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Expert Details

Steel Foundry, Steel Manufacturing, Alloy Steel, Abrasion Resistant & Ductile Iron Castings

ID: 723855 India

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Chromium-molybdenum steel and iron castings are used in various engineering industries where high tensile strength, toughness and abrasion resistance is of prime importance. For example, in mining industry, different parts of a P&H Shovel are made of chromium- molybdenum steel as well as high-chromium iron and austenitic manganese steel. Although both are carbide forming elements, each has different effects when dissolved in ferrit as a solid solution. While chromium increases tensile and yield strength, molybdenum increases depth of hardness and creep strength. For highly wear resistant castings such as grinding mill internals for cement plants and crushing units in mines, high chromium irons with molybdenum performs very well. By judicial compromise on toughness, he has converted many austenitic manganese steel castings to high-chrome-molybdenum composition to achieve much better performance.

He has in-depth knowledge and experience in metallurgy & manufacturing of High Chromium Iron Alloys for wear applications especially in cement industry. He has successfully executed turn-key assignments of designing, manufacturing and installation of internals including grinding media for a number of Tubular Grinding Mills in various cement plants. He has also experiences of manufacturing spares for Vertical Roller Mills for grinding cement, coal and refractory materials in High Chromium Iron.

For foundries manufacturing jobbing type heavy castings, CO2 molding process offers many advantages over other sand systems. It is superior with respect to cost and productivity and with necessary controls in selecting the ingredients and gassing techniques, the quality can be compared to that of resin bonded sands. The only negative point of CO2 sand system compared to others is its poor breakdown property. But with correct choice of a collapsible agent a breakdown property as good as resin bonded sands ca be achieved. It is a very suitable process of molding and core making for small and medium scale jobbing foundries.

No other manufacturing industry has so many variables in the process such as in Foundry industry. As such maintaining the quality standard in a foundry is not only a continuous function but also a continuous process up gradation. In a foundry it is almost impossible to have a fix quality standard because of continuous variations in the standard of numerous inputs and change of requirements of the end user. As a result a Foundry must always be in search of improved process controls to take care of the uncertainties.

Ferrous metal casting is the main activity throughout his carrier and he specializes in Cast Austenitic Manganese Steel, High Chromium Irons and Ductile Irons. He has done extensive research and field work on austenitic manganese steel and has developed a special grade of manganese steel which outperformed all known grades of manganese steel in use till date. He has written a technical paper on the subject in Indian Foundry Journal. The basic tenet of this development is the unique strain-hardening capacity of austenitic manganese steel and the factors influencing it.

Current challenge in ferrous metal melting is to produce a purest possible steel and pig iron. Phosphorous and Sulphur are the two most important impurities in iron and steel, the presence of whom should be brought down to as low a level as possible. Present and the predicted future growth of ductile iron castings especially in automobile and energy sectors calls for an immediate expansion of manufacturing capacity of extra low phosh-low sulphur pig iron. He has developed a ladle treatment process for mini-blast furnace and induction furnace operators to produce extra low phos-low Sulphur steel and iron.

He is involved in foundry industry in India since last 34 years and a member of The Institute of Indian Foundrymen. He specializes in Abrasion Resistant castings and Ductile Iron castings. He has published technical papers on both subjects in Indian Foundry Journal.

Sand casting is one of the important process of shaping metals. Complicated shapes, which cannot be produced by any other shaping process, can be produced by this process. This basically consists of preparing a negative impression by compacting a specially prepared sand aggregate around an exact replica of the shape required and pouring liquid metal into it. There are various types of sand aggregate used in foundries and Green sand, amongst them, is more widely used. It is an aggregate of silica sand, clay, dextrene and water. It is called green due to the presence of water. Dry sand which is free of water, such as chemically bonded sand or oven-dried clay-bonded sand, are used for weighty, heavy section and intricate castings.

Heat treatment is an important step in manufacturing iron & steel castings. It imparts the mechanical properties in the casting which are essential for the end use. Only giving shape to metal would not serve any useful purpose without necessary physical and mechanical properties. As such heat treatment shop is as important to a foundry as the melting shop or molding shop. Being a Metallurgist by qualification, he has made special contributions in this area to Iron & Steel Foundries in India.

He has assisted M/S.Krishnaferro Products Limited, Orissa, India for modernization and expansion and for manufacturing heavy Ductile Iron castings by In-mold treatment process.. He has assisted M/S. Milnars Pumps Limited, Bangladesh to manufacture Austenitic Manganese Steel and High Chrome Iron castings.He has assisted M/S. Blue Star Malleable, Jamshedpur, India, to start manufacturing High Chrome Iron Grinding Media.He has assisting M/s. Recon Castings Pvt. Ltd., Kolkata, India, to start manufacturing High Tensile Steel Castings for Railway and Mining Industry.He has assisted M/S. Devine Mechanical Engg. Pvt. Ltd.,
Kolkata, India, to start manufacturing heavy Ductile Iron castings by In-mold Treatment process.


Year Degree Subject Institution
Year: 1973 Degree: Bachelor of Engineering Subject: Metallurgical Engineering Institution: Regional Engineering College,Warangal,Osmania University, India

Work History

Years Employer Title Department
Years: 1992 to Present Employer: Undisclosed Title: Consultant Department: Steel Foundry
Responsible for Quality Assurance and Product Development.
Years Employer Title Department
Years: 1991 to 1992 Employer: Balaji Castings Pvt.Ltd., Kolkata, India Title: General Manager Department: Steel Foundry
Chief Executive Officer of Steel Foundry
Years Employer Title Department
Years: 1990 to 1991 Employer: Recon Castings Pvt. Ltd., Kharagpur, W.B. India Title: General Manager Department: Steel Foundry
Chief Executive Officer of Steel Foundry
Years Employer Title Department
Years: 1986 to 1990 Employer: RRL Steel Limited, Kolkata, India Title: General Manger Department: Steel Foundry
Chief Executive Officer of Steel Foundry
Years Employer Title Department
Years: 1973 to 1986 Employer: Electrosteel Castings Limited Title: Production Manager Department: Steel Foundry
Responsible for production and Quality Assurance.

International Experience

Years Country / Region Summary
Years: 2014 to Present Country / Region: Dhaka, Bangladesh Summary: He is assisting M/S.Milnars Pumps Limited, Bangladesh to manufacture Austenitic Manganese Steel and High Chrome Iron castings.

Additional Experience

Training / Seminars
Delivered a presentation on " Cast Austenitic Manganese Steels- Some Practical Notes" at Technical Seminar conducted by Institute of Indian Foundrymen.
Vendor Selection
Has experience in sourcing of Foundry inputs and castings.
Marketing Experience
Has experience in giving technical support to Marketing section.
Other Relevant Experience
Has experience in Research and Development work.

Language Skills

Language Proficiency

Fields of Expertise

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