met-019-19.pptxmalawwi University of Science and Technology

For materials Engineering

1. Malawi University Of Science and Technology SUBMITTED BY: DR. BOWA INTERNSHIP SITE: AGRIMAL INTERNSHIP REPORT

2. Contents Introduction Internship activities Knowledge learned/applied Practical skills learned/applied related to field of study Internship activities relevant to the program SWOT analysis Operational Problems experienced and proposed solutions Code of conduct/ Values learned Conclusion

3. Various Departments Steel melting Rolling mill Hoes plant

4. Introduction Malawi Iron and Steel Corporation is the national market leader in the field of foundry technology. The company is the main manufacturer and distributor of steel products such as steel bars and hoes. In this industry, scrap metal is main raw material which is further melted in electric arc furnaces. This process is done, so that the percentage of carbon can be either minimized or increased to produce low carbon steel ingots, which are rolled to produce hoes and steel bars.

5. Introduction Cont...

6. Internship activities Steel Melting Department Operation and monitoring of electric arc furnaces Welding of ladles and pouring cups using arc welding Cutting of scraps using gas cutting Testing of carbon in steel using oxidation analysis Monitoring the steel melting process, observing for any irregularities or issues, and reporting findings to Supervisors. Assisting maintenance personnel in routine tasks such as cleaning, lubricating, and inspecting equipment, as well as troubleshooting minor issues.

7. Internship activities Rolling Mill Department Conducting metallographic sample preparation. Tensile testing of steel bars using universal testing machine Helping with routine maintenance tasks, such as cleaning equipment, lubricating machinery, and replacing worn-out parts under supervision. Drilling of grinding media used in pulverized furnaces using drilling machines. Maintaining accurate records of production activities, observations, and any incidents that occur during the internship period.

8. Internship activities Hoes plant Department Operating pulverized furnaces Preparation of samples used in spectroscopy using lathe Assisting in the manufacturing process by operating machinery, assembling components, and participating in production line activities under supervision. Stamping of hoes using squeezing machine Coating of finished hoes using vanish Bundling and packaging of hoes in units Applying labels with product information and branding.

9. Internship activities Material Selection Tensile Testing Grinding

10. Knowledge learned/applied Applied Applying knowledge of phase diagrams and heat treatment techniques. Applying safety protocols in hazard identification, and environmental regulations related to metallurgical processes and facilities Applying principles of thermodynamics and kinetics to understand metallurgical reactions.

11. Knowledge learned/applied Learned Various processes involved in melting and refining steel, including electric arc furnace operations, basic oxygen furnace processes, and secondary refining techniques. Various methods for testing and analyzing materials, including tensile testing, hardness testing and spectroscopy. Quality control measures in steel manufacturing, including methods for analyzing and testing molten steel for chemical composition, temperature, and cleanliness to ensure it meets industry.

12. Practical skills learned/applied related to field of study W elding and joining processes used in steel fabrication, such as arc welding and gas welding. Gaining practical experience in welding techniques, joint design, and weld quality assessment. Operating metallurgical testing equipment such as spectrometers and tensile testers. Developing skills in investigating and analyzing the causes of steel component failures or defects. Applying metallurgical principles to identify failure mechanisms, such as fatigue, corrosion, or metallurgical defects, and recommending corrective actions.

13. Practical skills learned/applied related to field of study Gas cutting Arc welding Grooving

14. Internship activities relevant to the program All internship activities were directly aligned with the objectives of the metallurgy program, enhancing my understanding of: Quality Control: Participating in quality control activities, including inspection, testing, and analysis of materials to ensure compliance with industry standards and specifications. Failure Analysis: Investigating material failures and conducting root cause analysis to determine the factors contributing to the failure and recommend preventive measures.

15. SWOT analysis Strengths Expertise in metallurgical processes: The company have easier access to abundant and cost-effective raw materials for metallurgical processes. Access to raw materials: Being located in developing countries, the company may have easier access to abundant and cost-effective raw materials for metallurgical processes. Opportunity for growth: With increasing industrialization and infrastructure development there's a growing demand for metallurgical products and services.

16. SWOT analysis Weaknesses Technological limitations: Limited access to advanced technology and equipment hinders the company's ability to compete with global competitors. Regulatory issues: L ess stringent environmental and safety regulations, leading to potential risks and liabilities for the company. Skills shortage: Shortage of skilled workers or engineers with expertise in metallurgy, which could affect the company's ability to innovate and maintain quality standards.

17. SWOT analysis Opportunities Market expansion: There's a growing market for metallurgical products in construction, manufacturing, and infrastructure sectors Export potential: With competitive production costs, the company can explore opportunities to export metallurgical products to other developing and developed countries.

18. SWOT analysis Threats Economic volatility: S usceptible to economic downturns, and currency fluctuations, which can affect the company's profitability and growth prospects. Competition from global players: The company may face stiff competition from larger, more established metallurgy companies operating globally, especially in terms of technology, quality, and market reach. Supply chain disruptions: D isruptions in raw material supply or transportation, can impact production schedules and increase costs for the company.

19. Operational problems experienced and proposed solutions Problem Machinery breakdowns disrupted production and lead to costly downtime. Proposed Solutions Implement regular maintenance routines and invest in high-quality equipment to minimize breakdowns. Having backup equipment can help mitigate disruptions.

20. Problem Steel melting processes can generate emissions and waste, contributing to environmental pollution. Proposed Solutions Invest in pollution control technologies such as filters, to minimize emissions. Implement recycling programs to reduce waste and promote sustainability. Operational problems experienced and proposed solutions

21. Code of conduct/ Values learned Integrity: Adhering to ethical standards in data collection and analysis. Professionalism: Maintaining a positive attitude and respecting colleagues in the workplace. Safety: Prioritizing safety protocols to prevent accidents and ensure safe and secure working environment.

22. Conclusion In a nutshell, the metallurgy internship provided a comprehensive learning experience, combining theoretical knowledge with practical application in a professional setting. Through engaging in various activities, I gained valuable insights into the metallurgical industry, developed essential skills, and strengthened my understanding of metallurgical processes. The experience has not only enriched my academic pursuits but also prepared me for future endeavors in the field of metallurgy.

23. THANK YOU