Redefining industrial metallurgy for ease of manufacturing

A platform for all metallurgical process/product improvements & related solutions

Brief introduction of the Director K. G. S. PRASAD RAO

A Graduate Metallurgical Engineer, worked in various public sectors and private Manufacturing Industries in India and abroad. Practicing Metallurgy since 35+ years. Mr. Prasad is only focused on converting scientific innovations to solve day to day problems in Manufacturing Industries. Having worked in reputed manufacturing Industries like TVS Motors, LG Balakrishnan & Brothers, Altair India and Malaysia, Trinity Holdings Dubai, etc. he is able to contribute and help many MSME and small-scale industries technically by supporting with innovative ideas on manufacturing techniques. Expertise on product development, failure analysis, Process design and corrective action. Many of the Industries are supported with ‘Value Engineering’ concept and training the personnel’s on Metallurgical aspect and effect of the process parameters on quality and production repeatability. Completed successfully many turnkey projects

Faculty at
INDIAN MACHINE TOOL MANUFACTURERS ASSOCIATION (IMTMA), BANGALORE
Member: American Society of Metals. Since 1990. Presently Executive committee member
Chair 'Consultancy & Training' at ASMI Bangalore Chapter
Associate Member: Indian Institute of Metals, Kolkata, India

EXPERTISE ON THE FOLLOWING VERTICALS OF MANUFACTURING
HEAT TREATMENT PLANTS (EXPERT IN CQI-9 SYSTEM IMPLEMENTATION AND AUDITS)
FOUNDRY FERROUS, STEEL AND NON-FERROUS (ALUMINIUM, COPPER, LEAD, ETC)
ELECTROPLATING SHOPS
SHOT BLASTING/ PEENING
COLD EXTRUSION PLANT
HOT FORGING PLANT
ALUMINIUM (SAND CASTING, GRAVITY DIE CASTING, PRESSURE DIE CASTING AND LOW-PRESSURE DIE CASTING
VENDOR AUDITS FOR SUPPLY OF RAW MATERIALS LIKE ALUMINIUM INGOTS, ALUMINIUM BILLETS, ETC
METALLURGICAL TESTING AND RESEARCH LABORATORIES
STEEL WIRE DRAWING PROCESSING FOR SPRING STEEL WIRES FOR AUTOMOTIVE SPRING APPLICATIONS
METAL POWDERS PRODUCTION OF FERROUS, (Steel, Alloy steels, Stainless steel, etc.) NON-FERROUS, (Alumunium,Copper,etc), HARDMETALS (Tungsten carbide, Silicon carbide, etc.)
FERROUS FOUNDRY (Cast Iron, Steel, SG Iron, etc.)

METALLURGICAL TESTING & EVALUATION

We take up evaluation of the metallurgical aspects for new and existing product developments. suggesting the appropriate material for optimum service as per the service requirements of the components . Failure analysis and CAPA for both components and process

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Ferrous, steel and Non ferrous foundry

We offer solutions for foundries like Turn Key projects up to execution level, Method, Technology, Quality evaluation audits, Process Evaluation Audits, Process consumables,Casting development right from the scratch, Raw material, etc

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steel wires/Spring Manufacturing technology

We support industries MSME manufacturing steel wires / alloy steel wires for various applications like spring wire manufacturing, Leaf/ coiled springs for their process design especially on different manufacturing process. we take up turnkey projects for complete range of spring manufacturing

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Heat treatment of Steel, Stainless steel, Aluminium alloys, Copper Alloys, etc

We offer our expertise on Heat treatment process right from Turn key projects to execution, Process design, Failure analysis and CAPA, post heat treatment parameters testing and evaluation, Design furnace to optimal requirement, etc. Auditor and expert in implementation of ISO9001/TS1696/CQI9 system

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Mining tool manufacturing

We support mining tool manufacturers process requirements like heat treatment, forging and material selection especially on manufacturing activities like DTH Button bits, Hammers, casing and allied parts. Other parts like Drill Rods , cone bits, roller cone bits, etc used in rock drilling, excavations especially on their life consistency and service

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POWDER METALLURGY

FERROUS POWDERS & ALLOY POWDERS NON FERROUS POWDERS & ALLOY POWDERS INCLUDING TUNGSTEN CARBIDE POWDERS MANUFACTURING TECHNIQUES QUALITY ASSESSMENT AND TESTING MODIFICATIONS ON THE PROCESS FOR ADDITIONAL PRODUCTS POWDER METALLURGY PARTS MANUFACTURING SUPPORT 3 D PRINTING / ADDITIVE MANUFACTURING

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Establishment of Data Acquisition and analysis software on a conventional Heat Treatment process -pit type carburizing furnace process facility and salt bath hardening furnaces . Successfully established data acquisition, data analysis, process improvement, Failure analysis, CAPA, process/repeatability and control for a Mining tool manufacturing Industry
Sai Deepa Rock Drills (pvt) LTD, Hyderabad, India
Mining Tool Manufacturer

Continuous carbo Nitriding furnace facility for manufacturing of Self Drilling hardened screws. Total revamping of the furnace to increase the production capacity . Established carbo-nitriding using LNG as a media gas and LPG for enrichment a new combination of gas atmosphere with proper Carbon potential control. Established a full fledged Metallurgical testing procedure for ensuring life of screws
PRIMA FASTENERS , RAJKOT, INDIA

Established Continuous Heat treatment facility for Bearing race Hardening and tempering, Continuous annealing furnace , Metallurgical testing Laboratory established production, Material handling, Hot forging, validation and approvals as per customer requirement at Scion Exports, Jaipur
SCION EXPORTS PVT LTD, JAIPUR, INDIA
Agrasen Engineering Ltd, Jaipur India

Establishment of a new line of Heat treatment facility for a continuous heat treatment furnace for Heat treatment of various automotive components using a Mesh Belt furnace. Continuous mesh belt furnace with a pre-wash, drier, Hardening , quenching and post cleaning facility. Implementation of CQI Heat treatment quality system. Facilities Induction Hardening, Through Hardening, Carbo-nitriding, tempering , polishing, etc
PRECISION HEAT TREATERS & ENGINEERS INDIA PVT LTD, COIMBATORE
L G Balakrishnan & Bros, Reynolds chains LTD, etc

Established a Heat treatment facility for Fastener manufacturer. Continuous Hardening furnace with capacity of 1000Kg per hour. Furnace make Sanyung , Taiwan. Facility with pre-wash, drying, Hardening, quenching , post cleaning and tempering on a single line. Process establishment, CQI9 Heat treatment system implementation, Metallurgical testing lab procedures, Component validation at customer end, customer audit and approvals
M.K.Fasteners, Bangalore
Hyundai, Ford, Bosch, Toyota Boshuku, GM, TVS, etc

Metallurgy Simplified helped us stabilize our sealed-quench furnace line by redesigning the atmosphere control strategy and tightening dew point management. Their approach was practical: data-first, root-cause driven, and aligned to shop-floor realities. We saw measurable improvement in case depth consistency, a significant reduction in distortion-related rejections, and a much cleaner audit trail for process compliance.
Rohan Mehta
Plant Head - Heat Treatment Operations

METEXPERT METALLURGICAL CONSULTANCY (OPC) PVT.LTD 3387,2nd Cross, 6th Main Road, RPC Layout, Vijayanagar Bengaluru - 560040, Karnataka, India
Near Hampinagar Post office , Vijayanagar Bangalore

MET EXPERT METALLURGICAL CONSULTANCY is a specialized service that offers expert advice and solutions in the field of Industrial metallurgy. We also often provide training and technical support, helping companies stay up to date with the latest advancements in metallurgical science.