Faculty Publications
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Item Wetting kinetics and quench severity of selected vegetable oils for heat treatment(CRC Press, 2010) Prabhu, K.N.[No abstract available]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 Severity of quenching and kinetics of wetting of nanofluids and vegetable oils(ASTM International, 2010) Jagannath, V.; Prabhu, K.N.In the present work, the suitability of vegetable oil blends with mineral oil and alumina based nanofluids as quench media for industrial heat treatment was investigated. Sunflower oil, palm oil, and mineral oil were used for preparing the blends. Alumina based nanofluids of varying concentrations ranging from 0.01-4 % were used. The size of alumina particles was about 50 nm. The severity of quenching and heat transfer coefficients were estimated during quenching of copper probes. Heat transfer coefficients were estimated using a lumped heat capacitance model. The static contact angle was measured on copper substrates having a surface texture similar to the probes used for estimation of heat transfer coefficients. A dynamic contact angle analyzer was used for this purpose. The measured contact angles of nanofluids on copper were high compared to oils, indicating poor wetting by quench media that are polar in nature. Wetting characteristics had a significant effect on heat transfer coefficients estimated during quenching. Copyright © 2009 by ASTM International.