Manufacturing of turbines (gas, steam, hydro and wind)

By Prof. Sunny Zafar | IIT Mandi

Learners enrolled: 291 | Exam registration: 6

ABOUT THE COURSE:

This course will provide knowledge and background on how components used in energy generation facilities are manufactured. Course will deal with material selection and manufacturing process selection for gas turbines, steam turbines, hydro turbines and wind turbines. Students opting for this course will be get the basic as well as state of the art knowledge on these topics.

INTENDED AUDIENCE: UG (mechanical, production, metallurgy)

PREREQUISITES: Basic manufacturing processes

INDUSTRY SUPPORT: GE,Simens,LM Wind ,BHEL,Airbus

Summary

Course Status :	Upcoming
Course Type :	Elective
Language for course content :	English
Duration :	8 weeks
Category :	Mechanical Engineering Manufacturing Processes and Technology
Credit Points :	2
Level :	Undergraduate/Postgraduate
Start Date :	17 Feb 2025
End Date :	11 Apr 2025
Enrollment Ends :	17 Feb 2025
Exam Registration Ends :	24 Feb 2025
Exam Date :	04 May 2025 IST

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1: Introduction, manufacturing concepts and classification of engineering materials

Week 2: Selection of materials and manufacturing processes, manufacturability of materials, materials vs. manufacturing processes

Week 3: Manufacturing of gas turbines, selection of materials, properties of superalloys, process requirements,

Week 4: Manufacturing of gas turbines: Casting processes- investment casting, single crystal casting, hot isosttic pressing (HIP), laser beam machining (LBM), creep feed grinding (CFG), thermal barrier coating (TBC)

Week 5: Manufacturing of steam turbines: Steam turbine material requirements, Casting (Investment casting process), Deformation (Rolling), Laser metal direct fabrication, Machining (CNC milling, drilling or advanced machining)

Week 6: Manufacturing of hydro turbines: Challenges in material selection for hydroturbines, Casting (Dry sand casting process) Deformation (Rolling), Machining (CNC milling, drilling or advanced machining) Surface modification (for corrosion and erosion resistance) using thermal spary methods.

Week 7: Manufacturing of wind turbines: Material constraints for wind turbine blades, Composite materials and their classification, glass fibers and carbon fibers along their manufacturing

Week 8: Manufacturing of wind turbines: Hand-lay up Spray up, Vacuum bag molding (VBM), Vacuum infusion process (VIP), RTM processing and its variants, Prepreg, Out of autoclave processing routes, testing and quality assurance.

Books and references

1.DeGarmo's Materials and Processes in Manufacturing, Black and Kohser,Wiley
2.Process and Materials of Manufacturing, R. A. Lindburg
3.Advanced Machining Processes, V.K. Jain, Allied Publications.

Instructor bio

Prof. Sunny Zafar

IIT Mandi

Prof.Sunny Zafar is faculty member in School of Mechanical and Materials Engineering (SMME) at Indian Institute of Technology Mandi, where he has been since August 2016. He received a B.Tech. in Mechanical Engineering with distinction from Punjab Technical University in 2011, and an M.Tech. from the Indian Institute of Technology Roorkee in 2013. He received Ph.D. in Mechanical Engineering from the Indian Institute of Technology Roorkee in August 2016. His present research interests span Advanced Manufacturing Processes for Polymer Composites and Sustainable Biocomposites, Recycling of Polymer Composites, Surface Engineering and Experimental Tribology. Currently, research work is aimed towards development of microwave assisted compression molding (MACM) process and vacuum assisted resin infusion microwave curing (VARIMC) process for polymer composites. Furthermore, Dr. Zafar is also working on microwave assisted chemical recycling (MACR) for thermoset composites. He is also involved in development of electromagnetic energy based machining processes for fiber reinforced polymers

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.

The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).

Date and Time of Exams:May 4, 2025 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.

Registration url: Announcements will be made when the registration form is open for registrations.

The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.

Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 6 assignments out of the total 8 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

Please note that assignments encompass all types (including quizzes, programming tasks, and essay submissions) available in the specific week.

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Mandi .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team