Faculty Publications

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    Tribological Performance of Fe-Based Composite Coatings Under Elevated Temperature Conditions
    (Springer, 2025) Chandramouli, T.V.; Joladarashi, S.; Ramesh, M.R.
    The present study investigated the tribological performance of Fe-based coatings reinforced with carbides onto a maraging steel substrate using the HVOF spray technique. These materials are widely used in manufacturing various components in the aerospace and energy sectors. Commercially available SS316L and 17-4PH are reinforced with WC–Co feedstock powders to deposit these composite coatings on maraging steel substrate. The dry sliding wear tests were conducted using the ball-on-disc tribometer at varying temperatures (25 and 300 °C) with 10 N normal load using an alumina ball (Al2O3) as the counter body. The study includes micro-hardness, porosity, density, bond strength, and surface roughness of the coatings. The samples subjected to wear testing were analyzed using SEM/EDS and XRD techniques, and the wear scar volume was measured using a 3D profilometer to calculate the volume metric loss. The wear rate of SS316L30%WC–Co is 64.46% lower than that of 17-4PH30%WC–Co at room temperature and 67.33% lower at 300 °C under a load of 10 N. At room temperature, the worn surface exhibited abrasive wear, while at 300 °C, adhesive wear and oxidative wear were observed owing to the formation of protective layers. Therefore, SS316L-30%WC–Co demonstrates superior wear resistance compared to 17-4PH-30%WC–Co and offers enhanced mechanical strength, particularly in challenging environments. The deposition of these coatings effectively protects the maraging steel substrate. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.
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    Joining of Inconel-625 alloy through microwave hybrid heating and its characterization
    (Elsevier Ltd, 2015) Badiger, R.I.; Narendranath, S.; Srinath, M.S.
    Joining of bulk metals using microwave energy is being explored as a new processing method in the era of high technology applications. The present work investigates the results of on-going project in which joining of Inconel-625 alloy has been effectively carried out through microwave hybrid heating. Characterization of the microwave developed joints is done through SEM, XRD, UTM and Vicker's microhardness tester. The microstructural analysis through scanning electron microscope exhibits a fully fused weld interface free from interfacial cracks. XRD study reveals the formation of carbides of Ni, Cr and Mo in the joint interface. The average Vicker's microhardness in the joint region observed was 360 ± 20 Hv. Assessment of tensile strength shows an ultimate tensile strength of 328 MPa with 9.04% elongation. Further the fractured joints are subjected to fractography study which possibly reveals a mixed mode fracture. © 2015 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
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    Vibrational spectra of Ruthenium Carbide structures yielded by the structure search employing evolutionary algorithm
    (Elsevier Ltd, 2015) Harikrishnan, G.; Ajith, K.M.; Chandra, S.; Valsakumar, M.C.
    Out of the three dynamically stable structures of Ruthenium Carbides yielded by the exhaustive structure search employing evolutionary algorithm, Born effective charges are computed for the semiconducting RuC in Zinc blende structure using density functional perturbation theory. Using the phonon frequencies and the Born effective charge tensors of Ru and C in this structure, infrared spectrum is generated for this system. Computations of these dynamical quantities and IR spectra from first principles can be helpful in the unambiguous determination of the stoichiometry and structure by comparison of the experimental measurements with the computational predictions. The positive formation energies of the three systems show that high pressure and possibly high temperature may be necessary for their synthesis. Formation energies of these systems at different pressures are computed. One of the structurally stable systems, Ru3C with hexagonal structure (P6¯m2), has negative formation energy at 200 GPa. The system reported from the first synthesis of Ruthenium Carbide also has the same symmetry, though it has a different stoichiometry. © 2015 Elsevier Ltd. All rights reserved.
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    High temperature corrosion behaviour of HVOF sprayed WC-CrC-Ni coatings
    (Inderscience Publishers, 2016) Somasundaram, B.; Kadoli, R.; Ramesh, M.R.; RAMESH, C.S.
    The present work aims to study the hot corrosion resistance of high velocity oxy-fuel (HVOF) sprayed WC-CrC-Ni coating developed on three types of boiler tube materials such as SA213-T22, MDN-310 and Superfer 800 H steels. Hot corrosion studies were conducted in a molten salt environment of Na2SO4-60%V2O5 at 700°C and thermogravimetric analysis was used to establish kinetics of corrosion. Corrosion kinetics of coated steels followed nearly parabolic behaviour and showed a lower corrosion rate in comparison to uncoated alloys. It is concluded that corrosion is restricted to the external surface of the coating and the formation of thick scale composed of oxides of Cr, Ni and their spinel oxides, acts as a diffusion barrier to the transportation of corrosive species into the coating. The carbides of tungsten and chromium uphold the strength of the coating. © © 2016 Inderscience Enterprises Ltd.
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    Soft computing techniques during drilling of bi-directional carbon fiber reinforced composite
    (Elsevier Ltd, 2016) Shetty, N.; Herbert, M.A.; Shetty, R.; Shetty, D.S.; Vijay, G.S.
    Due to the intricacy of machining processes and inconsistency in material properties, analytical models are often unable to describe the mechanics of machining of carbon fiber reinforced polymer (CFRP) composites. Recently, soft computing techniques are used as alternate modeling and analyzing methods, which are usually robust and capable of yielding comprehensive, precise, and unswerving solutions. In this paper, drilling experiments as per the Taguchi L27 experimental layout are carried out on bi-directional carbon fiber reinforced polymer (BD CFRP) composite laminates using three types of drilling tools: high speed steel (HSS), uncoated solid carbide (USC) and titanium nitride coated SC (TiN-SC). The focus of this work is to determine the best drilling tool that produces good quality drilled holes in BD CFRP composite laminates. This paper proposes a novel prediction model 'genetic algorithm optimised multi-layer perceptron neural network' (GA-MLPNN) in which genetic algorithm (GA) is integrated with Multi-Layer Perceptron Neural Network. The performance capability of response surface methodology (RSM) and GA-MLPNN in prediction of thrust force is investigated. RSM is also used to evaluate the influence of process parameters (spindle speed, feed rate, point angle and drill diameter) on thrust force. GA is used to optimize the thrust force and its optimization performance is compared with that of RSM. It is observed that the GA-MLPNN is better predicting tool than the RSM model. The investigation in this paper demonstrates that TiN-SC is the best tool for drilling BD CFRP composite laminates as minimum thrust force is developed during its use. © 2016 Elsevier B.V. All rights reserved.
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    Comparative evaluations of machining performance during turning of 17-4 PH stainless steel under cryogenic and wet machining conditions
    (Taylor and Francis Inc. 325 Chestnut St, Suite 800 Philadelphia PA 19106, 2018) Sivaiah, P.; Dupadu, D.
    Productivity in machining of 17-4 PH stainless steel is adversely affected by the premature failure of tool and poor surface finish as a consequence of high cutting temperatures. Conventional cutting fluids not only create environmental and health problems but also fail to overcome the high cutting temperatures during machining. Cryogenic cooling is an environmentally clean cooling technology for attractive management of machining zone temperatures. The present study investigates the effect of cryogenic liquid nitrogen (LN2 at ?196°C) on cutting temperatures, cutting forces (main cutting force, feed force), surface roughness, tool flank wear and chip morphology in turning of 17-4 PH stainless steel with AlTiN PVD-coated tungsten-coated carbide inserts and results were compared to wet machining. In overall, cryogenic machining reduces the cutting temperature, cutting forces, surface roughness and tool flank wear to a maximum of 73.4, 17.62, 44.29 and 55.55%, respectively. Improved chip breakability was found in cryogenic machining. © 2018 Taylor & Francis Group, LLC.
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    Elevated temperature solid particle erosion behaviour of carbide reinforced CoCrAlY composite coatings
    (Institute of Physics Publishing helen.craven@iop.org, 2018) Nithin, H.S.; Desai, V.; Ramesh, M.R.
    CoCrAlY+WC-Co and CoCrAlY+Cr3C2-NiCr coatings are deposited on nickel based alloy using atmospheric plasma spray technique. Mechanical properties such as microhardness, adhesion strength and fracture toughness of coatings are evaluated. Elevated temperature solid particle erosion behaviour of these coatings are investigated at 600 °C using alumina erodent at 30 and 90° impact angle. Coatings are characterized utilizing Scanning electron microscope (SEM), x-ray diffraction (XRD) and Energy dispersive spectroscopy (EDS). CoCrAlY+WC-Co coating shows higher hardness, adhesion strength and fracture toughness than CoCrAlY+Cr3C2-NiCr coating. CoCrAlY+WC-Co coating exhibited approximately 3 times higher erosion resistance than CoCrAlY+Cr3C2-NiCr coating at 90° and 30° impact angles. SEM images of eroded surfaces of coatings reveals the combination of ductile and brittle fracture. CoCrAlY+Cr3C2-NiCr coating shows severe cracks, craters, carbide pull out and chipping than CoCrAlY+WC-Co coating. High temperature erosion is a combination of simultaneous building up of material by oxidation and removal of material by erosion process. Thus reforming the erosion process to oxidation modified erosion process. © 2018 IOP Publishing Ltd.
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    Microstructure and mechanical properties of Inconel-625 welded joint developed through microwave hybrid heating
    (SAGE Publications Ltd info@sagepub.co.uk, 2018) Badiger, R.I.; Narendranath, S.; Srinath, M.S.
    Application of microwave energy for processing of bulk metals is effectively utilized to join Inconel-625 plates through hybrid heating technique using Inconel-625 powder as an interface filler material. Post welding characterization of microwave developed joints through X-ray diffraction shows the development of carbides of niobium and chromium as well as intermetallic phases along with the primary ?-phase face-centered cubic matrix. Microstructural examination reveals the formation of Laves phase along the grain boundaries in the fusion zone. Microwave-induced joints exhibit average microhardness of 245 ± 20 HV and 0.7% porosity in the fusion zone. Average ultimate tensile strength and flexural strength of the developed joints were estimated at 375 and 377 MPa respectively. Average impact toughness of microwave-induced joints is observed to be 18 J. © IMechE 2017.
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    Structure-Property Correlation of Quenching and Partitioning Heat Treated Silicon-Manganese Steel
    (Springer Netherlands rbk@louisiana.edu, 2019) Acharya, P.P.; Bhat, R.
    The present investigation deals with the effect of varying quenching and partitioning parameters on microstructure and mechanical properties of American Iron and Steel Institute 9255 steel. The specimens were fully austenitised at 900 ?C for 45 min and then quenched at 190 ?C and followed by partitioning at various temperatures 280, 320, 360 and 400 ?C and partitioning times 15, 30, 45, 60 and 90 min for each temperature. Post heat treatment includes microstructural analysis that was carried out by using scanning electron microscope (SEM) along with electron back scattered diffraction (EBSD) and x-ray diffraction (XRD) and then correlated to the mechanical properties i.e. tensile properties and hardness of the steel. Results indicate that the specimens quenched at 190 ?C and partitioned over a temperature range 280 to 400 ?C generates multiphase microstructures containing major fraction of martensitic structure (lath and plate-type), transitional ?-carbides in tempered martensite matrix and retained austenite (RA) for all the conditions. At higher partitioning temperatures i.e. 360 and 400 ?C reveals some bainitic ferrite laths along with martensite and RA. Superior tensile strength, % elongation and modulus of toughness values of 1860 MPa, 12% and 207 MJ/m3 respectively was attained at partitioning time of 15 min at 280 ?C. © 2018, Springer Nature B.V.
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    Investigation on the performance of AlCrN and AlTiN coated cemented carbide inserts during end milling of maraging steel under dry, wet and cryogenic environments
    (Elsevier Ltd, 2019) Varghese, V.; K, A.; Ramesh, M.R.; Dupadu, D.
    The present study investigates the machining performance of AlCrN and AlTiN coated cemented carbide inserts during end milling of MDN 250 maraging steel. The mechanical and metallurgical characterization is carried out to determine the properties of the PVD coatings developed. The end milling experiments under dry, wet and cryogenic environment is carried out using coated uncoated inserts (UC) at different spindle speeds to evaluate the machining performance in terms of tool life, surface roughness and cutting forces. The coated inserts showed higher tool life, better surface finish, and low cutting forces during machining at different spindle speeds. It is found that the AlCrN coating had a better wear resistance and machining performance in comparison with AlTiN coating. The cryogenic environment reduced the surface roughness & cutting force and improved the tool life of the cutting tool compared to conventional dry and wet environment. It is revealed that coated tools along with cryogenic cooling can be employed for high-speed machining applications. © 2019 The Society of Manufacturing Engineers