Services · Asset Integrity and Engineering Consulting
Reverse Engineering and Indigenisation Services
Source the component at home against the imported part's own metallurgy, not just its drawing.
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In brief
TCR Engineering Services Pvt. Ltd., a NABL ISO/IEC 17025:2017 accredited laboratory in Navi Mumbai, provides reverse engineering and indigenisation services for imported capital-equipment components in India: metallurgical study of the imported reference, reverse engineering, prototype development, vendor identification, materials selection and acceptance test campaigns.
What Does TCR's Reverse Engineering Establish?
TCR's reverse engineering starts from the imported part and returns what a domestic manufacturer needs to make it: what the part is made of, how it was processed, how it must perform and the dimensions it must hold. The component is characterised against its design intent in the laboratory, measured on metrology instruments and modelled in CAD.
- Material of construction: composition and grade, by chemical analysis.
- Processing route: heat treatment and manufacturing process, read from the microstructure, case depth and case hardness.
- Properties: mechanical properties and surface finish.
- Dimensions and form: dimensional tolerances measured on a coordinate measuring machine, micro profile tester, roundness and roughness tester and profile projector, with CAD modelling and surfacing of the part.
- Prototyping: rapid prototyping, CNC machining, and jigs and fixtures.
What Indigenisation and Localisation Support Covers
Indigenisation support sits in TCR's asset integrity and engineering consulting pillar and covers reverse engineering, prototype development, vendor identification and acceptance test campaign management for capital equipment that the buyer wants to source domestically against an imported reference.
Technical Help for Indigenisation
To set the baseline standard for indigenisation, TCR studies the imported component metallurgically, by destructive and non-destructive methods, to establish its condition and properties. Technical help is provided to decide on the right manufacturing route or process and to develop quality checks on indigenously created components.
TCR asks the client for component details in these areas to scope indigenisation support:
- Working condition of component
- Type of loading and stresses
- Design and operation condition
- Service history of component
- Life of an important component
Selection of Materials
TCR recommends the material of construction for the indigenised part from weight loss and coupon exposure tests in simulated or actual plant environments and from accelerated electrochemical tests, run to NACE, ASTM and API methods and read against published data and expert experience.
Quality Improvement
Where an indigenous component must meet a stringent international specification, TCR audits the existing manufacturing procedure, investigates the raw material and components stage by stage, and recommends the changes to the metallurgical process or raw material, and the quality control checks, that keep production consistent.
TCR's metallurgists carry out the study. The report sets out how each metallurgical processing variable affects the final properties of the components and includes recommendations for corrective measures.
Representative engagement: Larsen and Toubro Vadodara, PFBR advanced material testing laboratory setup and indigenisation.
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Frequently asked questions
How does TCR set the baseline for an indigenised component?
TCR studies the imported component metallurgically, by destructive and non-destructive methods, to establish its condition and properties, then helps decide the manufacturing route and develops quality checks for the indigenous part.
What does TCR need from the client to scope indigenisation support?
The working condition of the component, the type of loading and stresses, the design and operating conditions, its service history and the life of the component.
How are materials selected for the indigenised part?
By weight loss experiments in simulated or actual plant solution, coupon exposure in the actual plant environment and electrochemical tests, against NACE, ASTM and API standards, with a recommended material of construction.
What does a reverse engineering service from TCR deliver?
It delivers what a domestic manufacturer needs to make the imported part: the material of construction, the heat treatment and manufacturing route, mechanical properties, case depth and case hardness, microstructure, surface finish and dimensional tolerances, measured by TCR and drawn up as a CAD model of the part where the brief needs one.