Faculty Publications
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Item Failure Analysis of Cooling Tower Fan-Arm(Springer, 2020) Padasale, B.; Kumar, J.K.R.; Sondar, P.R.; Cadambi, S.; Hegde, S.R.This work presents failure investigation of cooling tower fan-arms commissioned in a chemical processing plant. The analysis aims at understanding the mechanism and root-cause of the failure. The investigation involves site visits, microstructural analysis, fracture surface analysis, hardness measurements, numerical stress analysis and experimental simulation. Work concludes that the fan-arms failed due to the lack of post-weld heat treatment, which caused localized stress-corrosion and pitting at critical locations that served as crack initiation sites. Fatigue loading condition and presence of residual stresses at the weld enabled easy propagation of cracks that led to recurring premature failure. Based on the root-cause and the mechanism identified in this analysis, proper pre-heating and post-weld heat treatment is recommended to relieve the residual stresses at the critical locations and thus to avoid/minimize such recurring failures in future. © 2020, ASM International.Item Enhancement of dysprosium oxide doped zinc alumino borosilicate glasses in thermal, optical and luminescence domain for solid state lighting application(Elsevier B.V., 2022) Monisha, M.; Mazumder, N.; Melanthota, S.K.; Padasale, B.; Almuqrin, A.H.; Sayyed, M.I.; Karunakara, N.; Kamath, S.D.Zinc alumino borosilicate (ZABS) glasses incorporated with Dy3+ ions are prepared through melt-quenching technique. Non-crystallinity behaviour of the glasses are confirmed through XRD studies. The presence of functional and vibrational groups in the glass network are witnessed through FTIR studies. From the differential thermal analysis (DTA), the thermal stability of the glasses are found to be greater than 90 °C. UV–Visible–NIR spectra of glasses showed strong absorptions of Dy3+ ions in the NIR region (∼1267 nm). The highest bandgap value is obtained for ZABSDy0.5 (4.27 eV) glass that has the lowest amount of non-bridging oxygens. The ionic nature of dysprosium ions in the glass vicinity is thereby known through bonding parameter calculation. Judd-Ofelt (J-O) intensity parameters showed the trend Ω2 > Ω6 > Ω4, maintained same for all synthesized glasses. The luminescence spectra showed three emission peaks of Dy3+ ions at 482 (6H15/2), 575 (6H13/2) and 663 (6H11/2) nm. The hypersensitive transition observed at 4F9/2 → 6H13/2 exhibits a greater emission cross-section and radiative transition for all the glasses. Through the decay measurements, the lifetime of the Dy3+ ions are calculated. The estimated CIE coordinates for the glasses showed their location in white light region. The correlated colour temperature (CCT) values are obtained between 4200 and 4500 K suggesting the importance of glasses to use for white-LEDs application. © 2022 Elsevier B.V.Item Failure analysis of a fire water jockey pump shaft(Elsevier Ltd, 2022) Padasale, B.; Kulkarni, G.S.; Rakshan Kumar, J.K.; Cadambi, S.; Hegde, S.R.This work presents failure investigation of a fire water jockey pump shaft that is installed in the fire-station of a petrochemical plant. The jockey pump is driven by a 130 kW motor at about 1480 RPM whose shaft and the coupling key are made of 40C8 steel and 55C8 steel respectively. The drive-shaft of one of the pumps fractured after running for approximately 110 h, while its twin remained functional. The failure analysis involves visual inspection, hardness measurements, metallography, fractography, analytical design calculations, and numerical stress analysis. The analysis concludes that usage of square-ended key in the round-ended keyway is the primary cause, and usage of dissimilar materials for the shaft and the key is the secondary cause for the premature failure. The present work recommends a modified key design and use of the same grade of steel for both the shaft and the key to avoid such failures in the future. © 2022 Elsevier LtdItem TeO2 for enhancing structural, mechanical, optical, gamma and neutron radiation shielding performance of bismuth borosilicate glasses(Elsevier Ltd, 2023) D'Souza, A.N.; Padasale, B.; Murari, M.S.; Karunakara, N.; Sayyed, M.I.; Elsafi, M.; Al-Ghamdi, H.; Almuqrin, A.H.; Kamath, S.D.The synthesized 12Bi2O3– 8BaO–12ZnO-0.5CeO2-17.5SiO2- (50-x) B2O3- xTeO2 glasses with x = 0, 10, 20, 30 and 40 mol% (coded BiTe-0 to BiTe-40) were investigated in terms of physical, structural, optical and mechanical properties to examine the influence of CeO2 and TeO2 on the heavy metal oxide (HMO) borosilicate network. Density values increased continuously with increasing TeO2 concentration with BiTe-40 glass exhibiting maximum value of 5.0875 gcm−3. This property helped in enhancement of refractive index values from 1.769 for BiTe-0 to 1.942 for BiTe-40. Fourier transform infrared (FTIR) analysis of studied glasses revealed the presence of additional small peak at 683 cm−1 in BiTe-30 and BiTe-40 which confirmed the formation of stable TeO4 units in the glass network. The deep brown colour of the glass existing due to bismuth's presence was nullified by CeO2 and TeO2 additives which improved transparency of the glass. Urbach analysis of these glasses led to optical bandgap variation between 3.27 eV and 2.73 eV for 0–40 mol% TeO2 concentration. Makishima and Mackenzie model was utilized for evaluation of elastic property of the glasses, and Poisson's ratio ranging between 1.935 and 1.953 was obtained. Vickers micro-indentation test on the current glasses revealed decreasing microhardness from 4.116 to 4.076 GPa with TeO2 variation from 0 to 40 mol% at 9.8 N load. Gamma radiation shielding parameters were determined using Phy-X/PSD software and it was found that BiTe-40 glass produce maximum MAC (mass attenuation co-efficient) values in high photon energy region 3.5–15 MeV. The present article also contains a detailed emphasis on behaviour of gamma radiation build-up factors at different incident photon energy and TeO2 concentration. The increasing trend of exposure build up factor (EBF) was seen with increasing penetration depth inside the samples at all energies, indicating that glasses of larger thickness improve the escape probability of photons. Meanwhile, fast neutron removal cross-section (FNRCS) was highest for BiTe-10 sample (0.10118 cm−1) which also surpassed the value of ordinary concrete (0.093 cm−1). Overall, the present glass system bested other conventional shields available commercially in terms of gamma and neutron radiation shielding effectiveness. © 2022 Elsevier B.V.Item Failure of Soap Extruder Bolt Assembly(Springer, 2023) Kumar, J.K.R.; Mogra, N.; Padasale, B.; Dsilva, P.C.; Sondar, P.; Hegde, S.R.Present work investigates failure of EN8 steel bolt in a bolt–pin assembly that was used as a fastener in an industrial soap extruder. Unexpectedly, EN19 steel pin that is supposedly the sacrificial element in the assembly remained intact. The investigation follows standard failure-analysis procedure comprising, site-visit, visual inspection, metallography, mechanical-testing, design-analysis, numerical stress-analysis, and fractography. The design-analysis finds that the materials of construction were mistakenly swapped between the pin and the bolt that caused plastic-deformation, necking, and eventual failure of the bolt during operational peak-loading condition. The numerical stress analysis illustrates that the bolts failed at the thread-root region that acted as the stress-raiser. Additionally, the investigation finds that poor-quality machining left-behind jagged thread-root profile that increased the stress-concentration furthermore. The metallography and the fractography indicate that a transverse crack that was initiated at poorly machined thread-root led to the brittle fracture of the bolt. The investigation illustrates how human errors can cause recurring failure of critical components leading to production losses and makes suitable recommendations to prevent such failures in the future. © 2023, ASM International.Item Role of δ-phase on recrystallisation behaviour of Inconel 718(SAGE Publications Inc., 2024) Padasale, B.; Potphode, L.; Dsilva, P.C.; Hegde, S.R.The present work investigates the annealing behaviour of prior-coldworked Inconel 718 (IN718) sheets over wide reduction and temperature ranges by performing cold-rolling and isothermal annealing, followed by mechanical testing and structural characterisation. The study reveals that, with increasing annealing temperature, the prior-coldworked alloy shows non-monotonic M-Type variation with double peak-hardening at 0.3Tm and 0.6Tm. The study discovers that the first peak is due to the ‘static–strain–aging phenomenon’ that precedes recovery-softening. The second peak-hardening is due to precipitation-hardening, following which, the alloy softens due to recrystallisation. Supported by SEM, electron back-scattered diffraction and X-Ray diffraction results, the investigation suggests that the precipitation of fine rod-shaped δ-phase creates numerous nucleation sites at the shear bands that cause recrystallisation-burst at 0.75Tm. However, above 0.75Tm absence of the δ-phase activates grain-boundary migration resulting in rapid grain-coarsening. © The Author(s) 2024.Item Annealing Behavior of Cold-Rolled Inconel 601(Springer, 2024) Dsilva, P.C.; Padasale, B.; Vasavada, J.; Mishra, S.; Hegde, S.R.Present study investigates isothermal annealing behavior of prior cold-worked Inconel 601 (aka, IN 601) sheets. The study comprehensively covers the annealing response of the material over wide cold-reduction and temperature ranges. Using structural characterization and mechanical testing, the study tracks strain-hardening, strain-aging, recovery, and recrystallization stages of IN 601 sheets as a function of degree of cold-reduction and annealing temperature. Using X-Ray diffraction analysis, hardness measurements, and tensile tests, the study reveals that prior cold-worked IN 601, irrespective of the degree of cold-reduction, consistently exhibits strain-aging during low-temperature (~ 0.4Tm) annealing. The investigation establishes that the ‘recovery stage’ is preceded by ‘strain-aging-stage’ during which the alloy exhibits superior strength and hardness than the strain-hardened and recovered states. Based on the thermomechanical experimental results, the current work proposes a recrystallization map that integrates the ‘strain-hardening’ and ‘strain-aging’ stages with the recovery and recrystallization stages. Additionally, microstructural analysis and SEM-EBSD analysis presented in this work indicate that, by suitably controlling strain-hardening and the recrystallization annealing, a refined microstructure comprising high aspect-ratio grains having high-angle grain-boundaries can be obtained that may improve both fatigue and creep properties of IN 601 sheets. © ASM International 2023.Item Influence of ?-Phase on the Grain Shape and Mechanical Properties of Inconel 718(Springer, 2025) Padasale, B.; Hegde, S.R.The present work comparatively studies the thermomechanical processing of mill-annealed, aged, and solution-treated IN718 strips to study the influence of ?-phase precipitates on the grain aspect ratio and the mechanical properties. Prior-treated strips were subjected to thermomechanical processing by cold rolling followed by recrystallization annealing. The processed strips were then mechanically tested and characterized by: hardness measurement, tensile testing, microstructural analysis, electron backscatter diffraction (EBSD) analysis, and x-ray diffraction (XRD) analysis. The results suggest that the recrystallized strips do not show any crystallographic texture, yet possess orthotropic properties along the rolling and transverse directions. The microstructural features correlate well with the mechanical properties, suggesting that the precipitates of ?-phase positively influence the recrystallization kinetics and grain refinement. However, the presence of large fraction of coarse ?-phase precipitates adversely influence the grain aspect ratio and the tensile properties. The study reveals that solution-treated IN718, when subjected to suitable thermomechanical processing, yields a highly refined microstructure with high aspect ratio and superior mechanical properties, especially in the rolling direction. © ASM International 2025.