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Additive Manufacturing - Module 1 and 2

The document provides a comprehensive overview of Additive Manufacturing (AM), detailing its processes, advantages, classifications, and applications across various industries. It covers the evolution of AM, the differences between AM and CNC machining, and includes modules on system drives, polymers, powder metallurgy, nanomaterials, and manufacturing control. The course aims to equip learners with knowledge and practical skills in AM technologies, software tools, and the latest trends in product development.

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0% found this document useful (0 votes)

32 views171 pages

Additive Manufacturing - Module 1 and 2

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An Autonomous Institution

Affiliated to VTU, Belagavi,

Approved by AICTE, New Delhi,
Recognised by UGC with 2(f) & 12 ( B)
Accredited by NBA & NAAC

MVJ22ME643
Additive Manufacturing
Department of Mechanical Engineering

Approved by AICTE |Affiliated to VTU | Recognized by UGC with 2(f) & 12(B) status |Accredited by NBA and NAAC 1
Module 1
Introduction to Additive Manufacturing: Introduction to AM, AM evolution, Distinction between
AM & CNC machining, Advantages of AM, AM process chain: Conceptualization, CAD,
conversion to STL, Transfer to AM, STL file manipulation, Machine setup, build , removal and
clean up, post processing.
Classification of AM processes: Liquid polymer system, Discrete particle system, Molten
material systems and Solid sheet system.
Post processing of AM parts: Support material removal, surface texture improvement, accuracy
improvement, aesthetic improvement, preparation for use as a pattern, property enhancements
using non-thermal and thermal techniques.
Guidelines for process selection: Introduction, selection methods for a part, challenges of
selection
AM Applications: Functional models, Pattern for investment and vacuum casting, Medical
models, art models, Engineering analysis models, Rapid tooling, new materials development, Bi-
metallic parts, Re-manufacturing. Application examples for Aerospace, defence, automobile, Bio-
medical and general engineering industries

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Module 2

System Drives and devices: Hydraulic and pneumatic

motors and their features, Electrical motors AC/DC and
their features
Actuators: Electrical Actuators; Solenoids, Relays,
Diodes, Thyristors, Triacs, Hydraulic
and Pneumatic actuators, Design of Hydraulic and
Pneumatic circuits, Piezoelectric actuators, Shape
memory alloys.

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Module 3
POLYMERS & POWDER METALLURGY Basic Concepts: Introduction to Polymers used for additive
manufacturing: polyamide, PF resin, polyesters etc. Classification of polymers, Concept of functionality,
Polydispersity and Molecular weight [MW], Molecular Weight Distribution [MWD] Polymer Processing:
Methods of spinning for additive manufacturing: Wet spinning, Dry spinning. Biopolymers, Compatibility issues
with polymers. Moulding and casting of polymers, Polymer processing techniques General Concepts:
Introduction and History of Powder Metallurgy (PM), Present and Future Trends of PM Powder Production
Techniques: Different Mechanical and Chemical methods, Atomisation of Powder, other emerging processes.
Characterization Techniques: Particle Size & Shape Distribution, Electron Microscopy of Powder, Interparticle
Friction, Compression ability, Powder Structure, Chemical Characterization Microstructure Control in Powder:
Importance of Microstructure Study, Microstructures of Powder by Different techniques. Powder Shaping:
Particle Packing Modifications, Lubricants & Binders, Powder Compaction & Process Variables, Pressure &
Density Distribution during Compaction, Isotactic Pressing, Injection Moulding, Powder Extrusion, Slip Casting,
Tape Casting. Sintering: Theory of Sintering, Sintering of Single & Mixed Phase Powder, Liquid Phase
Sintering Modern Sintering Techniques, Physical & Mechanical Properties Evaluation, Structure-Property
Correlation Study, Modern Sintering techniques, Defects Analysis of Sintered Components Application of
Powder Metallurgy: Filters, Tungsten Filaments, Self-Lubricating Bearings, Porous Materials, Biomaterials etc.

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Module 4
NANO MATERIALS & CHARACTERIZATION TECHNIQUES: Introduction: Importance of Nano-
technology, Emergence of Nanotechnology, Bottom-up and Top-down approaches, challenges in
Nanotechnology Nano-materials Synthesis and Processing: Methods for creating Nanostructures;
Processes for producing ultrafine powders- Mechanical grinding; Wet Chemical Synthesis of Nano-
materials- sol-gel process; Gas Phase synthesis of Nano-materials- Furnace, Flame assisted
ultrasonic spray pyrolysis; Gas Condensation Processing (GPC), Chemical Vapour
Condensation(CVC). Optical Microscopy - principles, Imaging Modes, Applications, Limitations.
Scanning Electron Microscopy (SEM) - principles, Imaging Modes, Applications, Limitations.
Transmission Electron Microscopy (TEM) - principles, Imaging Modes, Applications, Limitations. X-
Ray Diffraction (XRD) - principles, Imaging Modes, Applications, Limitations. Scanning Probe
Microscopy (SPM) - principles, Imaging Modes, Applications, Limitations. Atomic Force Microscopy
(AFM) - basic principles, instrumentation, operational modes, Applications, Limitations. Electron
Probe Micro Analyzer (EPMA) - Introduction, Sample preparation, Working procedure, Applications,
Limitations.

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Module 5

MANUFACTURING CONTROL AND AUTOMATION CNC technology - An

overview: Introduction to NC/CNC/DNC machine tools, Classification of NC /CNC
machine tools, Advantage, disadvantages of NC /CNC machine tools, Application
of NC/CNC Part programming: CNC programming and introduction, Manual part
programming: Basic (Drilling, milling, turning etc.), Special part programming,
Advanced part programming, Computer aided part programming (APT)
Introduction: Automation in production system principles and strategies of
automation, basic Elements of an automated system. Advanced Automation
functions. Levels of Automations, introduction to automation productivity Control
Technologies in Automation: Industrial control system. Process industry vs
discrete manufacturing industries. Continuous vs discrete control. Continuous
process and its forms. Other control system components.

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Course Outcomes

1. Learn what Advanced/Additive manufacturing (AM) is and understand why it has become one of the most
important technology trends in decades for product development and innovation

2. Demonstrate comprehensive knowledge of the broad range of AM processes, devices, capabilities and
materials that are available.
3. Understand the various software tools, processes and techniques that enable advanced/additive
manufacturing and personal fabrication

4. Learn how to create physical objects that satisfy product development/prototyping requirements, using
advanced/additive manufacturing devices and processes. Articulate the various tradeoffs that must be made in
selecting advanced/additive manufacturing processes, devices and materials to suit particular product
requirements.
5. Opportunity to design, engineer and fabricate an actual multi-component object using advanced/additive
manufacturing devices and processes and Understand the latest trends and business opportunities in AM,
distributed manufacturing and mass customization.

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COURSE DESCRIPTION

In this course you will learn the importance of additive manufacturing ( 3D

Printing) and its huge role in global product development and innovation.
You will develop a rich knowledge of 3D printing technologies, devices,
capabilities, materials and applications.
You will learn the trade-offs between various 3D printing processes and
technologies, along with the various related software tools, processes and
techniques, such as 3D scanning, injection molding and casting.
You will explore the broad range of 3D printing applications, including
biomedical, aerospace, consumer products, and creative artistry, to mention a
few.
And finally, you will learn the latest trends and opportunities in 3D printing,
localized services, production parts, mass customization, and how to
commercialize your ideas.
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Definition

Additive Manufacturing (AM) refers to a

process by which digital 3D design data is
used to build up a component in layers by
depositing material

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Additive Manufacturing (AM) is an appropriate name to describe the
technologies that build 3D objects by adding layer-upon-layer
of material, whether the material is plastic, metal, concrete or one
day…..human tissue.
Common to AM technologies is the use of a computer, 3D modeling
software (Computer Aided Design or CAD), machine equipment and
layering material.
Once a CAD sketch is produced, the AM equipment reads in data
from the CAD file and lays downs or adds successive layers
of liquid, powder, sheet material or other, in a layer-upon-layer fashion
to fabricate a 3D object.
 The term AM encompasses many technologies including subsets
like 3D Printing, Rapid Prototyping (RP), Direct Digital Manufacturing
(DDM), layered manufacturing and additive fabrication.

This means CNC machining starts with a block of material (called a

blank), and cuts away material to create the finished part. To do this,
cutters and spinning tools are used to shape the piece.

Some advantages of CNC machining include great dimensional

accuracy as well as many compatible materials, including wood,
metals and, plastic

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 Both 3D printing and CNC machining are compatible
with a wide variety of materials, including both plastics
and metals.

 3D printing however is more focused on plastics overall,

though this is changing rapidly as better and more
affordable ways of 3D printing metal are being developed
by manufacturers such as 3D Systems, Arcam, Desktop
Metal and Markforged.

 The most commonly used plastics used in CNC include

ABS(Acrylonitrile butadiene styrene), Nylon (PA66),
Polycarbonate (PC), Acrylic (PMMA), Polypropylene (PP).
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A very commonly used metal in CNC machining is aluminium, used by
prototyping companies to create high-quality prototypes in a variety of
industries.

Aluminium is recyclable, has good protective qualities, and can create

effective prototypes for machining. Other commonly used metals include
stainless steel, magnesium alloy, zinc alloy titanium, and brass.

In 3D printing, commonly used thermoplastics include ABS(Acrylonitrile

butadiene styrene), PLA ( Polylactic acid), Nylon, ULTEM, but also photo-
polymers such as wax, calcinable or biocompatible resins.
Some niche 3D printers also allow for the printing of parts in sand,
ceramics, and even living materials.

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The most common metals used in 3D printing include
aluminium, stainless steel, titanium, and inconel.
It is also worth noting that to 3D print metal,
expensive ($100,000+) industrial machines are
required. Some materials such as super alloys or TPU
(flexible material) cannot be created with CNC, so must
be used with 3D printing or rapid tooling technology.

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Different thermoplastics

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1. CAD
2. STL convert
3. File transfer to machine 4 Machine setup
4. Machine shop set up
5. Build
6. Remove
7. Post-process
8. Application

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Step 1: CAD

All AM parts must start from a software model that fully describes
the external geometry. This can involve the use of almost any
professional CAD solid modeling software, but the output must be
a 3D solid or surface representation

Reverse engineering equipment (e.g., laser scanning) can also be

used to create this representation.

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Step 2: Conversion to STL

Nearly every AM machine accepts the STL file format,

which has become a de facto standard, and nearly every
CAD system can output such a file format.

This file describes the external closed surfaces of the

original CAD model and forms the basis for calculation
of the slices.

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Step 3: Transfer to AM Machine and STL File Manipulation

The STL file describing the part must be transferred to

the AM machine.

Here, there may be some general manipulation of the file

so that it is the correct size, position, and orientation for
building.

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Step 4: Machine Setup

The AM machine must be properly set up prior to the build

process.

Such settings would relate to the build parameters like the

material constraints, energy source, layer thickness,
timings, etc.

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Step 5: Build

Building the part is mainly an automated process and the

machine can largely carry on without supervision.

Only superficial monitoring of the machine needs to take

place at this time to ensure no errors have taken place like
running out of material, power or software glitches, etc.

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Step 5: Build

Building the part is mainly an automated process and the machine

can largely carry on without supervision.

Only superficial monitoring of the machine needs to take place at this

time to ensure no errors have taken place like running out of
material, power or software glitches, etc.

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Step 6: Removal

Once the AM machine has completed the build, the parts

must be removed.

This may require interaction with the machine, which may

have safety interlocks to ensure for example that the
operating temperatures are sufficiently low or that there are
no actively moving parts.

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Step 7: Post processing

Once removed from the machine, parts may

require an amount of additional cleaning up
before they are ready for use. Parts may be weak
at this stage or they may have supporting features
that must be removed. This therefore often
requires time and careful, experienced manual
manipulation.

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Step 8: Application

Parts may now be ready to be used. However, they may

also require additional treatment before they are acceptable
for use.

For example, they may require priming and painting to give

an acceptable surface texture and finish. Treatments may
be laborious and lengthy if the finishing requirements are
very demanding.

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Advantages of AM

Freedom of design
Complexity for free
Potential elimination of tooling
Lightweight design
Elimination of production steps

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Applications of AM

AM has been used across a diverse array of

industries, including;

 Automotive
 Aerospace
 Biomedical
 Consumer goods and many others

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Classification of Additive Manufacturing Systems

The Better way is to classify AM systems broadly by the initial form of its material, all AM
Systems can be easily categorised into
Liquid Based
Solid Based
Powder Based

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Photo Polymerization

• Stereolithography Apparatus (SLA) is a liquid-based process which builds parts directly from CAD
software.
• SLA uses a low-power laser to harden photo-sensitive resin and achieve polymerization.
• The process begins with a 3D CAD file. The file is digitally sliced into a series of parallel horizontal
cross-sections which are then provided to a Stereolithography Apparatus (SLA) one at a time.
• A laser traces the cross-section onto a bath of photopolymer resin which solidifies the cross-section.
The part is lowered a layer thickness into the bath and additional resin is swept onto the surface.
• The laser then solidifies the next cross-section. This process is repeated until the part is complete.
Most parts are completed in a matter of hours, thereby defined as a "Rapid Prototype".

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Discrete Particle Systems

• Discrete particles are normally powders that are generally graded into a relatively
uniform particle size and shape and narrow size distribution.
• The finer the particles the better, but there will be problems if the dimensions get too
small in terms of controlling the distribution and dispersion.

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Powder Bed Fusion Processes
Selective Laser Sintering(SLS)

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Powder Bed Fusion Processes

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Powder Bed Fusion Processes

• Selective Laser Sintering (SLS), the most prominent of the powder bed fusion processes, was
originally developed at the University of Texas at Austin.
• In SLS a layer of powdered material is spread out and levelled over the top surface
of the growing structure.
• A laser then selectively scans the layer to fuse those areas defined by the geometry of the
cross-section; the laser energy also fuses layers together.
• The unfused material remains in place as the support structure. After each layer is
deposited, an elevator platform lowers the part by the thickness of the layer, and the next layer of
powder is deposited.
• When the shape is completely built up, the part is separated from the loose supporting
powder.

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Solid Sheet Systems

• One of the earliest AM technologies was the Laminated Object Manufacturing (LOM) system
from Helisys, USA.
• This technology used a laser to cut out profiles from sheet paper, supplied from a continuous
roll, which formed the layers of the final part.
• Layers were bonded together using a heat-activated resin that was coated on one surface of the
paper. Once all the layers were bonded together the result was very much like a wooden block.

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Laminated Object Manufacturing

• Laminated Object Manufacturing (LOM) is a process that combines additive

and subtractive techniques to build a part layer by layer.
• In this process the materials come in sheet form. The layers are bonded together by pressure
and heat application and using a thermal adhesive coating.
• A carbon dioxide laser cuts the material to the shape of each layer given the information of
the 3D model from the CAD and STL file.
• The advantages of this process are the low cost , no post processing and supporting structures
required, no deformation or phase change during the process, and the possibility of building large
parts.
• The disadvantages are that the fabrication material is subtracted thus wasting it, low
surface definition, the material is directional dependent for machinability and mechanical properties,
and complex internal cavities are very difficult to be built.
• This process can be used for models with papers, composites, and metals

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Manufacturing

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Advantages
• Ability to produce larger-scaled models.
• Uses very inexpensive paper
• Fast and accurate
• Good handling strength
• Environmentally friendly
• Not health threatening.
Disadvantages
• Need for decubing, which requires a lot of labor
• Can be a fire hazard
• Finish, accuracy and stability of paper objects not as good as materials used with
other RP methods
Typical Uses
• Investment casting patterns
• Concept verification
• Masters for silicone-rubber injection tools
• Fit-check
• Direct use

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Molten Material Systems

• Molten material systems are characterized by a pre-

heating chamber that raises the
materialtemperature to melting point so that it can flow
through a delivery system.

The most well -known method for doing this is the Fused Deposition Modeling (FDM)
material extrusion technology developed by the US company Stratasys

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Fused Deposition Modeling

• FDM is a filament-based technology where a temperature-controlled head extrudes a

thermoplastic material layer by layer onto a build platform.
• A support structure is created where needed and built in a water-soluble material.

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Application areas
Prototypes are produced for form / fit and functional testing in standard materials by
FDM
Support parts (jigs, fixtures, helps) can be produced directly
Small series parts down to one of a kind are built in standard materials by fused
deposition modeling

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Post processing of AM parts

• Post-processing is an essential stage of additive manufacturing. It‟s the last step in the
manufacturing process, where parts receive finishing touches such as smoothing and painting.
• Why is post-processing important?
• Post-processing improves the quality of parts and ensures that they meet their design
specifications.
• The finishing process can enhance a parts surface characteristics, geometric accuracy,
aesthetics, mechanical properties, and more. For samples and prototypes, this can mean the
difference between a sale or a loss.
• For production parts, finishing creates a part that is ready to use.

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• A metal additive manufacturing (AM) part is essentially “welded” to the build plate, and
you will not be able to pull it off without some assistance. Even then, the AM part will need post
processing before it is ready to use.
• Here are some costs associated with post processing AM parts

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Powder Removal:

• AM parts build “down” in a powder-bed fusion system as new layers are added to the top, which
means that parts are buried in powder when they are done .
• After the build has finished and the parts/build plate have cooled, the machine operator
has to remove all of the powder
• from the build volume and sieve/filter/recycle it for later use, assuming you want to reuse it.
• This is not an expensive step, but it does take time.

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Stress Relief:

• The heating and cooling of the metal as the part builds layer-by-layer leads to internal stresses
that must be relieved before the part is removed from the build plate. Otherwise, the part may warp or
even crack.
• Stress-relieving the part requires an oven or furnace (preferably with environmental
controls) that is big enough to fit the entire build plate.
• Many recommend using an oven with an inert environment to minimize oxidation on the part
surface.

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Part Removal:

• Most companies use wire EDM to remove parts from the build plate, however many machine
shops are starting to use a bandsaw because it is faster and the bottoms of the parts must be finished
anyway.
• Keep in mind that materials such as Inconel strain-harden as they are worked, making it
difficult to remove them from the build plate with just a bandsaw.
• A bandsaw can complete the task in minutes.

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Heat Treatment:

• Heat treatment (aging, solution annealing and so on) improves the microstructure and
mechanical properties of the parts and is necessary for nearly all AM parts.
• In many cases, this step also requires an environmentally controlled furnace with the ability to
regulate the temperature and cool -down schedule.
• Heat treatment may affect the dimensions of the parts, so most people prefer to heat-treat parts
before they machine/finish them.
• The American Society for Testing and Materials (ASTM) just released a standard for thermal
postprocessing of metal AM parts.

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Machining:
• Machining of mating interfaces, surfaces, threads, support structures
and more likely will be required to ensure dimensional accuracy of the finished
part.
• Few AM parts meet specifications “as built,” and if nothing else,
the surface of the part that was connected to the build plate will need to be
finished.
• Most manufacturing companies already have machining systems on
hand, but registering parts and establishing datums for machining can be
tricky, especially for complex, organically shaped parts made with AM.
• Accessing internal channels or cooling passages that need to be
machined can also increase costs. The cost here is highly dependent on the
material and the job as well as the fixturing needed to hold the part.

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Surface Treatments:

• Surface finishing also might be required

to improve surface finish/quality, reduce surface
roughness, clean internal channels or remove partially melted
particles on a part.
• When outsourced, these costs can easily run in the hundreds
if not thousands of dollars.

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Inspection and Testing:

• Metrology, inspection and nondestructive testing using white/blue -

light scanning, dye-penetrant testing, ultrasonic testing, computed
tomography (CT) scanning and more will be needed after post processing and
possibly at multiple points during post processing.
• Destructive testing of sample parts and analysis of witness coupons
(for example, tensile bars), powder chemistry, material microstructure and
more also may be needed to gather data to help with process qualification
and ultimately part certification.
• Most companies will have a range of metrology and nondestructive
testing methods on hand, but AM parts with internal channels, lattice
structures and other internal enhancements may require CT scanning to
ensure clear passageways, evaluation of internal geometries and more.

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Guidelines for process selection
• A variety of AM technologies have been developed. According to
ASTM Standard F2792 (ASTM F2792-12a 2012), these technologies can be
catalogued into seven groups: binder jetting, directed energy deposition,
material extrusion, material jetting, powder bed fusion, sheet lamination
and vat photo- polymerization.
• More than 350 industrial AM machines and 450 materials have been
identified in the market (Senvol LLC 2015). The debate about which
machine or technology fares better than others has little value as each of
them has its targeted applications.
• AM technologies are no longer limited to prototyping usage,
but are increasingly also being used for making end products .
• Therefore, „Design for Additive Manufacture‟ (DfAM) becomes
increasingly significant for avoiding potential manufacturing pitfalls and
maximizing utilization of AM capability.

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The commonly used decision process can be described by a
six-stage sequential decision-making model as proposed

• Identification of the problem

• Obtaining necessary information
• Production of possible solutions
• Evaluation of such solutions
• Selection of a strategy for performance
• Implementation and subsequent learning and reformulation

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AM Applications

1. Rapid Prototyping
• Models and parts for research purposes can be easily manufacture
whenever required. Easy to make changes in the models as per the research
proceedings.
2. Food
• Cornell Creative Machines Lab is making food items such as chocolates,
candy, pasta, pizza using 3D printing technique since 2012.
3. Apparel
• Products such as customize shoes, clothes and eye wears are being
manufactured. •Nike is using 3D printing to manufacture the “Vapor Laser
Talon” football shoe for players of American football

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4. Vehicle
• In 2010 Urbee became the first car whose whole body was 3D
printed (by US engineering group Kor Ecologic and the company Stratasys ).
• In early 2014, Swedish supercar manufacturer, Koenigsegg
,manufactured a supercar having many 3D printed mechanical
parts in it.
5. Firearms
Defense arms such as guns, rifles and safety equipment has also been
manufacture by AM.
In 2012 US based group “Defense Distributed”, designed a working plastic
gun that could be downloaded and reproduced by anybody with a 3D printer.
In 2013, „Solid Concepts‟, based in Austin, Texas, US Asucceeded
in manufacturing first working metal gun.

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6. Medical
• •Nowadays medical devices, specific implants, hearing aids, dental
products and pills are being manufacture by AM. •During October 2014, a five
year old girl born without fully formed fingers on her left hand
• became the first child in the UK to have a prosthetic hand made with
3D printing . Till now more than 400 hands have been transplanted by E-
NABLE.
• •In august 2015, US FDA (Food and Drug administration) approved
3D printed pills which allows very porous pills to be produced, which enables
high drug doses in a single pill which dissolves quickly and can be ingested
easily.
• Currently, active research is pursued by different groups to use cells and
biomaterials by different print-heads to produce organs on demand. This might
answer the organ shortage scenario in regenerative medicine application.”

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7. Bioprinting
• Bioprinting refers to manufacturing artificial biological organs and body
parts capable of working like original ones.
• In this process, layers of living cells are deposited onto a gel medium or sugar
matrix and slowly built up to form three dimensional structures including vascular systems.
• The first production system for 3D tissue printing was delivered in 2009, based on
NovoGen bio -printing technology. •In 2013, Chinese scientists began printing ears, livers
and kidneys,with living tissue.•In 2014, researchers at the University of Hasselt, in Belgium
had successfully printed a new jawbone for an 83 year old woman.
8. Space
• In September 2014, “SpaceX” delivered the first zero gravity 3D printer to the
International Space Station (ISS).
• In December 2014, NASA emailed CAD drawings for a socket wrench to
astronauts aboard the ISS, who then printed the tool using its 3D printer.
• The European Space Agency plans to deliver its new advance Portable On
Board 3D Printer to the International Space Station by the end of 2015

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Assignment questions

• Define additive manufacturing(AM)?

• Distinguish between AM and CNC.
• List applications and advantages of CNC.
• List and explain stages of AM.
• Classify AM Process, explain any one in each processes.
• Explain post-processing of AM part.
• Explain guideline for process selection.
• Explain applications of AM in different areas.

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MVJ College of Engineering
Near ITPB, Whitefield
Bangalore-560 067
E-mail:
Thank You
[email protected]
Ph: +91 8073533599

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An Autonomous Institution
Affiliated to VTU, Belagavi,
Approved by AICTE, New Delhi,
Recognised by UGC with 2(f) & 12 ( B)
Accredited by NBA & NAAC

MVJ22ME643
Additive Manufacturing
Module - 2

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Module 1

Introduction to Additive Manufacturing: Introduction to AM, AM evolution, Distinction between

AM & CNC machining, Advantages of AM, AM process chain: Conceptualization, CAD, conversion to
STL, Transfer to AM, STL file manipulation, Machine setup, build , removal and clean up, post
processing.
Classification of AM processes: Liquid polymer system, Discrete particle system, Molten material
systems and Solid sheet system.
Post processing of AM parts: Support material removal, surface texture improvement, accuracy
improvement, aesthetic improvement, preparation for use as a pattern, property enhancements using
non-thermal and thermal techniques.
Guidelines for process selection: Introduction, selection methods for a part, challenges of selection
AM Applications: Functional models, Pattern for investment and vacuum casting, Medical models,
art models, Engineering analysis models, Rapid tooling, new materials development, Bi-metallic parts,
Re-manufacturing. Application examples for Aerospace, defence, automobile, Bio-medical and general
engineering industries

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Module 2

System Drives and devices: Hydraulic and

pneumatic motors and their features, Electrical
motors AC/DC and their features
Actuators: Electrical Actuators; Solenoids,
Relays, Diodes, Thyristors, Triacs, Hydraulic
and Pneumatic actuators, Design of Hydraulic
and Pneumatic circuits, Piezoelectric actuators,
Shape memory alloys.

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Module 4

NANO MATERIALS & CHARACTERIZATION TECHNIQUES: Introduction: Importance of Nano-

technology, Emergence of Nanotechnology, Bottom-up and Top-down approaches, challenges in
Nanotechnology Nano-materials Synthesis and Processing: Methods for creating Nanostructures;
Processes for producing ultrafine powders- Mechanical grinding; Wet Chemical Synthesis of Nano-
materials- sol-gel process; Gas Phase synthesis of Nano-materials- Furnace, Flame assisted ultrasonic
spray pyrolysis; Gas Condensation Processing (GPC), Chemical Vapour Condensation(CVC). Optical
Microscopy - principles, Imaging Modes, Applications, Limitations. Scanning Electron Microscopy
(SEM) - principles, Imaging Modes, Applications, Limitations. Transmission Electron Microscopy (TEM) -
principles, Imaging Modes, Applications, Limitations. X- Ray Diffraction (XRD) - principles, Imaging
Modes, Applications, Limitations. Scanning Probe Microscopy (SPM) - principles, Imaging Modes,
Applications, Limitations. Atomic Force Microscopy (AFM) - basic principles, instrumentation, operational
modes, Applications, Limitations. Electron Probe Micro Analyzer (EPMA) - Introduction, Sample
preparation, Working procedure, Applications, Limitations.

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Module 5

MANUFACTURING CONTROL AND AUTOMATION CNC technology - An

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Course Outcomes

1. Learn what Advanced/Additive manufacturing (AM) is and understand why it has become one of the most
important technology trends in decades for product development and innovation

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COURSE DESCRIPTION
In this course you will learn the importance of additive manufacturing ( 3D
Printing) and its huge role in global product development and innovation.
You will develop a rich knowledge of 3D printing technologies, devices,
capabilities, materials and applications.
You will learn the trade-offs between various 3D printing processes and
technologies, along with the various related software tools, processes and
techniques, such as 3D scanning, injection molding and casting.
You will explore the broad range of 3D printing applications, including
biomedical, aerospace, consumer products, and creative artistry, to mention a
few.
And finally, you will learn the latest trends and opportunities in 3D printing,
localized services, production parts, mass customization, and how to
commercialize your ideas.

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Definition

Additive Manufacturing (AM) refers to a

process by which digital 3D design data is
used to build up a component in layers by
depositing material

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Hydraulic motors

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Pneumatic motor

A pneumatic motor (air motor) or compressed air engine is a type of motor

which does mechanical work by expanding compressed air. Pneumatic motors
generally convert the compressed air energy to mechanical work through
either linear or rotary motion

Linear motion can come from either a diaphragm or piston actuator, while
rotary motion is supplied by either a vane type air motor, piston air motor, air
turbine or gear type motor.

Pneumatic motors have existed in many forms over the past two centuries,
ranging in size from hand-held motors to engines of up to several hundred
horsepower. Some types rely on pistons and cylinders; others on slotted rotors
with vanes (vane motors) and others use turbines.

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Many compressed air engines improve their performance by heating the
incoming air or the engine itself. Pneumatic motors have found widespread
success in the hand-held tool industry, but are also used stationary in a
wide range of industrial applications

Continual attempts are being made to expand their use to the

transportation industry. However, pneumatic motors must overcome
inefficiencies before being seen as a viable option in the transportation
industry.

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Classification
Linear

In order to achieve linear motion from compressed air, a system of pistons is

most commonly used. The compressed air is fed into an air-tight chamber
that houses the shaft of the piston
Also inside this chamber a spring is coiled around the shaft of the piston in
order to hold the chamber completely open when air is not being pumped
into the chamber
As air is fed into the chamber the force on the piston shaft begins to
overcome the force being exerted on the spring. As more air is fed into the
chamber, the pressure increases and the piston begins to move down the
chamber

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When it reaches its maximum length the air pressure is released from
the chamber and the spring completes the cycle by closing off the
chamber to return to its original position.

Piston motors are the most commonly used in hydraulic systems.

Essentially, piston motors are the same as hydraulic motors except they are
used to convert hydraulic energy into mechanical energy.

Piston motors are often used in series of two, three, four, five, or six
cylinders that are enclosed in a housing. This allows for more power to be
delivered by the pistons because several motors are in sync with each other
at certain times of their cycle.

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Rotary vane motors

A type of pneumatic motor, known as a rotary vane motor, uses air to produce
rotational motion to a shaft. The rotating element is a slotted rotor which is
mounted on a drive shaft. Each slot of the rotor is fitted with a freely sliding
rectangular vane.
The vanes are extended to the housing walls using springs, cam action, or air
pressure, depending on the motor design

Air is pumped through the motor input which pushes on the vanes creating
the rotational motion of the central shaft

Rotation speeds can vary between 100 and 25,000 rpm depending on several
factors which include the amount of air pressure at the motor inlet and the
diameter of the housing.

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One application for vane-type air motors is to start large industrial
diesel or natural gas engines. Stored energy in the form of compressed
air, nitrogen or natural gas enters the sealed motor chamber and
exerts pressure against the vanes of a rotor

This causes the rotor to turn at high speed. Because the engine flywheel
requires a great deal of torque to start the engine, reduction gears are
used

Reduction gears create high torque levels with the lower amounts of energy
input. These reduction gears allow for sufficient torque to be generated by
the engine flywheel while it is engaged by the pinion gear of the air motor
or air starter

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TYPES OF AIR MOTORS

VANE MOTORS

PISTON TYPE

TURBINE MOTORS

GEROTOR

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Rotary vane motors normally are used in applications requiring
low- to medium-power outputs
Simple and compact vane motors most often drive portable power tools, but
certainly are used in a host of mixing, driving, turning, and pulling
applications as well.
The vanes are biased to seal against the housing interior wall by springs,
cam action, or air pressure, depending on design
The vanes are biased to seal against the housing interior wall by springs,
cam action, or air pressure, depending on design
Torque develops from pressure acting on one side of the vanes.
Torque at the output shaft is proportional to the exposed vane area, the
pressure, and the moment arm (radius from the rotor centerline to the center
of the exposed vane) through which the pressure acts.

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VANE MOTORS

In the slot, there are generally 3 to 10 vanes.

To enable the vanes to come out of the slots they are designed with compression
spring or pressure air
For motors equipped with an even number of vanes, a connecting pin links
diametrically opposite vanes so that as the bore surface pushes one vane in,
the pin pushes the other vane
But leakage probability will be there when the vane tip wears out

Vane motors run at 100 to 25,000 rpm

Piston air motors are used in applications requiring high power, high starting
torque, and accurate speed control at low speeds.

They have either two, three, four, five, or six cylinders arranged either axially
or radially within a housing.

Output torque is developed by pressure acting on pistons that reciprocate

within the cylinders.
Power developed by a piston motor depends on the inlet pressure, the number
of pistons, and piston area, stroke, and speed.
Radial- and axial-piston motors have one significant limitation:
they are internally lubricated, so oil and grease supplies must be
checked periodically and replenished.
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Radial-piston motors :

Feature robust, oil-lubricated construction and are well-suited to continuous

operation.

They have the highest starting torque of any air motor and are particularly
beneficial for applications involving high starting loads.

Overlapping power impulses provide smooth torque in both forward and

reverse directions.

Sizes range to about 35 hp for speeds to 4,500 rpm.

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Axial-piston motors

Are more compact than radial-piston motors, making them ideal for
mounting in close quarters

Their design is more complex and costly than vane motors, and they are
grease lubricated

However, axial-piston motors run smoother and deliver maximum power

at much lower speeds than vane motors can.

axial-piston motors also tolerate higher ambient temperatures

It converts low velocity high pressure air to high velocity low pressure air by
passing it through metering nozzles
Major advantage of this is that there is no rubbing or sliding contact between
the rotating parts and the body cavity
This reduces wear and lubricated air is not required to seal and lubricant
problem

Application is advisable only in low ambient temperature because of lubricant

problem
These are high speed low torque motor for same volume of air than piston
vane type

These gerotor type motor are mostly used for low rpm pressure applications
such as 20-30 rpm.
Hence, they may not be suitable for high torque application.

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ADVANTAGES OF AIR MOTORS

Variable speed.
Easy to use.
Low weight.
Inexpensive.
Stall w/o damage - perfect for conditions where motor
works in stall conditions.
Runs cool - especially in overload conditions.
Explosion proof.
Instantaneously reverses - except when specifically
noted.

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APPLICATIONS OF AIR MOTORS
Construction Engineering.
Hand –tools.
Mining Engineering.
Wood working fields.
Mechanical applications like hammering, riveting and
drilling.
Indoor manufacturing plants.
Mobile / portable equipment at sea or on land.
Non-electrical for hazardous locations.
Emergency back-up to electric motors for critical
operations.
Outdoor / remote / underwater equipment.

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Electrical motors

Electrical motor: It is a machine which converts electrical energy into

mechanical energy.

AC Motor: motor that runs on alternating current (AC) electricity.

DC Motor: motor that runs on direct current (DC) electricity.

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AC Motor
AC motor is an electric motor driven by an alternating
current.
Commonly consists of two basic parts, an outside
stationary stator having coils supplied with alternating
current to produce a rotating magnetic field, and an
inside rotor attached to the output shaft that is given a
torque by the rotating field.
Two main types of AC motors- depending on the type of
rotor used.
• the asynchronous motor
• the synchronous motor

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DC Motor
DC motor is an electric motor that runs on direct current
(DC) electricity. Two types of DC motor - brush and
brushless DC Motor.
Brushed DC electric motor generates torque directly from
DC power supplied to the motor by using internal
commutation, stationary magnets (permanent or
electromagnets), and rotating electrical magnets.
Brushless DC motors use a rotating permanent magnet or
soft magnetic core in the rotor, and stationary electrical
magnets on the motor housing.

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Types of DC Motor:
Classification of the d.c. motor depends on the way
of connecting the armature and field winding of a
d.c. motor:
1.DC Shunt Motor
2.DC Series Motor
3.DC Compound Motor

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D C Motors

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DC Shunt Motor:
In dc shunt motor the armature and field winding are
connected in parallel across the supply voltage
The resistance of the shunt winding 𝑅sh is always
higher than the armature winding 𝑅𝑎
Since V and 𝑅𝑠h both remains constant the 𝐼𝑠h
remains essentially constant, as field current is
responsible for generation of flux. thus ∅∝ 𝐼𝑠h
So, shunt motor is also called as constant flux motor.

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Contd…

A DC shunt motor is a type of direct

current (DC) motor that has a field coil
connected in parallel with the armature.
It is also known as a shunt wound DC
motor.

 The field windings and armature

winding are exposed to the same
supply voltage.
 The motor armature turns faster
when the current in the field coil is
decreased.
 The motor can increase torque
without sacrificing speed by
increasing the motor current.

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Applications of DC shunt Motor:
These motors are constant speed motors, hence
used in applications requiring constant speed.
Like:
1)Lathe machine
2) Drilling machine
3) Grinders
4) Blowers
5) Compressors

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DC Series Motor

In this type of DC motor the armature and field windings are
connected in series.
the resistance of the series field winding Rs is much smaller than
the armature resistance Ra
The flux produced is proportional to the field current but in this
𝐼𝑓=𝐼𝑎 thus ∅∝𝐼𝑎
Thus flux can never become constant in dc series motor as load
changes If and Ia also gets changed
Thus dc series motor is not a constant flux motor

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A DC series motor is a type of electric
motor that converts electrical energy
into mechanical energy. It is a self-
excited motor with a field coil that is
connected in series to the armature
winding.

•The field coil and armature winding

are connected in series, which allows a
higher current to pass through the field
coil.
•The magnetic field around the current-
carrying conductor and an outside field
interact, which causes the output shaft
to rotate.
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Applications of DC series Motor-
These motors are useful in applications where
starting torque required is high and quick
acceleration. Like:
1) Traction
2) Hoists and Lifts
3) Crane
4) Rolling mills
5) Conveyors

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DC Compound Motor:
The DC compound motor is a combination of the series
motor and the shunt motor. It has a series field winding
that is connected in series with the armature and a shunt
field that is in parallel with the armature. The
combination of series and shunt winding allows the
motor to have the torque characteristics of the series
motor and the regulated speed characteristics of the
shunt motor. Several versions of the compound motor are:
Short shunt Compound Motors
Long shunt Compound Motors

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Short shunt compound motor:

 When shunt field winding is connected in parallel

with armature like dc shunt motor and this
assembly is connected in series with the series field
winding then this type of motor is called as short
shunt compound motor.
 Depending on the polarity of the connection short
shunt motor is classified as: 1.Cumulative compound
motor.
 Differential compound motor.

when the shunt field is connected in parallel with both the

series field and the armature then this type of motor is called
as long shunt compound motor.
Depending on the polarity of connection of shunt field
winding, series field winding and armature, long shunt motor
is classified as:
1.Cumulative Compound Motor. 2.Differential Compound
Motor.

Cumulative Compound Motor:

These motors have high starting torque.
They can be operated even at no loads as they run at a moderately
high speed at no load.
Hence cumulative compound motors are used for the following
applications.
1.Elevators
2. Rolling mills
3. Punches
4.Shears
5.planers

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Applications of DC Compound Motor:
Differential Compound Motor:

The speed of these motors increases with increases in the load

which leads to an unstable operation

Therefore, we cannot use this motor for any practical applications.

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Actuators

An actuator is a component of a machine that is responsible

for moving and controlling a mechanism or system, for example
by opening a valve. In simple terms, it is a "mover". An
actuator requires a control signal and a source of energy.

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Solenoids

Solenoid is an electromechanical device.

Electrical energy is used to magnetically cause mechanical movement

A solenoid is a long wire wound as a helix to produce a reasonably

uniform magnetic field B in the interior of the solenoid coils when the
solenoid carries a steady current I.
When the coils (turns) are closely spaced, each turn can be
approximated as a circular loop and the net magnetic field B is the
vector sum of the fields resulting from all of the turns.
Inside the solenoid, the field lines are nearly parallel, uniformly
distributed, and close together, indicating that the magnetic field is
uniform.

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The magnetic field lines between the turns tends to cancel
each other.
The magnetic field outside the solenoid is non uniform and
weak.
The field at exterior points, such as P, are weak because
current elements on the upper portions tends to cancel the
current elements on the lower portions.

AC Solenoid
 This type of solenoid are noise damping and would
likely cause premature overheating and failure.
 This solenoid requires great care to insure precise
alignment of plunger pole face to stator pole face.

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DC Solenoid
This solenoid have capability of being modified in such a fashion
to prevent the pole faces from making contact at end of stroke.
So in DC solenoid a slight gap between the pole pieces at the end
of stroke have drastic effect on improving overall life of solenoid.

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Applications of Solenoid
The solenoids are used in variety of fields

Locking applications
Automotive applications
Medical applications
Railway applications
Industrial applications

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Locking Applications

Solenoids are frequently used in locking mechanisms, it include

door locking, in hotels, offices and secure areas, vending machines,
remote access systems, turnstiles, car park and access barriers

The list is extensive. Latching can be mechanical or magnetic, and

the main function can suit the application to include single acting
solenoids, bistable solenoids, two-directional solenoids or holding
solenoids in many cases with or without springs.

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Automotive Applications

Other applications for solenoids include petrol cap locking, in-car

entertainment release mechanisms, anti-vibration engine
mountings, air conditioning control and security systems.
Automotive applications are not just for cars.

We supply solenoids for integration into joystick controls for

agricultural machinery, for lorry systems and many other
automotive applications. There are just far too many to be listed
here.

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Railway Applications

Applications within the railway industry are particularly diverse,

including functions on locomotives, rolling stock, tracks, signals and
power distribution as well as conventional uses in maintenance and
building.
Safety interlock on passenger car doors use a solenoid operated
mechanism that is controlled remotely by the train manager.
The Solenoid Company has developed a special solenoid for the
operation of fire extinguishers in locomotives. This application calls
for a very high force for the relevant size, to operate the jets of a fire
suppressant system.

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Industrial Applications

The use for solenoids in industry is extensive.

Anywhere that electrical power is required to achieve a
movement becomes an application for a solenoid.

Some general examples of use are locking, cutting, clamping,

punching, positioning, diverting, holding or rotating.

The range of standard or modified standard solenoids from The

Solenoid Company will satisfy most of these applications.

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Relays
Relays are switching that open and close circuit electromechanically or
electronically. Relays control one electrical circuit by opening and
closing contacts in another circuit.
When a relay contact is normally open (NO), there is an open contact
when the relay is not energized.
When a relay contact is Normally Closed (NC), there is a closed
contact when the relay is not energized. In either case, applying
electrical current to the contacts will change their state.
Relays consist of an electromagnet and also a set of contacts. A relay is
used when a circuit is to be controlled at a low power signal. Relays are
often grouped together or with other components like fuses. Relays have
two circuit: a control circuit and a load circuit.

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History about Relays
The relay was invented in 1835 by American scientist Joseph Henry in order to
improve his version of the electrical telegraph.

Basic design or operation

A simple electromagnetic relay consists of a coil of wire wrapped around a soft
iron core, an iron yoke which provides a low reluctance path for magnetic flux,
a movable iron armature, and one or more sets of contacts.
The armature is hinged to the yoke and mechanically linked to one or more sets
of moving contacts. It is held in place by a spring so that when the relay is
deenergized there is an air gap in the magnetic circuit. In this condition, one of
the two sets of contacts in the relay is closed, and the other set is open.

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Types of Relays
Basically, Relays are of two types either electromechanical or
solid-state relays. Both accomplish the same result but the
physical structure and functionality makes them different.
1. Electromechanical Relays (EMR) : In electromechanical
relays contacts are open or closed by a magnetic force. Basic
parts and functions of electromechanical relays include:
Frame
Coil
Armature
Contacts

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2. Solid State Relays(SSR): In solid state Relays there are no contacts and
switching is totally electronics. It consist of
 an input circuit
 a control circuit
Applications
 Amplifying a digital signal, switching a large amount of power with a
small operating power.
 Detecting and isolating faults on transmission and distribution lines by
opening and closing circuit breakers
 Isolating the controlling circuit from the controlled circuit when the two
are at different potentials
 In logic functions.
 Time delay functions.

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Advantages of Relays

Used as a kind of safety switch to allow a circuit with a

small current through to switch on a circuit that will have
a larger current flow through it
Minimize the amount of damage to the system during a
fault.
Small control signal controls a larger load current or
voltage.
Decreased electrical noise when switching
Totally silent operation

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Diodes
What’s a diode?
Diode is a semiconductor device with two terminals allowing the flow of current in one direction
only.

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What are diodes made of?
Silicon
Germanium
GaAs
Silicon (Si) and Germanium (Ge) are the two most common single
elements that are used to make Diodes.
Silicon and Germanium are both group 4 elements, meaning they
have 4 valence electrons. Their structure allows them to grow in a
shape called the diamond lattice.
Gallium is a group 3 element while Arsenide is a group 5 element.
When put together as a compound, Ga As creates a zincblend lattice
structure.

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Diode Is made from join P and N junctions
N-Type: When a small amount of pentavalent impurity is added to a pure
semiconductor, it’s known as a N-type semiconductor.

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P-type: when a small amount of trivalent impurity is added to a pure semiconductor, it’s called P-type
semiconductor.

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IDEAL DIODE
An ideal diode is a diode that acts like a perfect conductor when voltage is applied
forward biased and like a perfect insulator when voltage is applied reverse biased. So when
positive voltage is applied across the anode to the cathode, the diode conducts forward
current instantly.

FORWARD BIAS
When voltage is applied across a diode in such a way that the diode allows current and the
potential barrier reduced, the diode is said to be forward-biased.

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REVERSE BIAS
When voltage is applied across a diode in such a way that the diode prohibits current and
potential barrier increase, the diode is said to be reverse-biased.

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TYPES OF DIODES ZENER DIODE

A Zener Diode allows current to flow from its anode to its cathode like a normal semiconductor diode, but it
also permits current to flow in the reverse direction when its "Zener voltage" is reached
Zener diodes have a highly doped p-n junction. Normal diodes will also break down with a reverse voltage
but the voltage and sharpness of the knee are not as well defined as for a Zener diode.
Also normal diodes are not designed to operate in the breakdown region, but Zener diodes can reliably
operate in this region.

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LIGHT EMITTING DIODE(LED)

A light-emitting diode (LED) is a two-lead semiconductor light source. It is a p–n junction diode, which
emits light when activated

When a suitable voltage is applied to the leads, electrons are able to recombine with electron holes
within the device, releasing energy in the form of photons
This effect is called electroluminescence, and the color of the light (corresponding to the energy of the
photon) is determined by the energy band gap of the semiconductor.

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PHOTO DIODE

While LEDs emit light, Photodiodes are sensitive to received light. They are constructed so their pn junction
can be exposed to the outside through a clear window or lens.

APPLICATION OF DIODE

1.Diode Rectifier

 Type of diode that converts alternating current into unidirectional current (DC)
 Typically seen in power supplies

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2. Clippers

 Electronic circuits that have the ability to clip – off a portion of the input signal without distorting
the remaining part of the alternating waveform

 Other names are limiters, amplitude selectors and slicers

 3. Clampers

 Circuits that shift the waveform of the input signal either all above or below the reference voltage

 Add or restore a DC level to an electrical signal

 Also known as DC restorer

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4. Voltage Multiplier

 Circuit which produces a greater DC output voltage than AC input voltage to the rectifiers

 Uses clamping action to increase peak rectified voltages without the necessity of increasing
 the input’s transformers voltage rating

 Used in high – voltage, low current applications such as TV receivers

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Thyristors

Thyristor is a small device which can control large amounts of voltage and power. Thyristors are used as
current reversal to turn off the device.
Actually, it takes direct current so it is very difficult to apply to the device.

What is a Thyristor?
 A thyristor is a four layer solid-state semiconductor device with P and N type material
 Whenever a gate receives a triggering current

 It starts’ conducting until the voltage across the thyistor device is under forward bias.

 So it acts as a bistable switch under this condition.

 To control the large amount of current of the two leads.

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Thyristor Circuit Symbol

Different States in a Thyristor

There are three states in a thyristor

 Reverse blocking mode– In this mode of operation, the diode will block the voltage which is applied
 Forward blocking mode– In this mode, the voltage applied in a direction makes a diode to
conduct. But conduction will not happen here because the thyristor has not triggered.
 Forward conducting mode– The thyristor has triggered and current will flow
through the device until the forward current reaches below the threshold value
which is known as “Holding current”.

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Thyristor Layer Diagram
 Thyristor consists of three p-n junctions namely J1, J2, and J3.
 If the anode is at a positive potential with respect to the cathode and the gate
terminal is not triggered with any voltage.
 Then J1 and J3 will be under forward bias condition.
 While J2 junction will be under reverse bias condition.
 So J2 junction will be in the off state (no conduction will take place).
 If the increase in voltage across anode and cathode beyond the VBO (Breakdown
voltage). Then avalanche breakdown occurs for J2.
 Then thyristor will be in ON state (starts conducting).
 If a VG (Positive potential) is applied to the gate terminal.
 Then a breakdown occurs at the junction J2 which will be of low value VAK. The
thyristor can switch to ON state, by selecting a proper value VG.
 Under avalanche breakdown condition.
 The thyristor will conduct continuously without taking consideration of gate voltage,
until and unless,
o The potential VAK is removed or
o Holding current is greater than the current flowing through the device.
 Here VG– Voltage pulse which is the output voltage of the UJT relaxation oscillator.

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The two types of thyristor switching circuits are

1. DC Thyristor Circuit.
2. AC Thyristor circuit.

DC Thyristor Circuit

 When connected to the DC supply, to control the larger DC loads and current we use thyristor.
 The main advantage of thyristor in a DC circuit as a switch gives a high gain in current.
 A small gate current can control large amounts of anode current.
 So the thyristor is known as a current operated device.

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AC Thyristor Circuit

When connected to the AC supply,

Thyristor acts differently because it is not same as DC connected
circuit.
During one half of a cycle,
Thyristor used as an AC circuit causing it to turn off
automatically due to its reverse biased condition.
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Types of Thyristors

Based on turn on and turn off capabilities the

thyristors are classified into the following types:
o o Silicon controlled thyristor or SCRs
o o Gate turn off thyristors or GTOs
o o Emitter turn off thyristors or ETOs
o o Reverse conducting thyristors or RCTs
o o Bidirectional Triode Thyristors or TRIACs
o o MOS turn off thyristors or MTOs

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Based on turn on and turn off capabilities the thyristors
are classified into the following types:
o o Bidirectional phase controlled thyristors or BCTs
o o Fast switching thyristors or SCRs
o o Light activated silicon controlled rectifiers or LASCRs
o o FET controlled thyristors or FET-CTHs
o o Integrated gate commutated Thyristors or IGCTs

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Silicon Controlled Rectifier (SCR)
A silicon controlled rectifier is also known as thyristor rectifier.
It is a four layered current controlling solid state device.
SCRs can conduct current in only one direction (unidirectional
devices).
SCRs can be triggered normally by the current which is
applied to the gate terminal.

Gate Turn Off Thyristors (GTOs)

One of the special types of high power semiconductor devices is GTO
(gate turn-off thyristor).
The gate terminal controls the switches to be turned ON and OFF.

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Applications
Variable speed motor drives
High power inverters and traction

Emitter Turn OFF Thyristor

 The Emitter turn OFF thyristor is one type of the thyristor.
 It will turn ON and turn OFF by using MOSFET.
 It includes both the advantages of the MOSFET and GTO.
 It consists of two gates- one gate is used to turn ON
 Another gate with a series MOSFET is used to turn OFF.

Applications
ETO device is used for the fault current limiter and solid-state
circuit breaker.
Because of its high capability current interruption, fast switching
speed, compact structure and low conduction loss.

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Triacs

Triode for Alternating Current (TRIAC)

 Triac can conduct current in either direction and formally called bidirectional
triode thyristor Closely related to SCR
 Differences between Triac and SCR
 Triac is bidirectional devices (can conduct current in either direction) while SCR is
unidirectional devices (can conduct current only in one way) force commutation by
reversed biasing cannot be employed.
 TRIACs can be triggered by either a positive or a negative current applied to its
gate electrode while SCR can only triggered when a positive current apply to the
gate terminal
 In order to create a triggering current, a positive or negative voltage has to be
applied to the gate with respect to the A1 terminal (otherwise known as MT1)

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Parameters of TRIAC

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Characteristic
It can be seen that it is an extension IV characteristic
of SCR
The characteristic are symmetrical about the first and
the third quadrants
It shows the gate can be used to control the main
current flow in either direction
TRIAC will be continuously ON until the current
through A1 to A2 are below the holding current.

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Applications of TRIAC:
TRIACs are used in numerous applications such as
light dimmers, speed controls for electric fans and
other electric motors and in the modern computerized
control circuits of numerous household small and
major appliances. They can be used both into AC and
DC circuits however the original design was to replace
the utilization of two SCRs in AC circuits. There are
two families of TRIACs, which are mainly used for
application purpose, they are BT136, BT139.

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Hydraulic and Pneumatic actuators
Actuators :
• Actuators are those components of a fluid power system, which produces mechanical
work output.
• They develop force and displacement, which is required to perform any specific task.
The task may be of any kind, to move, to press, to lift, to clamp.
• Actuators are common for both hydraulic and pneumatic system.
• Hydraulic actuators are made stronger to with stand pressure of oil and develop huge
amount of force.
• Speed of actuator depends on rate of working fluid. Rate of flow of working fluid can
be controlled using Flow Control Valve (FCV).
• Force developed by cylinder is the product of pressure of working fluid and the piston
area.
• Force of actuator is controlled by controlling the pressure of working fluid using
Pressure Control Valve (PCV).
• Direction of motion of actuator is controlled by controlling the direction of flow of
fluid, by using Direction Control Valve (DCV).

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Actuators:
Actuators are of two types:
–Linear actuator
–Rotary actuator

Actuators :
• Linear actuator
–Rotating cylinder
–Non-rotating cylinder
• Single acting cylinder
• Double acting cylinder
–Special type cylinder
• Diaphragm cylinder
• Tandem cylinder
• Double rod end cylinder
• Telescopic cylinder
• Cylinder with cushioning.

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Hydraulics
- Economic
- Reliable
- Resistant to overloads
- Able to support heavy loads
Hydraulic actuators
- Low working speed
- Hydraulic group noisy

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Pneumatic actuators (cylinders)
Economic
Reliable
High operation speed
Resistant to overloads
Operation at constant force
No speed control
Poor position speed
Noisy operation

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MVJ College of Engineering
Near ITPB, Whitefield
Bangalore-560 067
E-mail:
Thank You
[email protected]
Ph: +91 8073533599

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