Faculty Publications
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Item Theoretical evolution of thermal behaviour of Ti-6Al-4V subjected to selective laser melting: A powder free approach(Elsevier GmbH, 2023) Dutta, J.; Bhanja, D.; Narendranath, S.Additive manufacturing (AM) processes are considered to be the pillar of the next industrial revolution due to their inherent qualities such as design flexibility, the ability to produce complex parts and prototypes, lower cost due to the reduced requirement of materials and curtailed lead time for manufacturing. Selective laser melting (SLM) is one of the most popular metallic AM technologies since it enables accurate control over part dimensions and fabrication of high resolution features. This research paper is aimed to develop an exact analytical model of three-dimensional thermal response captured in SLM of Ti based alloy (Ti-6Al-4V). A physical model has been proposed to predict the temperature profile during the metal additive manufacturing process with consideration of the effect of thermal history developed during moving laser heat source interaction. The corresponding mathematical solution is developed by employing an amalgamation of ‘Duhamel's theorem’ and ‘Finite Integral Transform method’. The parametric laser-substrate interaction phenomenon is the prime deciding factor for the successful accomplishment of the manufacturing process. This research paper theoretically investigates the thermal characteristics (peak temperature, temperature distribution curvature, pulse time, optical penetration depth, time of laser exposure, laser absorption radius, and so on) by employing Fourier's heat conduction model with a moving laser heat source. The theoretical estimation has been validated by the existing mathematical as well as experimental research outcomes. Present work might be an asset for deciding the design of process variables and protocols in terms of laser based additive manufacturing specifically the selective laser melting process. © 2022 Elsevier GmbHItem Effect of CMT-WAAM Process Parameters on Bead Geometry, Microstructure and Mechanical Properties of AZ31 Mg Alloy(Springer, 2024) Manjhi, S.K.; Sekar, P.; Bontha, S.; Balan, A.A.S.Fabrication of Mg alloys using the additive manufacturing process is quite challenging owing to high oxidation and volatile nature at high temperatures. The present study investigates the effect of wire feed speed (WFS) and travel speed (TS) on single tracks of AZ31 Mg alloy fabricated using the cold metal transfer wire arc additive Manufacturing (CMT-WAAM) process. The WFS and TS of CMT-WAAM are optimized to achieve better deposition quality. An increase in WFS increased the width, height, penetration depth, and heat-affected zone of single tracks. In addition, increasing TS decreased the deposited tracks' contact angle and height. The average grain size at the interface zone, center and top portion of single tracks are 35, 42, and 60 μm. The x-ray diffraction results show only the presence of primary phase α-Mg; interestingly, the β-Mg17Al12 and η-Al8Mn5 secondary phases are identified by SEM + EDS and TEM images. The microhardness increased from the substrate to the top section of single tracks due to the increased volume fraction of secondary-phase particles. Based on the best-chosen process parameters obtained from single-track deposition, a multilayer AZ31 Mg thin wall is deposited. The UTS, YS, and % EL of the deposited thin wall in travel direction (TD) are 222 MPa, 102 MPa, and 18%, while in build direction are 202 MPa, 110 MPa, and 14%, respectively. The tensile strength and elongation % of TD and BD samples exhibited comparable properties and were higher than cast AZ31 Mg alloy. © ASM International 2023.