What are your terms and conditions for In-situ metallography work?
Our scope of the work for In-situ metallography involves preparing the microstructure at site and replication subsequently photography at laboratory, (either in Mumbai or Vadodara, India). Only one copy of microstructure will be submitted with the report. Rs. 50.00 will be charged for extra copy of photograph. RS. 100.00 for each additional magnifications.
Electrical supply 230 Volt A/C board with ELCB for 5 amp connections (Minimum 2 points) should be provided by the client at site.
The client must select the locations for the replication work and only accessible locations will be attended.
Preliminary grinding to remove the oxide scales should be arranged by the client for each replication work.
The safety permits like hot work permit, work to start permit and confined space vessel entry permit should be obtained by the client for In-Situ Metallography.
The client should supply necessary Safety gadgets like safety goggles and hand gloves for in-situ metallography at site.
The client should provide all necessary help for handling of equipment at site including any casual labor if required.
The client must provide the list of the Materials of Constructions in advance for the components/equipment's required for in-situ Metallography.
The preliminary inferences will be conveyed to the client on-site, however the complete report will be submitted within 1 week of time after the complication of work at site. It also depends on the quantum of work for less than 10 spots the report may be submitted within 1 week time.
The payment shall be done within 15- days of the completion of the work at site otherwise 18% interest will be charged.
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Can you advise us on the properties of a LM 24 grade Aluminum?
LM 24 has higher Copper Low Magnesium and Silicon contents. High Copper helps in machineability whereas higher Silicon increases brittleness. Magnesium increases strength but upto 0.3% would not make much of a difference. Higher Magnesium content may also result in Oxide formation if proper casting of methods are not employed.
In case you need more information or guidance, we will advise you to seek our engineering consulting services.
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What is meant by STEP STRUCTURE MICRO on SS 304 plate material?
This term means checking of Microstructure at site (i.e. on job itself without cutting a piece). Step Structure in SS means that there is no evidence of Chromium Carbide Precipitation and therefore Solution Annealing has been done properly. We normally call it INSITU METALLOGRAPHY and we do conduct this test. Please let us know the details and we shall give you our quote.
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Can you perform Replica Metallography for power boilers?
TCR Engineering Services of Mumbai, India is a 31 years old independent materials testing laboratory in India. We do undertake Replica Metallography for power boilers. We have 5 sets of the following equipments:
- Insipol 2000 and advanced electrolytic flow type polisher and etcher
- Portable rough grinder with self adhesive papers
- Portable fine polishing (mini grinder)
- Portable microscope capable upto 400X magnification
- Replica kit, we use specialized plastic based slides for replica preservation which has longer durability and easy to handle at site.
- We have 5 teams comprising of expert metallography technicians capable to deliver quality and satisfactory services.
We have undertaken In-situ Metallography for reputed clients including, Alstom Projects India Limited, Vadodara (Worked on more than 20 RLA projects), BARC (Mumbai), Heavy Water Board (Mumbai), BARC, Reliance Industries Limited (Jamnagar and Hazira), SPIC-SMO, Gujarat Electricity Board, Ahmedabad Electricity Board, GSFC Limited, GNFC Limited, IOCL (Vadodara), L & T, Hindustan Lever Limited (9 Boiler RLA Work), Narmada Chematur Petrochemicals Limited, Bharuch and many more.
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Can you check a forging made of Stainless steel (size 1" X 1" X 1") for Microstructure, Grain Flow, Cold laps, Cracks and Chemical Composition?
We can carryout all tests requested by you from 1" X 1" X 1" piece. Please make sure that this is a full forging and not a cut piece from a forging. If 1" X 1" X 1"is not a full forging, we need a complete forging to find grain flow, cold laps and cracks. Approximate charges will be Rs. 1500/- plus 12.24% Service Tax. We would need about 10 days time to complete the job.
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Can you carry out a metallography investigation on failed tube samples for desalination units?
We do undertake insitu metallography by replica technique in which metallography is done by polishing & etching of test surface and then getting the microstructure image on a plastic film which in turn is viewed on a microscope. This technique allows study of microstructure without cutting a sample. We can carryout this on all type of metals. Our charges for this type of service will depend on number of locations which need to be tested. Please let us know the number of locations, material of construction and tentative date of inspection and we shall send you a complete quote.
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Which tests should we do ascertain soundness as well as good quality of our die?
We can conduct Radiography Test and Ultrasonic Test (For Internal Cracks), Dye Penetrant Test (For Surface Cracks), Hardness Test and Micro Examination (Non Destructive Insitu)for ascertaining that Heat Treatment is good of your die.
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We have the complaint of short life for the electroplating and want to test the life of the electroplating and the means to improve the life?
We can help you to compare your coating with someone else’s coating which lasts longer by carrying out salt spray test on both components. Once a comparative measure is established by carrying out the test and coating thickness test by microscopy, we can suggest ways to improve on your coating. We can take up this as a consultancy project if you so desire.
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Can you conduct testing as per ASTM G28 in your lab in India?
We are pleased to inform you that we can carryout test as per ASTM G28. Please note that cast product however like ASTM A 494 Gr. CW12MW is not covered under ASTM G28 scope. This specification is for wrought products only. As part of this test we will undertake a 24 hours test as per Method A, Micro examination at 100x and measurement of depth of attack at 100x with photographs, and Microexamination to determine presence of secondary phases. We will need about 8 days time to complete the job. Please send us approx 25 x 25 x 10mm test piece.
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Can you conduct IGC testing and PMI of SS materials?
TCR routinely conducts IGC as per ASTM A-262 Practice A thru E test, and PMI testing for Stainless Steel SS 304, 321, 316 and others. For ASTM A-262 practice E test we will need at least 80mm long sample. The test can be completed in 4 days.
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What method do you adopt to measure the case hardness?
We use microhardness test at 100 or 50 mg load to measure hardness at various depth and then determine effective case depth.
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We would like to know if TCR can test a sample of FOAM PAD for TRIORAGANOTIN presence.?
We regret to inform you that TCR has no facilities to undertake this test.
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Can TCR analyze samples for thin film microscopy?
We regret to inform you that TCR has no facilities to undertake this test.
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Can you test compression, flexural strength and porosity on our carbon-graphite material?
TCR undertake each of the above mentioned tests. For Compression test we will require a specimen cube of size 50x50x50mm. For the Flexural Test we will require a specimen of size 50x50x200mm and for the Porosity test we will require a specimen cube of size 25x25x25mm.
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Which tests can you not conduct on a non-ferrous product?
We regret to inform that we cannot conduct Dielectric strength (IEC 243), Water absorption (ISO 62), Elongation at break after ageing (150°C, 168 hrs), Operating temperature (IEC 216), Elongation at break (ASTM D 638).
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Can you conduct creep rupture test as per ACRT in India as per IBR guidelines?
We regret to inform you that TCR does not undertake the ACRT test.
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We are interested in looking for Kirkendall voids between solder and copper in the cross sectioning of circuit boards and solder joints.?
TCR can certainly assist. We are in business of Metallography and feel that we can serve electronic industry too. Please send a Solder Joint and we shall send you our observations with microphotograph (from 100X upto 500X magnification).
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Can you perform micro examination of samples and give microphotographs by email?
We can carryout Micro examination on the above samples (please mention grade of the sample for etching purposes) and give Micro Photographs by mail and also hard copy by courier. Our charges for the same will be US$ 20 per sample. A 12.24% Service Tax shall also be applicable on total invoice value. Charges can be paid by Electronic Wire Transfer or credit card.
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What details do you require for the interpretation of microstructure prepared on various Exhaust Valves?
We require the following Process Details / Operation Parameters for the interpretation of microstructure prepared on various Exhaust Valves:
- Design Temperature in °C
- Operating Temperature in °C
- Design Pressure in kg/cm2
- Operating Pressure in kg/cm2
- Flue Gas Temperature in °C
- Commissioned Year
- History of damage, If any
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Can you perform replica interpretation?
Our charges for interpretation will be as under:
Routine Observation for CS, AS & SS - US $ 25 Per Replica
Routine Observation for Inconel, Monel & Non Ferrous - US $ 40 Per Replica
Observations under SEM with Gold Sputtering - US $ 75 Per Replica
A service tax of 12.24% is applied on all invoices.
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Can you undertake Material Testing of Sintered parts (powders)?
We are pleased to inform you that we can carryout tests requested by you. You may send your powdered or sintered samples to us and list the tests you need. In particular please inform number of elements to be analyzed and any particular phase you need to know in microstructure.
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Do you have testing facilities for analysis of Oxygen & Hydrogen content from the Austenitic material?
We regret to inform that we do not have this facility at our labs.
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What services can you provide to the Construction Industry?
We are glad to inform that TCR Engineering Services is India’s most experienced and most well equipped independent metallurgical testing laboratory. We are capable of testing all kinds of metallic materials for heir various properties. For your construction project, we feel that we can provide excellent facilities for testing of your following materials for their Physical, Chemical, Metallurgical and Corrosion properties:
- All types of Structural Steels including Deformed Steel Reinforcement Bars and High Tensile Wires
- All types of architectural steel, Stainless Steel and non ferrous metal products for their various properties
- All types of Aluminum Alloy extruded sections and products for their castings and other properties
- Compression testing of Cement Cubes for their compressive strength after 7 or 28 days curing
- All kinds of steel piping materials used for water purpose to fire fighting systems as per relevant material specifications.
- All types of armored steels for their compression and mechanical properties.
- Measurement of Paint, Zinc and Anodizing Coating at site.
Please note that our lab is an ISO 17025 accredited lab which is equivalent for A2LA accreditation in the USA. We do provide 3rd party inspection services also. Wherein we draw samples fro the supplies made to our clients. Our testing facilities are located at Navi Mumbai, India and we welcome your officers to visit us for personal assessment of our capabilities.
List of Customers of TCR in Construction Vertical in India:
Larsen & Toubro Ltd - ECC Division
Shapoorji Palonji & Company Ltd.
Oberoi Commercial Towers
Kalpataru Constructions Pvt. Ltd.
The Phoenix Mills Ltd
Lokhandwala Builders Pvt. Ltd.
R N A Builders
Marathon Reality
Gopalkrishna Construction Pvt. Ltd.
Petron Engineering Construction Company
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What tests can you recommend for our Engine valves?
We do undertake all sorts of Metallurgical Investigations and NDT Services on Engine valves including mechanical and chemical testing, radiography, Micro Structure etc. We also offer Elevated Temp Tensile Test on Engine Valves in case you need these services.
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Can you help us compare SS 304L or 316 in storing and carrying distilled fatty acid?
We can plan on testing for comparison of AISI 304 to AISI 316 to determine which material is better in carrying distilled fatty acid. We will need you to send us samples of both types of SS of sizes 50 x 75mm each. We will carryout Micro examination of both samples to ascertain that they are in amended condition. We shall analyze Iron content of 2 items of fully acid sample submitted to us for corrosion testing. We will carryout 5 cycles of 46 hours each (total 10 days) and calculate loss in Wt (Mg) and plot a graph for the two samples. The sample will be maintained at 90°C in special glass vessels shown to you. We shall determine rate of corrosion for 5 periods and also calculate average rate of corrosion. We will find iron content of the two Fatty acid solutions used for corrosion testing. The above data will give us a good comparison of the 2 samples. We will require 2 weeks time to complete the job.
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Can you take a photo of the micrograph of the bond interlayer between two metals of a Composite Tri metallic piece of Aluminum 12.7mm + Titanium 2mm + Carbon Steel Clad 40mm?
We need approx 50mm long sample and we will use different etchants to reveal different phases. We shall send you photographs and we assure you of our best quality. You will find the interface very clear in your photographs. Please indicate no of indentation for hardness test that you need.
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Do you provide mounting and polishing of samples?
We can provide to undertake mounting and polishing sample of less than 50mm size. The maximum we may be able to go is 50mm mount size (i.e. 40mm component size).
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Can you supply us with ASNT UT Level II trained personnel?
The manpower deployment team at TCR will gladly place ASNT UT Level II trained personnel at your company. Please let us know your target remuneration.
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Can you check grain flow structure of the material which we want to procure for our power plant?
In order to check flow lines, we need a 50mm long cut piece of the square bar representing full section. We shall cut, grind, polish and etch the same to reveal grain flow lines. Our charges will depend on size of bar.
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Can you predict metal failure onsite based on the present working condition?
We can undertake such prediction using In-Situ Metallography. In-situ Metallography is performed as NDT on actual site with a team comprising of expert Metallographers and metallurgists. It is used to find out in-service degradation of critical components of process plants operating under high temperature/ high pressure/ corrosive atmosphere. TCR can also develop a data bank of critical components of equipment of process plant by periodical monitoring for preventive maintenance and planning for inventory control. In-situ Metallography checks the microstructure of component for intended service prior to being put in use. In-situ Metallography is used for remaining life assessment studies.
To conduct this test we will depute one full time metallurgist on-site at your location to undertake the job, and we will need two technicians to speed up the job at on-site. We will provide the digital microcopy at site so that decisions can be made of on site with evidence on photography. We will record the evidence on replica tapes for later to view in the lab also.
In order for us to quote can you let me know the location of the Metallography as well as the number of points to be checked? Our typical charges are $125-$175 per location plus all travel and related expenses. All laboratory testing charges are extra at actual.
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What details do you need to give a quotation for an RLA study of a boiler?
In order to conduct a Remaining Life Assessment Study on a Boiler, we will need the following information before we quote for our services:
- Capacity of Boiler
- Make & Year of Manufacture
- Fuel used
- Type of Boiler
The Remaining Life Assessment tests (RLA) includes the costs of performing on-site NDT and in-situ Metallography in order to achieve the desired objective, i.e. to estimate the life remaining of a given boiler. This is a study / investigative subject. Any NDT projects originating from the given recommendations as part of this project are not covered within the quote. Those will be separate projects. Our RLA quote does not cover the cost of any sandblasting or extensive cleaning that may be required. More on this subject can be finalized once our senior metallurgist has made a plant visit.
Our RLA quote does include the cost of Collection of back ground data and Visual Examination, Survey on past NDT records, Dimension measurements of critical areas, Collection of soot and scales from different section of boiler, Extensive thickness survey, WFMPI at critical weld joints, UT of critical weld joints, Replica micro structure examination through in-situ Metallography approach (details on this subject are given below), Hardness survey, Destructive study on selected tubes for chemical analysis, Cross section microscopy, Scanning electron microscopy, hot tensile test and stress rupture test.
The safe remaining life will be estimated by correlation of test results and operating parameters.
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Do you undertake In-situ Metallography and expand on your service offering?
We can undertake in-situ Metallography. You can read about our service offering in this area on our webpage of In-Situ Metallography.
As an NDE technique, In-situ Metallography is ideal for assessing the remaining life of power and petrochemical plants. TCR Engineering Services, India has qualified and experienced field services team that regularly conducts In-situ Metallography on-site at major plants, refineries and process industries. This team from TCR determines in-service degradation of critical components of process plants operating under high temperature/ high pressure/ corrosive atmosphere. The technique enables real-time component condition monitoring and health assessments.
Do note that The Metallurgists at TCR Engineering Services in India have strong experience in the interpretation of microstructure. The Metallurgists have an experience of more then 10,000 replica microstructures and past experiences are well captured into a database. This data base comprises of various plants and information is collected over a different length of time. It also includes a rare collection for different level of damage in the microstructure for power industries/petrochemical/fertilizers and other process industries. The team is highly skilled in the preparation of the replica. This is more of an art then technique as it is very important to differentiate between the artifacts and the actual defects in the microstructure interpretation.
We can also undertake other NDT tests such as
- In-Situ Metallography
- Ultrasonic Inspection
- TOFD
- Ferrite Measurement
- Thickness Survey
- Dye Penetrant
- Magnetic Particle Testing
- Radiography
- Weldability Study
- Visual Inspection and Field Services
- Portable Hardness
- Residual Life Assessment (RLA) of Boilers and pressure vessels
- Positive Material Identification using portable alloy analyzers
- RoHS Compliance Testing
- Training and Certification as per ASNT Level I and II
The on-site NDT personnel are supported by our state of the art material testing laboratory in Mumbai, India. Samples sent to our lab in India can then be analyzed for their mechanical and chemical properties, resistance to corrosion, Macro and Micro structure evaluation, and failure analysis.
Our deep domain strength in corrosion determination allows our team to determine intergranular corrosion attack, weight loss corrosion, pitting corrosion, sulfide stress cracking (SSCC), salt spray, stress corrosion cracking, and hydrogen-induced cracking (HIC) in oil and gas, power, construction, shipping, petrochemical and process industries.
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What are the sample sizes required for DSS testing?
The following are the samples sizes required for various testing on a DSS material.
- Pitting Test: 25mm X t X 50 mm where t (thickness) should be 10 mm. If the material has more thickness then you should cut the sample to 10mm in thickness.
- Crevice Test: 25mm X t X 50 mm where t (thickness) should be 10 mm. If the material has more thickness then you should cut the sample to 10mm in thickness.
- Chloride Stress Test: 15mm X 15mm X 125mm
- Ferrite Test: 1 inch X 1inch
- Sulphide Stress Corrosion Test (SSCC): 15mm X 15mm X 150mm
- Intergranular Corrosion (IGC): 25mm X t X 25mm (where thickness can be anything)
- Hardness Test: 25mm X t X 25mm (where thickness can be anything)
- Impact Test: We will need 6 samples from the same material of the size 15mm X 15mm X 55 mm
- Tensile Test: 16mm X 16mm X 150mm
With respect to Hydrogen Induced Cracking (HIC) testing on a flange, we will need to get a sample of the following size: 20 mm width X 100 mm length X T. Please note that T (thickness) of the flange can be anything up to 30 mm. If the flange has bigger thickness than 30 mm, then we will need to machine the sample to meet the 30mm length requirement.
Should you need any other sample sizes, please do not hesitate to ask us.
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