot gas generated to
the chamb

8. FABRICATION
Fabricationprocess includes –
 Cutting
 Milling
 Drilling
 Piercing
 De-burring
IMPORTANCE OF DIE – A die is used to pierce the solar frames using a press. Like moulds, dies
are generally customized to the item they are used to create. The material used in the die is
HCHC steel (High carbon high chromium) and MS (Mild steel).
The main components for die tool sets are:
 Die block - This is the main part that all the other parts are attached to.
 Punch plate - This part holds and supports the different punches in place.
 Blank punch - This part along with the blank die produces the blanked part.
 Pierce punch - This part along with the pierce die removes parts from the blanked finished
part.
 Stripper plate - This is used to hold the material down on the blank/pierce die and strip the
material off the punches.
 Pilot - This will help to place the sheet accurately for the next stage of operation.
 Guide, back gauge, or finger stop - These parts are all used to make sure that the material
being worked on always goes in the same position, within the die, as the last one.
 Setting (stop) block - This part is used to control the depth that the punch goes into the die.
 Shank - Used to hold in the presses. It should be aligned and situated at the center of
gravity of the plate.

9. SOLAR FRAMES
Solar energy is an environmental friendly form of renewable energy. This energy is harnessed
using photovoltaic or solar cells in solar panels of varying sizes, which are used to convert solar
energy into electricity for residential and commercial applications.
Innovations in aluminium extrusion technology are providing improved stability for solar panels
in the field. To maximize efficiency, solar panels need to be positioned with exceptional
accuracy. Even minor positional shifts of a few degrees can reduce the power output potential
by several percentage points.
Aluminium extrusion can be used to create a comprehensive framework for solar panels in a
variety of situations, including frames, supports and connectors. Products made from
aluminium offer numerous benefits over other metal choices.
The aluminium frames are fabricated in the Solar Frame Department as per the approved
drawings of the customers. Dimensions of the entire frame are given in the drawings.
Rectangular frames are prepared consists of two top and two bottom frames which are later
assembled.
Two different types of solar frames are manufactured.
 Hollow solar frames – These hollow solar frames are 45o angled at the two ends. They
are anodized before the fabrication process. The frames are punched 1st and assembled
together by corner keys or blocks. They consist of mounting holes, drain holes and
earthing hole as per requirement. The mounting holes are made elliptical for
adjustment purpose. The drain holes serve as the passage of water drainage. And the
circular earthing hole is made for grounding.
 Screw type solar frames – These frames are attached together by means of aluminium
screws. These are fabricated first and later anodized.

10. SOLAR FRAME SECTION:
Rectangular frames are prepared which consists of two side & two bottom frame.
Different types of fabrication processes doneon the frames-
 Mounting Hole: To mount the whole frame. Elliptical hole is made to adjust
the position of the screw.
 DrainHole: It is used to drain out water which deposited inside the each
frame. Itmay be circular or rectangular.
 Ground Hole: To insert a wire for earthing purpose.
Holes are made by piercing. According to the customer’s drawing & dimensions,
die & punch are developed. The main cost for those fabrication processes is
associated with the die development. Then die & punch are mounted with the
hydraulic press machines in appropriate position so that the dimension of those
holes remains within acceptable limit.
Die & Punch are made up of HCHC (High Carbon High Chromium). Die & Punch
holder, base plate, die head, stripper plate are made up of Stainless Steel.
Cross Cutting machine: Carbide cutter is used to cut the frames into proper size.
The cutter angle (450
or 900
as per requirement) can be adjusted.

11. WATER EFFLUENT TREATMENT PLANT
The etching rinsewater (pH
8.9), the acid rinsewater (pH
3-5) are fed together to
bring the pH
around 6 which is stored in the underground pre-treatmentreservoir.
PURPOSE–To avoid direct dischargeof etching rinsewater leading sewage line
blockage & also to avoid the direct dischargeof acidulated water.
PROCESS – The pH
of the water in the underground reservoir is tested. If the pH
if
acidic (around 5-6) it is fed in the reactor ( volume – 900 ltrs ) & requisite quantity
of Lime & flocculating agent inflocc 433 (to settle the lighter/suspended particles)
is added in it to bring/raisethe pH
value to 7 and the resultantsolution becomes
turbid completely. Itis then transferred by means of a pump in the primary
settling tank and kept undisturbed for sometimes leading to the settling of around
70-70% heavier particles.
The partially turbid solution is then transferred to the secondary settling tank and
kept undisturbed for sometimes. The precipitate fromthe bottom of both the
settling tanks is passed through the filter bed where the residue/solid particles
get arrested between the clothes of the filter bed & the neutral water is passed to
the sewageline.
In treating 900 ltrs of water it takes around 1 hr 15 mins to 1 hr 20 mins.
When it takes more time in treating the same it indicates that filter bed is jamor
blocked and the bed needs to be dismantled and skimmed off the solidified
residue fromthe cloth.
The residue is then collected in HDPEbags and disposed off.

12. LAYOUT OF CHILLING SYSTEM
CHILLER UNIT
CONDENSER
EVAPORATOR
FORCED
/INDUCED
DRAFT
COOLING
TOWER
CHILLED
WATER TANK
PUMP
PUMP
BATH
PUMP
ACID OUT WATER IN
COUNTER FLOW
HEAT EXCHANGER
WATER OUT ACID IN

13. OBSERVATIONS
Dimensional Analysis was carried outto measurethe accuracy of the finished
products as per the demand of the drawing. Various instruments including
Vernier Callipers, Depth Gauge, Measuring tape, Sliding Protector etc weretaken
into account for measuring the dimensions. 3 to 4 fromeach type had undergone
deep inspection under my presence keeping in mind all the given parameters. The
products werefound to meet the demand of the drawing within the tolerance
range.
CONCLUSION
Ithas been a privilege for me to be a part of the Alom Group and attend their
Induction Training Programme. Ithas been for the first time that I have been
given such an Industrialexposureto learn and interact with the people working in
an Industry which has helped me a lot to enhance my technical skills. Looking
forward to be partof the Alom Group, I would like to sharemy technical skills to
bring new innovations and changes.