Faculty Publications
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Item Effect of Process Parameters on Track Geometry and Porosity in Laser Direct Energy Deposition of High Strength Aluminum Alloy(Springer, 2024) Balla, S.K.; Manjaiah, M.; Selvaraj, N.; Bontha, S.Laser Directed Energy Deposition (LDED) is a metal Additive Manufacturing (Metal AM) process that has attracted significant attention due to its ability to produce complex geometries with material properties comparable to cast and wrought parts. High-strength aluminum alloys especially 2xxx, 6xxx, and 7xxx series are difficult to fabricate using LDED process since these alloys are prone to hot cracking due to rapid solidification during the LDED process. The focus of this work is to evaluate the effect of LDED process parameters on track geometry and porosity of Al7075 powder. The effects of process parameters such as laser power, scan speed, and powder flow rate on track geometry and porosity, were investigated using a Formalloy LDED machine via L27 orthogonal array of experiments. Increasing the laser power resulted in an increase in bead width and wetting angle, whereas increasing the scan speed led to a decrease in bead height and wetting angle and a minor increase in width. The results also showed a linear increase in wetting angle and bead height with increased powder flow rate, while the width of the bead remained relatively constant. Furthermore, it was also observed that increasing the laser power to 750 W resulted in a decrease in the cross-sectional porosity of the bead due to the availability of sufficient energy density thereby facilitating proper melting. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2024.Item Key Variables Influencing the Performance of 3D Printed Concrete: A Comprehensive Analysis(Springer Science+Business Media, 2025) Barbhuiya, S.; Das, B.B.; Adak, D.This chapter examines key variables influencing 3D printed concrete performance, focusing on material, process, environmental, and geometric factors essential for achieving optimal strength and durability. It begins with an overview of 3D printed concrete, performance metrics, and the scope of the study. The chapter then delves into material composition, discussing how cement type, aggregate characteristics, additives, and water-cement ratios affect mix consistency, workability, and structural integrity. Process parameters, such as layer height, print speed, and extrusion rate, are analysed for their impact on layer adhesion and structural stability. Environmental factors—including temperature, humidity, and curing—are examined, highlighting their influence on setting time and strength. Geometric and structural considerations, like wall thickness and layer bonding, reveal the effects of design complexity on stability. The chapter concludes by synthesizing these findings, offering insights into optimizing 3D printed concrete performance through coordinated control of materials, process, and environmental conditions. © 2025 The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Switzerland AG.Item Process parameter optimization for ultimate tensile strength of friction stir welded joint of Al-10Mg-8Ce-3.5Si aluminium alloy plates using Taguchi technique(Elsevier Ltd, 2022) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.The Friction stir welding (FSW) process has become a popular method of joining metals, due to its clean and efficient nature of producing welds. The input process parameters: the tool rotation speed, tool feed and tool pin shape are the deciding parameters for an optimum output quality characteristic, the Ultimate tensile stress (UTS) of the weld joint. Here in this research, the Taguchi full factorial design technique is discussed for maximizing the UTS of the weld joint formed in Al-10Mg-8Ce-3.5Si aluminium alloy plates. The ANOVA of means and Signal to Noise ratios for UTS was used to assess the influence of each of the input process parameters on output UTS. The main effect plots of the ANOVA results demonstrated that, the tool rotation speed at level 2 or 1000 rpm, the tool feed at level 3 or 20 mm/min and tool pin shape at level 1 or triangular cross section, gave the optimum results for output UTS. The ANOVA for UTS also showed the percentage contribution of input process parameters; the shape of tool pin as 60.06%, the tool feed as 15.42% and shape of tool pin as 2.41%. The UTS value predicted by the Taguchi analysis was at 108.47 MPa which was in good agreement with the experimentally obtained value of 106.84 MPa. A nonlinear regression equation was developed by correlating the input process parameters, which could be used to predict the optimum UTS results. © 2022 Elsevier Ltd. All rights reserved.Item Influence of Process Parameters on Microstructural Properties of L-DED Produced Ti64 Alloy(Springer Science and Business Media Deutschland GmbH, 2025) Suresh, S.; Kuriachen, B.; Kumar, V.; Bontha, S.; Gurugubelli, R.C.Additive manufacturing (AM) techniques have revolutionized the manufacturing of complex and customized parts across various applications. However, they are known for producing titanium parts with high anisotropy and low ductility, due to high cooling gradient in the build direction and the presence of martensite phase in microstructure respectively. These are inherent problems which limit their application in critical engineering fields. Laser—Direct Energy Deposition (L-DED) produced parts also have the same disadvantages. Thus, the primary objective of this paper is to identify the optimal combination of process parameters for L-DED that can mitigate these inherent limitations. Keeping the parameters such as powder size, orientation angle and hatch angle as constant, the laser power and scan speed are varied to fabricate 9 different sets of samples using L-DED. The research methodology includes an analysis of the microstructure, focusing on grain width, phase distribution, lath characteristics and presence of defects, if any. Microscopy and XRD techniques were used to observe the microstructure. Additionally, hardness studies were performed to evaluate the changes in material hardness. It was noticed that laser power significantly influences β width and α’ length while scan speed has a lesser dominant effect on both of them. The findings will contribute to the development of process-structure-property relations for L-DED-produced Ti64 and further, optimized manufacturing strategies for producing titanium parts with reduced anisotropy and increased ductility. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.Item A comprehensive review of friction stir techniques in structural materials and alloys: challenges and trends(Elsevier Editora Ltda, 2022) Prabhakar, D.A.P.; Shettigar, A.; Herbert, M.A.; Gowdru Chandrashekarappa, M.; Pimenov, D.Y.; Giasin, K.; Prakash, C.Friction-stir techniques are the potential alternative to fusion-based systems for processing and welding metallic alloys and other materials. This review explores the advantages, applications, limitations, and future directions of seven friction-based techniques namely, Additive Friction Stir Deposition (AFSD), Friction Stir Additive Manufacturing (FSAM), Friction Stir Welding (FSW), Friction Stir Processing (FSP), Friction Surfacing (FS), Friction Stir Spot Welding (FSSW), and Friction Stir Lap Welding (FSLW). The basic underlying principle of these processes uses friction as a thermal energy source to weld/process/deposit materials. The common control parameters of all friction stir processing techniques are axial force, rotational speed, and weld or traverse speed. In addition, tool profiles and tool dimensions are known to influence the weld quality. The tool's rotational speed and axial force generate friction between the workpiece and tool material interface, which could plasticize the material. The additive powder bed friction stir process (APBFSP) is another new solid-state manufacturing technique that focus on fabricating the polymer matrix nanocomposites (PNC). In this, a hollow tool like AFSD and the fundamental principle of FSP are combined. The said parameters affect the quantity of material getting deposited/welded. However, weld speed/traverse speed alters the weld quality, and higher traverse speed results in porosity and voids in the welded/deposited/processed region. The only difference between AFSD and other friction stir techniques (FSTs) is that in the AFSD technique, the hollow rotating tool comprises two protrusions with different tool profiles (cylindrical, threaded cylindrical, and tapered cylindrical, square) used. Threaded cylindrical profile and tool steel as the tool material is the most commonly employed in FSTs. Apart from that, tungsten carbide is preferred for hard materials. The working principles and process parameters of FSTs that affect the part quality are discussed in detail. The above review gives the reader an understanding of the domain of FSTs that can be researched further. A summary of some of the potential research works with objectives, process parameters, and outcomes is highlighted. This will provide the readers with an overview of the work carried out by researchers across the globe. Finally, the potential research gaps for future directions to be explored soon across the globe are outlined. © 2022 The Author(s).Item Taguchi's technique in machining of metal matrix composites(Brazilian Society of Mechanical Sciences and Engineering, 2009) Shetty, R.; Pai B, R.B.; Rao, S.S.; Nayak, R.This paper presents the study on Taguchi's optimization methodology, which is applied to optimize cutting parameters in turning of age hardened Al6061-15% vol. SiC 25 ?m particle size metal matrix composites with Cubic boron nitride inserts (CBN) KB-90 grade using steam as cutting fluid. Analysis of variance (ANOVA) is used to study the effect of process parameters on the machining process. This procedure eliminates the need for repeated experiments, time and conserves the material by the conventional procedure. The turning parameters evaluated are speed, feed, depth of cut, nozzle diameter and steam pressure. A series of experiments are conducted using PSG A141 lathe (2.2 KW) to relate the cutting parameters on surface roughness, tool wear, cutting force, feed force, and thrust force. The measured results were collected and analyzed with the help of the commercial software package MINITAB15. As well, an orthogonal array, signal-to-noise ratio is employed to analyze the influence of these parameters. The method could be useful in predicting surface roughness, tool wear, cutting force, feed force and thrust force as a function of cutting parameters. From the analysis using Taguchi's method, results indicate that among the all-significant parameters, steam pressure is the most significant parameter. © 2009 by ABCM.Item Abrasive wear behavior of granite-filled glass-epoxy composites by SiC particles using statistical analysis(2011) Basavarajappa, .S.; Manjunath Yadav, S.M.; Kumar, S.; Arun, K.V.; Narendranath, S.This experimental investigation deals with the evaluation of abrasive wear behavior of Glass Epoxy (G-E) composites on pin-ondisc test rig. A plan of experiments, based on the Taguchi Design of Experiments, was performed to acquire data in controlled way. An orthogonal array and the analysis of variance were employed to investigate the percentage of contribution of various process parameters like sliding speed, applied load, sliding distance and their interactions affecting the abrasive wear volume loss of composites. The correlations between the various factors affecting the abrasive wear behavior of composites were obtained by using multiple linear regression equations. The obtained results indicate that applied load and sliding distance were the wear factors that have the highest physical as well as statistical influence on the abrasive wear behavior of both filled and unfilled G-E composites. A good agreement between the predicted and actual wear resistance was observed within±12%. © Taylor & Francis Group, LLC.Item Parametric study of manufacturing ultrafine polybenzimidazole fibers by electrospinning(Springer, 2012) Anandhan, S.; Ponprapakaran, K.; Senthil, T.; George, G.Polybenzimidazole (PBI), a high performance polymer, was synthesized from 3,3?-diaminobenzidine (DAB) and isophthalic acid (IPA) through polycondensation. The chemical structure of PBI was confirmed by Fourier transform infrared spectroscopy. Thermal characterization of PBI was done by thermogravimetry and differential scanning calorimetry. PBI nanofibers were fabricated by electrospinning of N, N-dimethyl acetamide solutions of PBI of different solution concentrations, at different voltages. The effects of solution and process parameters (namely, solution concentration and DC voltage) on morphology and average diameter of electrospun PBI fibers were investigated. The electrospun ultrafine fibers' diameter and morphology were characterized by using scanning electron microscopy. Nanofibers were obtained only from PBI solutions of concentrations 12 and 14 % (w/v). At concentrations of 8, 10, and 16 %, fibers could not be obtained. The process parameters were optimized by using the statistical tool, factorial or two-way ANOVA (analysis of variance), DOE (design of experiments) and the results indicate that the applied voltage and the interaction of voltage and solution concentration are influential in determining the diameter and morphology of the electrospun ultrathin PBI fibers. Electrospun PBI fibers, as small as 56 nm, could be successfully produced by using the right combination of solution concentration and spinning voltage. © 2012 Central Institute of Plastics Engineering & Technology.Item Reactive distillation using an ion-exchange catalyst: Experimental and simulation studies for the production of methyl acetate(2013) Sandesh, K.; JagadeeshBabu, P.E.; Math, S.; Saidutta, M.B.In this study, the performance of a packed-bed reactive distillation (RD) column for the production of methyl acetate (MeOAc) using an ion-exchange catalyst and simulation of the same using CHEMCAD were analyzed. An ion-exchange catalyst, Indion 190, was used in this study. The performance of the RD column was evaluated based on the MeOAc concentration in the top product. Both steady- and unsteady-state behavior of the column was simulated using CHEMCAD, and the results were experimentally validated. The process parameters, viz., reboiler temperature, enriching temperature, reactor temperature, catalyst loading, molar ratio of the reactant, and flow rate of reactants, were studied, and the optimal values were found to be 73 C, 56 C, 72 C, 100 g, 1:2, and 15 mL/min, respectively. Feed locations of acid and alcohol to the reactor that gave maximum MeOAc concentration in the top product were determined. A mathematical model based on the rigorous calculation using SCDS (used to calculate the nonideal K value) was used to simulate the RD in CHEMCAD. The simulated values were found to deviate from the experimental values within ±5-10%. © 2013 American Chemical Society.Item Experimental investigations on performance characteristics in wire electro discharge machining of Ti50Ni42.4Cu7.6 shape memory alloy(2013) Narendranath, S.; Manjaiah, M.; Basavarajappa, S.; Gaitonde, V.N.This article investigates the effect of pulse on time, peak current and pulse off time on wire electro discharge machining characteristics of Ti 50Ni42.4Cu7.6 shape memory alloy. A Ti 50Ni42.4Cu7.6 alloy was prepared by conventional tungsten arc melting. The machining experiments were performed as per Box-Behnken design on computer control wire electro discharge machining machine using molybdenum wire electrode. The relationships between the process parameters (pulse on time, peak current and pulse off time) and wire electro discharge machining responses (surface roughness and material removal rate) have been established using response surface methodology-based quadratic models. The analysis of variance has been employed to test the significance of the developed second-order mathematical models. The parametric analysis-based results reveal that low peak current with prolonged pulse on duration leads to reduced surface roughness. However, combination of low peak current with low pulse on time is beneficial for achieving better material removal rate for machining of shape memory alloy. © IMechE 2013.