CMTI Final Report

Testing and quantification of porcelain insulators by XRD techniques.
INTERNSHIP REPORT
on
Testing and quantification of porcelain insulators
by XRD techniques.
at
CENTRAL MANUFACTURING TECHNOLOGY INSTITUTE(CMTI),
Bengaluru-22
August-September 2022
Submitted by
Rathish M (BE- 4th year)
Department of Mechanical Engineering
JSS Academy of Technical Education, Bengaluru-60
Under the guidance of

Mr. Kumar Abhinav
Scientist C, C-SMPM
Central manufacturing technology institute, Bengaluru -22
1
Central Manufacturing Technology Institute, Bengaluru-22
DECLARATION
I hereby declare that the Internship Training Report entitled “Testing and quantification of porcelain
insulators by XRD techniques” done At CENTRAL MANUFACTURING TECHNOLOGY
INSTITUTE, BANGALORE-22. is submitted to the DEPARTMENT OF MECHANICAL
ENGINEERING, JSS ACADEMY OF TECHNICAL EDUCATION BANGALORE, is a record of
original work done by me under the guidance of Mr. Kumar Abhinav, Scientist-C, C-SMPM, CMTI,
BENGALURU-22.
The internship Report is for reference only and no part of the report will be published or copied anywhere
without the written permission from CENTRAL MANUFACTURING TECHNOLOGY INSTITUTE
OFFICIALS.
Date: 21.09.2022
Place: Bangalore
SIGNATURE OF STUDENT
(Rathish M)
2
ACKNOWLEDGEMENT
The internship opportunity I had with Central Manufacturing Technology Institute (CMTI) provided through
Drishti Internship Portal was a great chance for my learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an opportunity to be a part of it. I am also
grateful for having a chance to learn, research and work upon so many new and wonderful domains which
will prove to have massive impact in the future of machine tools manufacturing.
First and foremost, I am using this opportunity to express my deepest gratitude and special thanks to the
Scientist Mr. Kumar Abhinav of Centre for Smart Manufacturing Precision Machine Tools & Aggregates
(C-SMPM) who in spite of being extraordinarily busy with his duties, took time to teach, guide and keep me
on the correct path at every step of internship and allowing me to carry out my work at such an esteemed
organization under his guidance.
I perceive this opportunity as a big milestone in my career development. I will strive to use gained skills and
knowledge in the best possible way, and I will continue to work on their improvement, to attain desired
career objectives. Hope to continue cooperation in the future
Sincerely,
Rathish M
Place: Bangalore
3
CONTENTS
Chapter Chapters Page no.

no.
0. About CMTI: Central Manufacturing 5

Technology Institute
1. Introduction. 12
a) X ray
b) Diffraction
c) Bragg’s law.
2. X Ray diffractometer 14
3. XRD components 16
4. XRD specifications 17
5. Application of XRD 20
6. 21
Porcelain insulator
7. 21
Testing of Porcelain insulator
8. 22
Quantification using XRD
9. Conclusion 23
10. References 24
4
ABOUT – CMTI
About CMTI
Central Manufacturing Technology Institute’, CMTI, is a Research & Development organization focusing
on providing ‘Technology Solutions’ to the manufacturing sector and assisting technological growth in
the country. CMTI plays a key role in applied research, design, and development (RD&D), technology
forecasting, assimilation, and dissemination of manufacturing technology to Indian industries.
CMTI is a registered Government of India Society, an autonomous institution under the administrative
control of the Ministry of Heavy Industries, Government of India, governed by a Governing Council which
has representation from the machine tool manufacturing and user industries, the Union Government, and
the Government of Karnataka. The Governing Council evolves Policies and monitors policy
deployment. A Research Advisory Board (RAB), a Technical Committee with
representatives from industries and academia, assists the institute on matters relating to
technology advancement.
The Stakeholders of CMTI are:
 Government of India
 Industries at large in all sectors (both private and public) – specifically manufacturing and user
industries.
CMTI over the last five decades developed Special Purpose Machines, Inspection Systems, Test Rigs for
Qualification testing of products, Tooling, complex machined parts for public and private sectors. CMTI has
continuously aligned its facilities and expertise with the fast- changing technology in thrust areas of
manufacturing to support and serve the manufacturing sector. Nanotechnology, Precision engineering,
Metrology (Micro and Nano), Additive Manufacturing, Mechatronics, Vision and Image processing, Digital
Design and Human Resource Development (creating ‘Industry Ready’ engineers) are the current areas of
focus of the Institute.
Technology Profile
CMTI over the past five decades has executed multi-domain, complex projects with predominant R&D
content giving technology thrust to industries. Eco-system of Pre- competitive RD&D projects has created
a pool of multi-disciplined, skilled, experienced, and knowledgeable human resource with an R&D
inclination. Knowledge and Skill sets of scientific community are upgraded continuously to meet the
challenges of manufacturing industries.
Technical manpower has been continuously updating their knowledge and expertise in emerging
technologies to spread awareness, transfer knowledge and deploy advanced solutions in the manufacturing
sector.
 Product Design
 Computer Aided Analysis
5
 Computer aids in Project Simulation and Visualization

 CAD, CAM, CIM
 Process planning
 Additive Manufacturing
 Mechatronics
 Control Systems
 Vision System
 Nanotechnology
 Ultra-precision engineering
 Metrology and Calibration
 Condition monitoring
 Test system development
Vision and mission
Purpose
To Support Industries to Achieve Excellence in Technology and Stimulate Economic Growth
Mission
We will:
 Achieve Technological Leadership

 Achieve Excellence in Quality of Products and Service
 Establish a Dynamic, flexible and result oriented organizational structure
 Achieve organizational excellence through transparent, professional management system
 Achieve financial self-sufficiency
 Train, Motivate and provide Growth oriented environment to employees
Values
We believe in:
 Our people being our Greatest Assets

 Mutual trust Building
 Open Mind ness
 Effective and Open Communications
 Teamwork and Team Spirit
 Participative, Co-operative Work Culture
 Passion for Quality
 Attention to Detail
 Optimal use of Resources
 Prompt Response to Customer Needs
Research & Development Centers and Facilities

1. Machine Tools & Special Purpose Equipment
6
a. Product Design and Engineering

The core activity of Product Design and Engineering department is design & engineering of
Advance Technology products and Special purpose machines. For the last 5 decades, PDE has been
actively involved in delivering its services to various industries such as Machine Tool, Space,
Textile, Aerospace, Auto-components, Ship building, Medical, Chemical Processing, etc.
b. Product Manufacturing and Development

The Product Manufacturing Department (PMD) has a team of engineers and scientists having
comprehensive experience in product development and caters to sponsored and R&D projects in
manufacturing technology. PMD is the hub of manufacturing activities in CMTI.
c. Product Assembly and Testing

i. Electrical Group
AT Electrical group is involved in the assembly & testing of electrical control cabinets for
SPMs, testing & configuration of PLC I/Os, testing of PLC machine logics, HMI screen
design of SPMs & testing and inspection of the machine subsystems, interlocks as per the
design. PAT group also undertakes AMCs of SPMs at customer places.
ii. Mechanical Group

PAT Mechanical group core strength is assembly of mechanical subsystems, overall
integration of SPMs with required alignments. The machine built is thoroughly tested both in
qualitative and quantitative terms before dispatch to customer. The test results are recorded
and reported to customer for their feedback.
d. Materials and Metallurgy

Materials & Metallurgy Group under the Centre for Special Purpose Machines vertical is equipped
for carrying out Materials characterization comprising of Chemical and Mechanical properties. The
activities of the group are to synchronize and strengthen materials related R & D activities for on-
going in- house R & D projects by maintaining stringent quality control and document control
through NDT and Heat treatment procedures as well as Grant-in-aid projects.
e. Materials and Metallurgy

Materials & Metallurgy Group under the Centre for Special Purpose Machines vertical is equipped
for carrying out Materials characterization comprising of Chemical and Mechanical properties. The
activities of the group are to synchronize and strengthen materials related R & D activities for on-
going in- house R & D projects by maintaining stringent quality control and document control
through NDT and Heat treatment procedures as well as Grant-in-aid projects.
2. Smart Mfg., Precision Machines Tools & Aggregates

Centre for Smart Manufacturing, Precision Machine Tools, and Aggregates (C- SMPM) is focused
primarily on development of technologies for Smart Manufacturing and Industry 4.0, High precision
machine tools, Aggregates of machine tools, IIoT& artificial Intelligence based solutions to
manufacturing industries. The Centre also provides services to industries/academia in Advanced
materials characterization, Noise & vibration mitigations, and Nano finishing.
a. Smart Manufacturing, IIoT and Artificial Intelligence

CMTI is pioneer in the field of Manufacturing has been mandated by DHI under the SAMARTH
Udyog Bharat 4.0 Platform to set up a Smart Manufacturing Demo & Development Cell as a
Common Engineering Facility Centre (CEFC) to propagate and support the process of adoption of
smart manufacturing practices by the rapidly growing Indian manufacturing industry.
7
b. Precision Machines and Machine Tool Aggregates

Precision Machine Tools and Aggregates are involved in the Indigenous development and production
of high value machine tools and the aggregates of machine tools. The group is also involved in
development of process technology for advanced manufacturing, which have the potential to bring
sustainable growth and major economic benefits to our country.
c. Advanced Material Characterization

Advance Material Characterization lab under the Centre for Smart Manufacturing, Precision Machine
Tools & Aggregates, C-SMPM, houses an array of state-of-the-art national facilities for materials
characterization. These services have been widely used by the industries, the academia & the scientists
from R&D organizations apart from meeting in house R&D and characterization requirements.
d. Noise and Vibration Laboratory

Noise and Vibration Laboratory, caters to the measurement of parameters like Force, Displacement,
stress and strain in machine tools and components. The laboratory is equipped with qualified, trained,
and experienced Technical Staff and state of the art facility for measurement and analysis of various
parameters such as Sound, Vibration, Temperature, Spindle Error Measurement, Dynamic balancing,
Structural Testing etc.
3. Sensors, Vision Tech & Controls

Center for Sensors, Vision Technology and Controls (C-SVTC) is focused primarily on research &
development of MEMS Sensors, Machine vision, Controls and Micro- Nano Systems engineering. The
Center also provides services to industries/academia in the related areas.
a. MEMS and Sensors

The focus of STDC (Sensors Technology Development Centre) involves creating a state-of-the-art
facility encompassing equipment & cleanroom at CMTI for ‘Micro System’ development and
‘MEMS packaging’ for the machine tool, general engineering & public sector organizations.
Research and Development, product & process knowledge creation for industry needs, skilling &
human resource development, proliferation of sensor-based systems
/ packages / solutions, support & service as Common Engineering Facility Centre for CG
networking with national & international industry / academia are the major objectives of this
center.
b. Machine Vision
We focus mainly on three areas of machine vision technology incubation, prototyping and
product development. We also assist Indian industries in factory automation through machine
vision to enhance product quality, performance, operational safety, and reliability
c. Control Systems
Controls group is actively involved in Design & Development of Controllers for trailor made
applications. Broad Spectrum of areas covered are Machine Tools, Textile machines, Smart
Manufacturing / IoT and any other related fields.
d. Micro-Nano System Engineering

This is an Integral part of Centre for Sensors, Vision Technology & Controls department. The focus
of this group is development of systems and subsystems of tools which are being used for
fabrication & packaging of Microsystems. These developmental activities grossly contribute to
import substitution and development of systems for academic versions which enables
students/researchers to carry out their research independently at institute level.
8
4. Micro Nano Mfg. and Metrology

The Centre for Micro – Nano Manufacturing and Metrology focuses on services and research &development
of high precision components for industrial requirements. Presently, the C-MNTM takes up projects
sponsored by Indian Industries, Industry consortiums and Government funded R&D and fabrication of high
precision miniaturized micro and Nano components having feature sizes in the order of less than one milli
meter. Micro manufacturing is one of the emerging areas and CMTI has well established the facility to meet
the requirement of Indian Industry.
a. Precision Metrology
The Metrology Laboratory is a part of the Centre for Micro and Nano Manufacturing at CMTI.
Metrology activities comprises of services to industry in measurement, calibration and testing,
development of measuring instruments and artefacts in metrology.
b. Surface Engineering and Laser Processing

The Surface Engineering section is a part of the Centre for Micro-Nano Manufacturing and
Metrology at CMTI. The Surface Engineering group focuses particularly on the development of thin
films. The group is involved in purely Research and Development of nano films and nano
composites by using state of the art facilities like PVD and PECVD systems
c. Precision Manufacturing and Process Engineering

Precision Manufacturing & Process Engineering group is a part of the Department of Centre for
Micro-Nano Manufacturing and Metrology (C- MNTM) at CMTI. Micromachining facility at CMTI
with its state-of-the-art infrastructure and expertise promotes the benefit of micromachining and
ultra- precision technology for manufacture of micro-components to the Indian industries through
consultancy, services, and training.
d. Outreach Centre Rajkot

Regional Centre “Centre for Advancement of Manufacturing Technology (CAMT)”, Rajkot has been
set up at NSIC, Campus, Rajkot – Gujarat by CMTI, Bengaluru as a part of its outreach programs.
Regional Centre provides Dimensional Metrology, Material Characterization Services, Training
&Consultancy services.
5. Additive & Special Mfg. Processes

CMTI's Centre for additive and special manufacturing (C-ASMP) is a cluster of teams with a specific focus
on Prototyping, product and testing technologies which cater to the very need as discussed.
Core Competencies of C-ASMP are:
a. Additive manufacturing
b. Manufacturing processes of special products
c. Hydraulic and Pneumatic systems
d. Aerospace test rig and calibration
Technology & Services

1. Machines, Systems and Process Technology
a. Ultra-Precision Machine Tools
b. Special Purpose Machines
c. Sensors and Machines
9
d. Textile Machinery
e. Smart Manufacturing and Industry 4.0
f. Laser Processing
g. Surface Coating
h. Design Test Rigs
i. Laboratory Services
2. Laboratory Services
a. Precision Manufacturing and Process Engineering
b. Precision Metrology & Calibration
c. Noise and Vibration
d. Nano material Characterization
e. Prototyping (Additive and subtractive)
f. MEMS & Sensors
g. Hydraulic tests
h. Materials and Metallurgy
3. Consultancy Services
a. Design Expert Services
b. Operation Management Services
c. Business Consultancy
Infrastructure Facilities
1. Library
CMTI Library, popularly known earlier as NICMAP (National Information Centre for Machine Tools &
Production Engineering) has a comprehensive collection of more than 30,000 documents (Books, Journals,
Reports, Standards, and Non-Book Materials) predominantly related to Machine Tools & Production
Engineering to meet the information needs of Machine Tool & General Engineering Industries, R&D units,
academic institutions, and individuals pursuing research activities. Library activities are computerized using
“KOHA – an Integrated Library Management Software”.
Some of the major services rendered by the library are bibliographic data search facilities, article supply on
request, resource sharing arrangement with other libraries etc.
2. IT Infrastructure
The IT Division meets the various computing needs of the different research and development
groups of the Institute. The IT facilities consist of multi-CPU multi-core servers having various
applications installed are accessed by users from their Workstation, Desktops.
a. Local Area Network

The CMTI campus network consists of a switched Gigabit backbone on fiber and wired Gigabit
Ethernet to the Servers, Workstations, desktops.
Additionally, wireless connectivity is provided for Specific project purpose. A campus-wide local
area network hooks up these systems. The servers with application-specific software packages
like, Solid works, Unigraphics, ANSYS, AUTOCAD, E-PLAN, LABVIEW, TALLY etc. along
with
development tools are available on these platforms.
b. Email and Internet

NIC email facility has provided to all the Scientists, Officers, Laboratory service groups &
Administration and Accounts group. A dedicated high- speed Internet facility is provided to the
organization with secured Firewall.
10
c. Other Services
Video Conference facility to suite for Classroom to conduct Training Programs and
Meeting room facility made available for the institute.
All the Servers Workstation, Desktop and Laptop PCs are protected with Highly secured
antivirus software & Campus wide CCTV network and Biometric attendance system facility
has been provided.
3. Clean Room Facilities

Under the Centre for Sensors and Vision Technology and Controls, a facility for sensor technology
development is created. This facility consists of all necessary processes for micro systems packaging,
characterization, and basic fabrication. All these processes demand clean room environment due to the
feature sizes and the cleanliness that is required for the processes to be conducted. Hence to accommodate
all these processes, clean rooms of class 1000 (ISO6), 10000(ISO7) and 100000(ISO8) are created. Class
100(ISO5) is also created under a laminar flow within the ISO8 facility.
The ISO 6 clean rooms are yellow rooms which are dedicated mainly for lithography and fabrication
purposes. The other ISO 5, 7 and 8 clean rooms are white light-based which support for packaging,
characterization, and some fabrication. The ISO 5 clean room consists of Flip Chip Bonding, Hot
Embossing, and Electroplating. The ISO 6 clean rooms consist of Mask Aligner, Wet benches with spin
coating, Mask Writer, Nano Imprint Lithography, and wafer bonding. The ISO 7 clean room consists of
wire bonding, bond testing and optical characterization.
4. Auditorium/E-classroom
5. Guesthouse and Canteen

 Guest House
 Canteen Facility
11
Introduction
X-ray
An X-ray is a penetrating energetic electromagnetic radiation which has a wavelength between 10 nanometres
and 10 picometers.
Diffraction
Diffraction is the spreading out of waves as they pass through an aperture or around objects. It occurs when
the size of the aperture or obstacle is of the same order of magnitude as the wavelength of the incident wave.
For very small aperture sizes, most of the wave is blocked. For large apertures the wave passes by or through
the obstacle without any significant diffraction.
Bragg’s Law
Bragg’s law is a special case of Laue diffraction, which determines the angles of coherent and incoherent
scattering from a crystal lattice. When X-rays are incident on a particular atom, they make an electronic cloud
move like an electromagnetic wave. The movement of these charges radiates waves again with similar
frequency, slightly blurred due to different effects, and this phenomenon is known as Rayleigh scattering. This
law explains the relationship between an x-ray light shooting and its reflection from a crystal surface.
Fig.1 Bragg’s law
Brag’s Law states the following:

When the X-ray is incident onto a crystal surface, its angle of incidence, θ, will reflect with the same angle of
scattering, θ. And, when the path difference, d is equal to a whole number, n, of wavelength, λ, constructive
interference will occur.
The exact process takes place upon scattering neutron waves via nuclei or a coherent spin interaction with an
isolated electron. These wavefields that are re-emitted interfere with each other destructively or
constructively, creating a diffraction pattern on a film or detector. The diffraction analysis is the resulting
wave interference, and this analysis is known as Bragg diffraction.
12
Bragg Equation
According to Bragg Equation:
nλ = 2d sinΘ
Therefore, according to the equation of Bragg’s Law:
 The equation explains why the faces of crystals reflect X-ray beams at particular angles of incidence
(Θ, λ).
 The variable d indicates the distance between the atomic layers, and the variable The variable d
indicates the distance between the atomic layers, and the variable λ specifies the wavelength of the
incident X-ray beam and n as an integer.
Fig 2. Formation of Constructive interference
Bragg’s Diffraction
Bragg’s diffraction was first proposed by William Henry Bragg and William Lawrence Bragg, in 1913.
Bragg’s diffraction occurs when a subatomic particle or electromagnetic radiation waves have wavelengths
that are comparable to atomic spacing in a crystal lattice.
Applications of Bragg’s Law

There are numerous applications of Bragg’s law in the field of science. Some common applications are given
in the points below.
 Bragg law is useful for measuring wavelengths and for determining the lattice spacings of crystals.
 In the case of XRF (X-ray fluorescence spectroscopy) or WDS (Wavelength Dispersive Spectrometry),
crystals of known d-spacings are used for analyzing crystals in the spectrometer.
 In XRD (X-ray diffraction) the inter-planar spacing or d-spacing of a crystal is used for
characterization and identification purposes.
13
X Ray diffractometer
Fig.3 X-Ray Diffractometer
A typical diffractometer consists of a source of radiation, a monochromator to choose the wavelength, slits to
adjust the shape of the beam, a sample and a detector. In a more complicated apparatus, a goniometer can also
be used for fine adjustment of the sample and the detector positions. When an area detector is used to monitor
the diffracted radiation, a beam stop is usually needed to stop the intense primary beam that has not been
diffracted by the sample, otherwise the detector might be damaged. Usually, the beam stop can be completely
impenetrable to the X-rays, or it may be semi-transparent. The use of a semi-transparent beam stop allows the
possibility to determine how much the sample absorbs the radiation using the intensity observed through the
beam stop.
There are several types of X-ray diffractometer, depending on the research field (material sciences, powder
diffraction, life sciences, structural biology, etc.) and the experimental environment, if it is a laboratory with
its home X-ray source or a Synchrotron. In laboratory, diffractometers are usually an "all in one" equipment,
including the diffractometer, the video microscope, and the X-ray source. Plenty of companies manufacture
"all in one" equipment for X-ray home laboratory, such as Rigaku, Analytical, Thermo Fisher
Scientific, Bruker, and many others.
14
Nano material characterization lab

BRUKER D-8 Advance XRD
The D8 ADVANCE Family represents a range of hardware and software solutions for X-ray diffraction and
scattering applications, including phase identification, quantitative phase analysis, micro-structure and crystal
structure analysis, residual stress and texture investigations, X-ray reflectometry, SAXS and PDF analysis,
and micro-diffraction.
 Bruker XRD solutions consist of high-performance components configured to meet the analytical
requirements. The modular design is the key to configure the best instrumentation.
 All categories of components are part of Bruker’s key competence, developed and manufactured by
Bruker AXS, or in close cooperation with third party vendors.
 Bruker XRD components are available for upgrading the installed X-ray systems for improving their
performance.
XRD Components
Fig 4. Components of XRD
 X-ray sources: The high intensity nearly monochromatic K x-rays can be used as a radiation source
for X-ray diffraction (XRD) studies. It can be of chromium, cobalt etc.
 Filter: Used to reduce unwanted noise. Nickel is used for this purpose.
 Goniometer: Is an instrument t allows an object to be rotated to a precise angular position.
15
D8 ADVANCE Specifications
Feature Specification Benefit
Software push-button switch

Fully automatic, motorized
between:
switching between up to six
Motorized Divergence Slit different beam geometries without
(Bragg-Brentano) any manual user intervention
High Intensity Ka1,2 Parallel

Perfectly suited for all sample
Beam
TRIO and TWIN optics
types including powders, bulk
High Resolution Ka1 Parallel
Beam materials, fibers, sheets, and thin
films (amorphous, polycrystalline,

Patents: US10429326,
and epitaxial)
US6665372, US7983389
Data virtually free of air,

Dynamic synchronization of:
instrument, and sample support
Dynamic Beam Optimization
motorized divergence slits scattering
motorized anti-scatter screen Significantly enhanced lower

limits of detection enabling
16
quantification for minor

crystalline and amorphous phases
Unparalleled performance at low

variable active detector window
2Ɵ angles enabling accurate

2Ɵ Angular range: <1 to >150
investigations of clays,
pharmaceuticals, zeolites, porous
framework materials and more
No need for Kß filters and

secondary monochromators
Energy Resolution: < 380 eV @ 8 100% filtering of Fe-fluorescence

KeV with Cu radiation
Detection Modes: 0D,1D, 2D Up to 450 times faster than

conventional detector systems
Wavelengths: Cr, Co, Cu, Mo,
LYNXEYE XE-T
and Ag BRAGG2D: Collect 2D data with
a divergent primary line beam
Patents: EP1647840, EP1510811,
Unique detector warranty: No
US20200033275
defective channels at delivery
time
Seamless integration of 0D, 1D

and 2D detection in step,
EIGER2 R The latest generation multi-mode
continuous and advanced
17
scanning modes
Ergonomic, alignment-free
detector rotation to optimize γ or
2Ɵ angular coverage
(0D/1D/2D) detector based on the
Panoramic, tool-free diffracted
Hybrid Photon Counting
beam optics using the complete
technology, developed by Dectris detector field of view
Ltd.
Continuously variable detector
positioning to balance angular
coverage and resolution
No disconnecting of electric
cables or water hoses or
unmounting of tubes
Easy, fast, and alignment-free

DAVINCI.DESIGN: Fully
TWIST.TUBE switch between line and point
automatic detection and
focus applications
configuration of the focus
orientation
FLIPSTICK: 9 Samples
Operation in reflection AND
Sample Changers
AUTOCHANGER: 90 samples transmission geometries
18
Unparalleled accuracy and

precision as manifested by
Bruker's unique alignment
Two-circle goniometer with guarantee
D8 Goniometer independent stepper motors and

Absolutely maintenance free drive
optical encoders
mechanism / gearings with
lifetime lubrication
Temperature: Ranging from ~85K

up to ~2500K
Investigations under ambient and
Non-ambient Pressure: 10-⁴ mbar up to ten bar non-ambient conditions
Easily exchanged stages with

Humidity: 5% to 95% RH
DIFFRAC.DAVINCI
Applications of XRD
XRD is one of the most important tools in materials research as it allows linking of structural and physical
properties of materials. The D8 DISCOVER is the flagship XRD instrument for materials research. Equipped
with leading technology components the D8 DISCOVER delivers top performance and full flexibility and
enables researchers for a detailed characterization of their materials:
 Phase Identification and structure determination
 Micron strain and crystallite size analysis
 Stress and Texture analysis
 Determination of Particle size and distribution.
 Local XRD analysis using µm sized X-ray beams
19
Porcelain insulator
Insulators used for high-voltage power transmission are made from glass, porcelain or composite polymer
materials. Porcelain insulators are made from clay, quartz or alumina and feldspar, and are covered with a
smooth glaze to shed water. Insulators made from porcelain rich in alumina are used where high mechanical
strength is a criterion. Porcelain has a dielectric strength of about 4–10 kV/mm. Glass has a higher dielectric
strength, but it attracts condensation and the thick irregular shapes needed for insulators are difficult to cast
without internal strains. Some insulator manufacturers stopped making glass insulators in the late 1960s,
switching to ceramic materials.
Recently, some electric utilities have begun converting to polymer composite materials for some types of
insulators. These are typically composed of a central rod made of fibre reinforced plastic and an outer weather
shed made of silicone rubber or ethylene propylene diene monomer rubber (EPDM). Composite insulators are
less costly, lighter in weight, and have excellent hydrophobic capability. This combination makes them ideal
for service in polluted areas. However, these materials do not yet have the long-term proven service life of
glass and porcelain.
Fig.5 Porcelain insulators
Testing of Porcelain insulators
Solid samples are broken down into powder either by hydraulic press or hand press after which the powder
sample is gradually heated and cooled in hot furnace to about 200 degrees Celsius for up to 4 hours. 3mg of
sample is mixed along with 4% of internal standards such as zinc oxide according to RDSO. Isopropyl alcohol
is used as a cleaning agent. In the process sample is mixed thoroughly to make fine powder and then loaded in
the sample holder after which XRD testing is done.
20
Quantification using XRD
Graph is plotted using XRD commander within the required angle of detector. Quantification is done using
Topas software.
Structure files are loaded into software to generate ideal graphs, The experimental XRD raw data by running
sample on diffractometer is loaded into the TOPAS software then the ideal graph is compared by overlapping
with experimental plot to determine the variation between both the graphs. Based on the amount of variation
in the graphs an estimated weight percentage of crystalline compounds present in the sample is quantified.
 Experimental results obtained
Fig 6. Graph obtained using XRD Commander software
Fig 7. Quantification using TOPAS software
21
Fig 8. Results obtained by XRD quantification
Conclusion
This interaction gave me knowledge and direct involvement of industrial scenario outside the institute
curriculum. Furthermore, the introduction gave me the practical information about the general working
procedure of the organization, human behavior in industry helped me correlate theoretical ideas of study hall
and reasonable way to approach to industrial production.
I am pleased to be related with this esteemed organization as an intern and fortunate to have the exposure
across most of the departments and its industrial functioning. Overall, it was a good learning and rewarding
experience. The entire duration about a month in CMTI helped me in understanding the process which was
involved in manufacturing. The final product undergoes various inspection processes to check whether the
product obtained is capable to run on different environmental conditions. This internship will retain its
significance when I embrace my professional career as an engineer.
22
References
1. https://www.bruker.com/en/products-and-solutions/diffractometers-and-scattering-
systems/x-ray-diffractometers/d8-advance-family.html
2. https://www.iitk.ac.in/che/pdf/resources/XRD-reading-material.pdf
23

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Testing and quantification of porcelain insulators by XRD techniques.

Under the guidance of

Chapter Chapters Page no.

0. About CMTI: Central Manufacturing 5

The Stakeholders of CMTI are:

 Computer aids in Project Simulation and Visualization

To Support Industries to Achieve Excellence in Technology and Stimulate Economic Growth

 Achieve Technological Leadership

 Our people being our Greatest Assets

Research & Development Centers and Facilities

a. Product Design and Engineering

b. Product Manufacturing and Development

c. Product Assembly and Testing

ii. Mechanical Group

d. Materials and Metallurgy

e. Materials and Metallurgy

2. Smart Mfg., Precision Machines Tools & Aggregates

a. Smart Manufacturing, IIoT and Artificial Intelligence

b. Precision Machines and Machine Tool Aggregates

c. Advanced Material Characterization

d. Noise and Vibration Laboratory

3. Sensors, Vision Tech & Controls

a. MEMS and Sensors

d. Micro-Nano System Engineering

4. Micro Nano Mfg. and Metrology

b. Surface Engineering and Laser Processing

c. Precision Manufacturing and Process Engineering

d. Outreach Centre Rajkot

5. Additive & Special Mfg. Processes

Technology & Services

a. Local Area Network

b. Email and Internet

3. Clean Room Facilities

5. Guesthouse and Canteen

Fig.1 Bragg’s law

Brag’s Law states the following:

Fig 2. Formation of Constructive interference

Applications of Bragg’s Law

Fig.3 X-Ray Diffractometer

Nano material characterization lab

Fig 4. Components of XRD

Feature Specification Benefit

Software push-button switch

High Intensity Ka1,2 Parallel

films (amorphous, polycrystalline,

Data virtually free of air,

motorized anti-scatter screen Significantly enhanced lower

quantification for minor

Unparalleled performance at low

2Ɵ angles enabling accurate

pharmaceuticals, zeolites, porous

framework materials and more

No need for Kß filters and

Energy Resolution: < 380 eV @ 8 100% filtering of Fe-fluorescence

Detection Modes: 0D,1D, 2D Up to 450 times faster than

Seamless integration of 0D, 1D

positioning to balance angular

coverage and resolution

Easy, fast, and alignment-free

Unparalleled accuracy and

D8 Goniometer independent stepper motors and

Temperature: Ranging from ~85K

Easily exchanged stages with

 Phase Identification and structure determination