Advanced manufacturing methods which produce the components closer to its final geometry in minimum number of stages is known as Near Net Shape (NNS) manufacturing. NNS technologies are now getting wider acceptance all over the world for obvious benefits like maximum utilization of raw material, minimum energy requirement and competitive price of the final product. One of the NNS technologies is - Manufacturing of Engineering Components through ADI route. ADI components are now  being used in different types of engineering machinery because it offers a combination of design flexibility, higher strength-to-weight ratio, good toughness, superior wear resistance and low cost of production. Design innovation and development of new process technology for manufacturing of ADI components will benefit simultaneously the manufacturing industries and user segments. 

ADI is a new class of engineering material which is being manufactured from SG Iron through Austempering process. Austempering is an isothermal heat treatment process applied to ferrous materials to produce a microstructure that is stronger and tougher than the structures resulting typically from conventional heat treatment. Mechanical properties of ADI product depends mainly on composition and heat treatment parameters. ADI manufacturing technology consist of Computerised methoding-Pattern making- Selection of raw material – Melting and Casting of SG iron component – Machining of component - Austempering treatment – Finishing operation- Inspection. By controlling the process parameters and composition it is also possible to produce high quality SG iron castings which is essential for manufacturing ADI products. Based on the mechanical properties, ADI material are classified into 6 different grades(as per ASTM 897-06). Each grade can be produced through closer control of composition, casting parameters and heat treatment parameters. 

CSIR- CMERI has successfully developed the comprehensive process technology for manufacturing of ADI components like L type Rotavator blades for agricultural sector, Crank shaft for 35 hp tractor engine, Hammers for mining sector and Gudgeon pin for heavy duty compressor. Field trials of these components revealed encouraging results.

Advantages of ADI technology –

1. Easy to produce complex geometry components
2. Mechanical properties comparable to some grades of steel
3. 20% Cheaper than forged steel parts
4. Needs less energy than forged steel parts
5. Superior wear / abrasion resistance
6. 10% lighter than steel