Internship Report on

CUBEX TUBINGS
STUDY OF
Major Departments of CUBEX TUBINGS
A summer Internship Report
Submitted by
KANTHULA ASHOK
In partial fulfillment of Summer Internship for the award of
the degree Of BACHELOR OF TECHNOLOGY

In
METALLURGICAL & MATERIALS ENGINEERING
Under the guidance of

A.KIRAN KUMAR
(Assistant Professor)
RGUKT (Basar)

RAJIV GANDHI UNIVERSITY OF KNOWLEDGE TECHNOLOGIES (RGUKT)

BASAR, NIRMAL(Dist.),TELANGANA

July 2021

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 DECLARATION

I am ASHOK.K (B151597) here by declare that the whole work done in

completing this project is my own effort and I have not practiced any sort of
plagiarism throughout the project. During this project my guide Mr. A. KIRAN
KUMAR guided me to complete this project contributing his valuable time.

Signature of the student

K.ASHOK

Department of MME
Rajiv Gandhi University of Knowledge

TechnologiesBasara, Nirmal(Dist),

Telangana

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 CERTIFICATE

This is to certify that the thesis on “CUBEX TUBINGS PVT LTD” is

submitted by K.ASHOK (B151597) to RGUKT Basar under my
supervision and is worthy for the partial fulfillment of the summer internship
(MME) of the institute. He has fulfilled all the prescribed requirements and
the report, which is based on candidate's own work, has not been
submitted else where.

Signature of the HOD Signature of the Student

Shastry Indrakanti K.ASHOK

HOD , MME. ID:-B151597

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Contents

1. Introduction to CUBEX TUBINGS PVT LTD.

2. THE SERIES OF DEPARTMENTS IN CUBEX TUBINGS LTD.

I.Raw material Department

II.Production Department

III.Quality Inspection Lab

IV.Dispatch

3. REFERENCES

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1. INTRODUCTION
“CUBEX TUBINGS Ltd.” incorporated in 1979, has an international reputation as an
innovative,dependable and high quality producer of copper and copper base alloy products under
one roof.The company manufactures seamless tubes, rods, strips, profiles and wires.

The company started by Mr. Pushparaj Bhandari who is the Managing Director of the company is
a Technocrat with 34 years of experience in nonferrous metal Industries and is well versed with
the latest technology.

The company has manufacturing facilities at Patancheru and Pondicherry in India with its world
class facilities and is able to satisfy customer requirement globally.

The major application of its products goes to power sector, medical gases, automotives,
refineries, railways, shipping and general engineering

Our Clientele

• Chemicals and Fertilizers Plants.

• Petrochemicals and Oil Refineries.
• Electronics and Telecommunication.
• Ship Building and Automotive Transport.
• Power Generation and Energy Distribution
• Atomic Energy, Space Research and Defence.
• Machine Building and General Engineering.
• Electrical Industries.

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2. RAW MATERIALS DEPARTMENT

2.1 Copper:
Copper is a chemical element with symbol Cu and atomic number 29. It is a ductile material with
very high thermal and electrical conductivity. Pure copper is soft and malleable; a freshly
exposed surface has a reddish-orange color.

It is used as a conductor of heat and electricity. Copper does not react with water but it does
slowly react with atmospheric oxygen to form a brown-black oxide layer which, unlike rust which
forms when Iron is exposed to moist air, protects the underlying copper from more extensive
corrosion.
Different types of Copper are:
• DHP Copper
• ETP Copper
• DPA Copper
• OF Copper
Different types of Copper based alloys like:
• Brass
• Cupronickel
• 70/30 cupronickel
• 90/10 cupronickel
• Monel

2.2 Copper types:

2.2.1 DHP Copper (Deoxidized high phosphorous copper):

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 C122 is commercially pure copper, which has been deoxidized with phosphorous, leaving
relatively high residual phosphorous content. Copper alloy 122 is not susceptible to hydrogen
embrittlement, but is relatively low electrical conductivity due to the amount.
Chemical composition:
Cu p
Min./Max. 99.9 min 0 .015-04

Nominal - 0 .02

2.2.2 ETP Copper:

C11000 Electrolytic Tough pitch, known as ETP Copper or tough pitch copper, has long been
the standard type of commercial wrought copper used in the production of sheet, plate bar, rod,
strip and wire. Copper 110 has an extremely wide range of applications based on its conductivity,
corrosion resistance, workability, and beauty.
Cu-ETP-Electrolytic Tough Pitch Copper – is an electrolytic refined copper widely used for
electrical and electronic applications. Cu-ETP has the properties required in all applications with a
hydrogen free atmosphere.

In the presence of hydrogen and heat all oxygen bearing coppers suffer from so-called
hydrogenembrittlement. This is a chemical reduction of copper oxide by diffusing hydrogen
leading to the formation of water within the microstructure, resulting in embrittlement of the grain-
boundaries. The phosphorous of this copper content is very low, so that the electrical conductivity
is comparable to the best performing materials.

2.2.3 DPA Copper:

Phosphorous-deoxidized copper containing Arsenic, either as an international alloying element or

occurring naturally in the metal. Arsenic raises the softening temperature and enhances corrosion
resistance in specific environments

Chemical composition (weight %)

Cu 99.7
P 0.013-0.050
As 0.15 – 0.50

2.2.4 OF Copper:

Oxygen free copper (OFC) or Oxygen free high thermal conductivity (OFHC) copper is a group of
wrought high conductivity copper alloys that have been electrolytically refined to reduce the level
of oxygen to .001% or below.

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 C10200 also known as Oxygen Free(OF). While OF is considered oxygen free, its conductivity
rating is no better than the more common ETP grade below. It has a 0.001% oxygen content,
99.95% purity and minimum 100% IACS conductivity. For the purposes of purity percentage,
silver (Ag) content is counted as copper (Cu).

Oxygen free high thermal conductivity (OFHC) copper is widely used in cryogenics. OFHC is
produced by the direct conversion of selected refined cathodes and castings under carefully
controlled conditions to prevent contamination of the pure oxygenfree metal during processing.
The method of producing OFHC copper ensures extra high grade of metal with a copper content
of 99.99%. With so small a content of extraneous elements, the inherent properties of elemental
copper are brought forth to a high degree. Characteristics are high ductility, high electrical and
thermal conductivity, high impact strength, good creep resistance, ease of welding, and low
relative volatility under high vacuum
2.3 Copper alloys:

2.3.1 Brass:

Brass is an alloy made of copper and zinc; the proportions of zinc and copper can be varied to
create a range of brasses with varying properties.

Properties:

Brass has higher malleability than bronze or zinc. The relatively low melting point of brass (900 to
940 °C, 1652 to 1724 °F, depending on composition) and its flow characteristics make it a
relatively easy material to cast.
By varying the proportions of copper and zinc, the properties of the brass can be changed,
allowing hard and soft brasses. The density of brass is approximately 0.303 lb/cubic inch, 8.4 to
8.73 grams per cubic centimeter.

Applications:
Brass is used for decoration for its bright gold-like appearance; for applications
where low friction is required such as locks, gears, bearings doorknobs, ammunition casings and
valves; for plumbing and electrical applications; and extensively in brass musical instruments
such as horns and bells where a combination of high workability (historically with hand tools)
and durability is desired.

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 It is also used in zippers. Brass is often used in situations in which it is important that
sparks not be struck, such as in fittings and tools around explosive gases.

2.3.2 Brass types:

Alpha brasses: Copper (%)>65, Zinc(%)<35.

Alpha brasses are malleable, can be worked cold, and are used in pressing, forging, or similar
applications. They contain only one phase, with face centered cubic crystal structure.

Alpha-beta brasses : Copper (%) 55-65, Zinc (%) 35-45.

These are also called duplex brasses. Suited for hot working it contains both α and β' phase; the
β'-phase is body centered cubic and is harder and stronger than α. Alpha-beta brasses are
usually worked hot.

Beta brasses: Copper (%) 50-55, zinc (%) 45-50.

These can only be worked hot, and are harder, stronger and suitable for casting.

White brasses : Copper (%) <50, zinc (%)>50.

These are so brittle for general use. The term may also refer to certain types of nickel silver
alloys as well as Cu-Zn-Sn alloys with high proportions (typically 40%+) of tin and /or zinc, as well
as predominantly zinc casting alloys with copper additive.

2.3.3 Cupronickel:

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 Cupronickel or copper-nickel is an alloy of copper that contains nickel and strengthening
elements, such as iron and manganese. Cupronickel is highly resistant to corrosion inseawater,
because its electrode potential is adjusted to be neutral with regard to seawater. Because of this,
it is used for piping, heat exchangers and condensers in seawater systems, as well as marine
hardware, and sometimes for the propellers, crankshafts and hulls of premium tugboats, fishing
boats and other working boats.
A more familiar common use is in silver-colored modern circulation coins. A typical mix is 75%
copper, 25% nickel, and a trace amount of manganese. In the past, true silvercoins were debased
with cupronickel. Despite high copper content, cupronickel is silver in colour.
Thermocouples and resistors whose resistance is stable across changes in temperature contain
the 55% copper-45% nickel alloy constantan.
Monel metal is a nickel-copper alloy, containing a minimum of 63% nickel.

90/10 Copper-Nickel:
90/10 cupro-nickel tubes have excellent resistance to corrosion in sea water. These have good
strength and ductility at ordinary temperatures and relatively high strength at elevated
temperatures. These are widely used in condensers, coolers and heat exchangers as well as
marine applications.

Applications:
• Light duty condensers
• Feed water heaters (to preheat water) and evaporators in power stations, sugar plants and
desalination plant
• Condensers, evaporators and heat exchangers
• Sea water pipe work
• Hydraulic lines and boat hulls

70/30 Copper-Nickel:

70/30 is a 70% copper, 30% nickel alloy with additions of iron and manganese. These elemental
additions make it somewhat more resistant to corrosion and erosion and with slightly improved
strength level than 90/10, making it suitable for more demanding applications. In particular, its
corrosion resistance is notably improved in high-velocity waters (up to 4.5m/s) and polluted
seawater.70/30 is readily cold worked, fabricated and welded without any special material
considerations.

Applications:

Offshore & marine: Salt water flanges, salt water piping and pipe fittings, valve bodies, sea
water intakes, pipe fittings, water boxes, propeller sleeves, pump bodies and parts. Chemical
processing: Heat exchanger and cooling plant, evaporator tubes, distiller tubes, refrigerator and
condenser components.
Other : Welding backing rings, flexible metal hose, weld wire and boiler parts.

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2.3.4 Monel:

Monel is a group of nickel alloys, primarily composed of nickel (up to 67%) and copper, with small
amounts of iron, manganese, carbon, and silicon. Stronger than pure nickel, Monel alloys are
resistant to corrosion by many agents, including rapidly flowing seawater. They can be fabricated
readily by hot- and cold-working, machining, and welding.
It is a very expensive alloy, with cost ranging from 5 to 10 times the cost of copper and nickel,
hence its use is limited to those applications where it cannot be replaced with cheaper
alternatives. Compared to carbon steel, piping in monel is more than 3 times as expensive.

Applications:

• In Aerospace
• Oil production and refining
• Marine applications
• Musical instruments
• Directional drilling

3.PRODUCTION DEPARTMENT
Sequence of operations:

• Melting
• Extrusion
• Pickling
• Grinding
• Reeling
• Pilgering (or) Cold Drawing
• Annealing

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3.1 MELTING :

Melting is a physical process that results in the phase transition of a substance from a solid to a
liquid. This occurs when the internal energy of the solid increases, typically by the application of
heat or pressure, which increases the substance's temperature to the melting point.
Induction furnaces are ideal for melting and alloying a wide variety of metals with minimum melt
losses, however, little refining of the metal is possible.

3.1.1 INDUCTION FURNACE:

An induction furnace is an electrical furnace in which the heat is applied by induction heating of
metal. Induction furnace capacities range from less than one kilogram to one hundred tons
capacity and are used to melt iron and steel, copper, aluminium and precious metals.

3.1.2 Melting process:

The furnaces which are used here have the capacity of 500kg and 1000 kg for melting
compositions of charge is to be calculated as per the required chemical composition.

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3.1.4 Induction furnace lining material:

Acidic Ramming Mass (Silica Ramming Mass):

Acidic Ramming Mass is used for the lining of Induction Furnaces. Various grades of acidic
ramming mass are available as per the size of the furnace, the type metal to be melted. Ramming
mass mixed with Boric acid which has 99.5-100% purity. It is used to protect the furnace wall from
melting temperatures.

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3.2 Extrusion:
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is
pushed or pulled through a die of the desired cross-section. The two main advantages of this
process are its ability to create very complex cross sections and to work materials that are brittle
because the material only encounters compressive and shear stresses. It also forms with an
excellent surface finish.
Commonly extruded materials include metals, polymers, ceramics, concrete, play dough, and
foodstuffs. Drawing metal is the main way to produce wire and sheet, and bar and tube are also
often drawn. Hallow cavities within extruded material cannot be produced using a simple flat
extruded die, because there would be no way to support the centre barrier of the die.

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3.2.1 classification of extrusion processes:

3.2.2 Process:

Hot extrusion: the principle variables influencing the force required to cause extrusion:

1) type of extrusion (direct /indirect)

2) extrusion ratio
3) working temperature
4) deformation
5) frictional conditions at the die and the container wall

3.2.3 Extrusion defects:

In homogeneous deformation
Surface cracking
Centre burst or chevron cracking Variations
in structure and properties.

3.2.4 Advantages and disadvantages of extrusion:

Advantages:

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• continuous process
• high production volumes
• low cost per pound
• efficient melting
• many types of raw materials
• good mixing(compounding)

Disadvantages:
• limited complexity of parts
• uniform cross sectional shape only

3.3 PICKLING:
DEFINITION: Pickling is a metal surface treatment used to remove impurities such as stains,
inorganic contaminants, rust from ferrous metals, copper, precious metals and aluminum alloys.

3.3.1 Process:

In a hot working process that occurs at high temperature leave a discoloring oxide layer on the
surface. To remove this work piece dipped into a vat of pickle liquor, primary acid used is hcl ,
although H2SO4 more common. Hcl is more expensive than H2SO4 , but it pickles much faster
while minimizing base metal loss. More commonly H3 PO4 , HNO 3 , HF acids are used. Most cu
alloys are pickled in dil.H2SO4 but brass is pickled in conc. H2 SO4 and HNO3 mixed with NaCl.
For cu and cu alloys like brass and bronze the most commonly used pickling medium is warm
dilute H2SO4 at about 8% concentration (add 1% HNO3 for cu ni). This gives quite rapid and
effective removal of surface oxides. Through washing in water is necessary after pickling
operation to remove all traces of acids.Pickling tanks should be used either stainless steels or
RCC lined by acid proof tiles.
3.3.2 Pickling cycle:

1 . pickling in 8 to 10 % h2so4 for copper, brasses and bronze. Cupronickel tubes 8 to 10%
H2SO4 + 3 to 5 % HNO3 at about 50 0 C for 5 to 15 minutes.
2. Dip it in cold water for 10 minutes.
3. Soak in 5 to 10 % solution of drawing compound (alkali base) for about 1 hour.
In jewellery making pickling is used to remove copper oxide layer that results from
heating copper and sterling silver during soldering and annealing. In this industry we will go by in
two different ways, one from the extrusion and one from the air annealing.

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3.4 GRINDING:

After accomplishing the pickling process scratches, cracks and holes are appear on the surface of
the tubes. To remove all these defects we are using grinding process. In this process tubes get
polished. After this process tubes get send to pilgering or cold drawing processes.

3.5 REELING:
It is the process of straightening the hollow tubes which are irregular in shapes and as per the
pipe size we can adjust the rotors in the equipment.
After straightening tubes are send to the pilgering or cold drawing process.

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3.6 Cold drawing and Pilgering:
3.6.1 Drawing:

Tube drawing involves the reducing the cross section and wall thickness through a draw die. The
cross-section can be circular, square, hexagonal are in any shapes. Tubes are cold drawn using
dies, plugs or mandrels to the required shape, size, tolerances and mechanical strength, Provides
good surface finishes. Increase mechanical properties by strain hardening. Reducing the diameter
through plastic deformation while the volume remains the same in drawing. Wires are in small
diameter products < 5mm diameter. Rods are relatively larger diameter products.

3.6.2 Tube drawing:

When a hollow tube is drawn through a die generally a mandrel or plug is used to support inside
diameter of the tube this process is called tube drawing. The function of the plug is to effect wall
reduction and to control the size of the hole. In drawing tubes over a stationary mandrel, the
maximum practical sectional area reduction does not exceed 40% per pass the increased friction
from the mandrel .Problem with friction in tube drawing are minimized with a long mandrel, we
used lubricant oils to reduce friction of die.

Pilgering:

It is replacement of drawing process In general the pilgering process has two primary purposes.
1. Pilgering is cold working process that greatly improves the material grain structure. 2. It
is a way of reducing large amount of the outside diameter and inside diameter of
preexisting tube very quickly. Reduction rates are can be as high as nearly 100% on some
alloys, drawing is very slow process compare to pilgering.

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3.7 ANNEALING :
Annealing is a heat treatment process where the sample is heated above is A3 temperature and
cooled in the furnace. In extrusion process quenching is done, because of sudden fall of
temperature the exists some internal stress between the grains, because of this internal stress the
tube becomes hard and brittle. We can to remove this stress by using annealing process. When
cold worked material is heat at a steady rate in furnace, three phenomena occur as the
temperature gradually rises.

1. At approximately 150c to 250c recovery occurs. This results in the relief of internal stresses
within the material caused by previous cold deformation. There is also a rise in the of electric
conductivity to a value equal to that of the fully annealed material. The mechanical properties
are not affected, thus the enhanced strength due to cold working remains constant. Since the
most important change taking place is the reduction in internal stress, healing to the “Recovery”
temperature only and subsequently cooling back to room temperature is often termed “stress
Relief Annealing” and is beneficial in reducing distortion when manufacturing components from
heavily cold worked material.

2. As the temperature progressively increases RECRYSTALLISATION takes place.

3. The effect of recrystallisation on microstructure and mechanical properties is very marked

structurally, the distorted, strained grains are replace by a completely. New set of fine distorted
structure. The effect on mechanical properties is a revision to the soft, ductile conditions which
existed before the commencement of the cold working operation.

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The temperature at which recrystallisation occurs depends on three main factors.

1. As the amount of the cold working increases the recrystallisation temperature is

progressively lowered. The presence of impurities and small addition which raise the
recrystallisation temperature.
2. Whether the copper is tough pitch, deoxidized or oxidized, impurities exert a much
influence on eg. The residual phosphorus in deoxidized copper has a consistent influence.
3. If the temperature is further increases after recrystallisation or annealing grain growth
occurs. The structure effect is a progressive coarsening grain size by the amalgamation of
adjacent grains to form a small number of large grains. In contrast to behaviors of many
copper alloys grain growth is not a serious problem with unalloyed copper.

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4.QUALITY ASSESSMENT
To check quality of the product some tests should be done . Those are
: • Eddy current test.
• Hydro or Pneumatic test
. • Mechanical tests.

4.1 EDDY CURRENT TEST :

Eddy-current testing uses electromagnetic induction to detect flaws in conductive materials. There
are several limitations, among them: only conductive materials can be tested, the surface of the
material must be accessible, the finish of the material may cause bad readings, the depth of
penetration into the material is limited by the materials' conductivity, and flaws that lie parallel to
the probe may be undetectable.

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4.2 HYDRO TEST:

In this testing the hollow pipes has been inspecting to find out the holes of the pipes. Water is
supplying into the copper pipe along with certain pressure and this pressure is maintained by
using pressure gage. Whenever the water is entered into the pipe if any hole is detected, simply
water is coming out from the pipe.

4.3 PNEUMATIC TEST :

It is same as hydro test instead of water we use air to fill the copper pipes, the air is fill into pipe
and dip into the water tube for 10 sec, if the is any hole on the surface of the pipe the air comes
out as small water bubbles, generally we use oxygen gas to fill the tube, the air contains
70kg/cm2 while filling the pipes. It is very speed process compare to hydro test.

The overall time taken for this test is 30 sec for each pipe.

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4.4 Mechanical Tests:

Tensile test
Flattening
Drifting
Hardness measurement

4.4.1 Tensile test:

It is a destructive test process that provides information about the tensile strength, yield strength
and ductility of a material.

4.4.2 Flattening:

The flattening test involves multi stage flattening of a tube section so as to check the plastic
deformation capacity of the tube. Tube flattening testing reveals the compression strength of the
tested metallic tube .It is also used to determine whether or not the tube will rupture upon
flattening .

4.4.3 Drifting:

Drifting means the measuring a pipe’s inner roundness. Drifting is typically performed by passing
a cylindrical mandrel through the length of the pipe to detect occlusions.

4.4.4 Hardness Measurement:

Hardness is the resistance of a metal to plastic deformation, usually by indentation. The term
may also refer to stiffness or to resistance to scratching, abrasion or cutting. The greater the
hardness of the metal, the greater resistance it has to deformation.

Hardness measurement methods: There are 3 most common hardness test methods used in
today’s technology. They are

• Rockwell hardness test

• Brinell hardness test
• Vickers hardness test

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5. DISPATCH

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7. REFERENCES

 http://www.google.com/
 https://www.cubextubings.com/
 https://en.wikipedia.org/
 https://www.generalkinematics.com/

https://economictimes.indiatimes.com/cubextubing
s-ltd/stocks/companyid-10900.cms

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