Faculty Publications
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Item Inverse modeling of heat transfer with application to solidification and quenching(2002) Prabhu, K.N.; Ashish, A.A.The inverse modeling of heat transfer involves the estimation of boundary conditions from the knowledge of thermal history inside a heat conducting body. Inverse analysis is extremely useful in modeling of contact heat transfer at interfaces of engineering surface during materials processing. In the present work, the one-dimensional transient heat conduction equation was inversely modeled in both cartesian as well as cylindrical coordinates. The model is capable of estimating heat flux transients, chill surface temperature, and total heat flow from the source to the sink for an input of thermal history inside the sink. The methodology was adopted to solve boundary heat transfer problems inversely during solidification and quenching. The response of the inverse solution to measured sensor data was studied by carrying out numerical experiments involving the use of varying grid size and time steps, future temperatures, and regularization techniques.Item Metal-mould interfacial heat transfer during solidification of cast iron against cast iron chills(2000) Prabhu, K.N.; Griffiths, W.D.Heat transfer during the unidirectional solidification of a cast iron alloy against cast iron chills was investigated using an inverse modelling approach. Chills of thickness 100 mm and 10 mm were used, to simulate gravity die casting conditions and the use of chills in sand moulds. In both cases transient heat transfer, measured by the interfacial heat flux and heat transfer coefficient, declined from initially high values in the first few seconds of solidification, to values about an order of magnitude lower which persisted for the remainder of the experiments. In the case of the thin chill it became saturated with heat until it was no longer in a position to extract further heat from the casting. These results were interpreted by studying the resistance to heat transfer from the casting offered by the casting-chill interface and the chill itself. For example, the thermal resistance of the casting-chill interface can be influenced by the deformation of their respective surfaces and their subsequent relationship.Item One-dimensional predictive model for estimation of interfacial heat transfer coefficient during solidification of cast iron in sand mould(2002) Prabhu, K.N.; Griffiths, W.D.A one-dimensional predictive model is proposed to estimate the interfacial heat transfer coefficients during unidirectional solidification of a cast iron alloy, vertically upwards, against a sand block. The model is based on the surface roughness characteristics of the casting and sand surfaces and the concave deformation of the initial solidified casting skin towards the sand surface. The modelled interfacial heat transfer coefficients and predicted temperatures inside the casting and the sand block showed an approximate agreement with experimentally determined values. The model showed that radiation was a significant mode of casting/sand interfacial heat transfer with the predicted contribution of radiation to the overall heat transfer being nearly 50%. The evaluation of the model in comparison to the interfacial heat transfer models proposed by Zeng and Pehlke suggested that the interfacial conditions considered in this model, namely, the mean peak to valley heights of the casting/sand mould surfaces and the gap width calculated from the deformation of the initial solid skin, gave a more accurate prediction. This predictive heat transfer model has an advantage over the inverse modelling technique as the matching of experimentally measured temperatures to determine the boundary conditions is avoided and the heat transfer coefficients can be estimated as an integral part of the casting simulation.Item Microstructure evolution in AI-7Si-0.3Mg alloy during partial melting and solidification from melt: A comparison(2006) Nyamannavar, S.; Ravi, M.; Prabhu, K.N.In the present work, a comparative study of microstructure evolution in Sr modified AI-7Si-0.3Mg alloy isothermally held at semi-solid state under conditions of (i) cooling from liquid state and (ii) partial melting from solid state to the semi-solid temperature was carried out. The effect of cooling rate (0.01 to 100 K/s) on the microstructure during solidification of semisolid alloy is studied. Partial melting of alloy results in the fine and more spherical solid phase compared to cooling of the same alloy from liquid state. Chemical modification of the eutectic silicon by Sr addition was found to remain same for both cooling the melt from liquid as well as partial melting from solid state, contrary to the reported results. The morphology of eutectic silicon corresponding to the liquid entrapped in solid phase is finer compared to that in interconnected liquid channel.Item Effect of volume fraction and particle size of reinforcement on thermal analysis and heat transfer parameters of gravity die cast hypereutectic Al-22% SI alloy matrix composites(2006) Subramanya, P.K.; Hegde, S.; Prabhu, K.N.The properties of cast metal matrix composites are largely dependent on the solidification behaviour which is dictated by the thermophysical properties of the melt, mould and the interfacial heat transfer from the metal to the mould. In the present investigation the thermal analysis parameters and heat transfer aspects of hypereutectic aluminium alloy matrix composites were studied. As the vol% of SiC p increases the total solidification time decreases and the cooling rate increases. The morphology of the primary silicon was very much dependent on the presence of SiC p. The estimated peak heat flux for the composites are lower than matrix alloy melts solidified under similar conditions. The particle size has a negligible influence on the cooling behaviour. However, composite with finer particle size shows slightly higher peak heat flux.Item Determination of wetting behavior, spread activation energy, and quench severity of bioquenchants(2007) Prabhu, K.N.; Fernandes, P.An investigation was conducted to study the suitability of vegetable oils such as sunflower, coconut, groundnut, castor, cashewnut shell (CNS), and palm oils as quench media (bioquenchants) for industrial heat treatment by assessing their wetting behavior and severity of quenching. The relaxation of contact angle was sharp during the initial stages, and it became gradual as the system approached equilibrium. The equilibrium contact angle decreased with increase in the temperature of the substrate and decrease in the viscosity of the quench medium. A comparison of the relaxation of the contact angle at various temperatures indicated the significant difference in spreading of oils having varying viscosity. The spread activation energy was determined using the Arrhenius type of equation. Oils with higher viscosity resulted in lower cooling rates. The quench severity of various oil media was determined by estimating heat-transfer coefficients using the lumped capacitance method. Activation energy for spreading determined using the wetting behavior of oils at various temperatures was in good agreement with the severity of quenching assessed by cooling curve analysis. A high quench severity is associated with oils having low spread activation energy. © 2007 THE MINERALS, METALS & MATERIALS SOCIETY and ASM INTERNATIONAL.Item Microhardness of laser ablated alumina coating on Ti-6A1-4V(2008) Sujaya, C.; Shashikala, H.D.; Umesh, G.; Prabhu, K.N.; Hegde, S.Alumina coated on Titanium alloys find wide tribological applications due to the improvement in hardness of substrate. This paper presents the effect of deposition of alumina by pulsed laser ablation on Vickers hardness of Ti-6A1-4V substrate. Nd: YAG laser of wavelength 1064nm is used with sintered alumina disc as target for ablation. The variation of Vickers microhardness with load in Ti-6A1-4V shows indentation size effect. Proportional Specimen Resistance (P.S.R) model is applied to separate load -independent hardness from the load - dependent hardness. Composite hardness of Alumina coated Ti-6A1-4V is measured for different laser processing conditions. The film hardness has been separated from the composite hardness of the film-substrate system by the use of an approach based on the law of area of mixtures model taking into an account of ISE, due to proportional specimen resistance of the material to indentation. Film hardness of different films produced by varying the target - substrate distance is presented. As the film thickness increases its hardness decreases as compared to bulk hardness. These studies will be useful in the selection of appropriate coating thickness and substrate hardness to achieve a required composite hardness in the design and production of wear-resistant parts of engineering devices.Item Constitutional undercooling and growth of globuletic particle(2008) Nyamannavar, S.; Ravi, M.; Prabhu, K.N.Isothermal holding of an alloy at semi-solid temperature and quenching/cooling, results in formation of instabilities on the globuletic α-particles. The aspect of instability formation is necessary input for accurate simulation and modeling of microstructure evolution for semi-solid metal forming (SSM) process. In the present work instability formation is studied for Al-7Si-0.3Mg alloy. Small cylindrical samples (10 mm, height 10 mm) were subjected to isothermal holding at semisolid temperature followed by quenching/cooling to room temperature. Instabilities were found to form at cooling rates 30 and 100 K/s. Instability formation is explained by interface stabilization theory based on the constitutional undercooling of liquid ahead of the solid/liquid interface.Item Heat transfer during quenching and assessment of quench severity-A review(2009) Prabhu, K.N.; Fernandes, P.In the heat treatment of steel, quenching is done to prevent ferrite or pearlite formation and allows formation of bainite and martensite. For a particular grade of steel, the effectiveness of quenching depends on the cooling characteristics of the quenching medium. The cooling rate is not a constant throughout the quenching process; instead it varies depending upon the various stages that occur during the quenching process. Knowledge of heat transfer during various stages of quenching and kinetics of wetting of the quench medium is fundamental to the understanding of the relationship between material, quench medium, microstructure, and properties. In this paper the characteristics of various quench media, the effect of process parameters on quenching, mechanisms of thermal transport, methods of assessing severity of quenching, and techniques of estimation of heat transfer coefficients are reviewed. An attempt is also made to highlight the importance of wetting kinetics of liquid media on quenching. Copyright © 2009 by ASTM International.Item Review of non-reactive and reactive wetting of liquids on surfaces(2007) Kumar, G.; Prabhu, K.N.Wettability is a tendency for a liquid to spread on a solid substrate and is generally measured in terms of the angle (contact angle) between the tangent drawn at the triple point between the three phases (solid, liquid and vapour) and the substrate surface. A liquid spreading on a substrate with no reaction/absorption of the liquid by substrate material is known as non-reactive or inert wetting whereas the wetting process influenced by reaction between the spreading liquid and substrate material is known as reactive wetting. Young's equation gives the equilibrium contact angle in terms of interfacial tensions existing at the three-phase interface. The derivation of Young's equation is made under the assumptions of spreading of non-reactive liquid on an ideal (physically and chemically inert, smooth, homogeneous and rigid) solid, a condition that is rarely met in practical situations. Nevertheless Young's equation is the most fundamental starting point for understanding of the complex field of wetting. Reliable and reproducible measurements of contact angle from the experiments are important in order to analyze the wetting behaviour. Various methods have been developed over the years to evaluate wettability of a solid by a liquid. Among these, sessile drop and wetting balance techniques are versatile, popular and provide reliable data. Wetting is affected by large number of factors including liquid properties, substrate properties and system conditions. The effect of these factors on wettability is discussed. Thermodynamic treatment of wetting in inert systems is simple and based on free energy minimization where as that in reactive systems is quite complex. Surface energetics has to be considered while determining the driving force for spreading. Similar is the case of spreading kinetics. Inert systems follow definite flow pattern and in most cases a single function is sufficient to describe the whole kinetics. Theoretical models successfully describe the spreading in inert systems. However, it is difficult to determine the exact mechanism that controls the kinetics since reactive wetting is affected by a number of factors like interfacial reactions, diffusion of constituents, dissolution of the substrate, etc. The quantification of the effect of these interrelated factors on wettability would be useful to build a predictive model of wetting kinetics for reactive systems. © 2007 Elsevier B.V. All rights reserved.
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