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 Heat flow at the casting/mold interface was assessed and studied during solidification of Al-Cu-Si (LM 21) alloy in preheated cast iron molds of two different thicknesses, coated with graphite and alumina based dressings. The casting and the mold were instrumented with thermocouples connected to a computer controlled temperature data acquisition system. The thermal history at nodal locations in the mold and casting obtained during experimentation was used to estimate the heat flux by solving the one-dimensional inverse heat conduction problem. The cooling rate and solidification time were measured using the computer-aided cooling curve analysis data. The estimated heat flux transients showed a peak due to the formation of a stable solid shell, which has a higher thermal conductivity compared with the liquid metal in contact with the mold wall prior to the occurrence of the peak. The high values of heat flux transients obtained with thin molds were attributed to mold distortion due to thermal stresses. For thin molds, assumption of Newtonian heating yielded reliable interfacial heat transfer coefficients as compared with one-dimensional inverse modeling. The time of occurrence of peak heat flux increased with a decrease in the mold wall thickness and increase in the casting thickness. © ASM International.(Casting/mold thermal contact heat transfer during solidification of Al-Cu-Si alloy (LM 21) plates in thick and thin molds) Prabhu, K.; Chowdary, B.; Venkataraman, N.2005Item Effect of surface roughness on metal/quenchant interfacial heat transfer and evolution of microstructure(Elsevier Ltd, 2007) Prabhu, K.N.; Fernandes, P.In the present work, the effect of surface roughness on heat transfer rates in various quenchants was determined. The heat flux transients at the probe/quenchant interface were estimated by inverse modeling of heat conduction during end quenching of stainless steel probes with three different surface roughness (grooved, Ra = 3.0 and 1 ?m). Heat transfer during quenching was correlated with the hardness obtained for medium carbon AISI 1060 steel specimens. The effect of surface roughness on heat transfer rate during quenching in water and brine was significant for rough surface whereas its effect on heat transfer rate is only marginal in high viscosity oil quenchants. A fully martensitic structure was observed with grooved surface subjected to water quenching. With a smooth surface a mixed microstructure was obtained. The oil quenched specimens were found to be less sensitive to surface roughness. © 2005 Elsevier Ltd. All rights reserved.Item Effect of section size and agitation on heat transfer during quenching of AISI 1040 steel(2007) Fernandes, P.; Prabhu, K.N.In the present work an attempt has been made to determine the heat flux transients during quenching of Ø28 mm × 56 mm height and Ø44 mm × 88 mm height AISI 1040 steel specimens during lateral quenching in brine, water, palm oil and mineral oil. The heat flux transients were estimated by inverse modeling of heat conduction. The variation of heat flux transients with surface temperature for different quenching media is investigated. Higher peak heat flux transients are obtained for 28 mm diameter specimen than 44 mm diameter specimen during quenching in aqueous media. However quenching with oil media shows opposite results. Agitation of quenching medium increases the peak heat flux during the quenching of steel specimen in all the quenching media. Peak hardness is obtained at the surface and with smaller diameter specimens during agitation. © 2006 Elsevier B.V. All rights reserved.Item Significance of axial heat conduction in non-isothermal adsorption process in a desiccant packed bed(2014) Ramzy, K.A.; Kadoli, R.; Ashok Babu, T.P.Numerical simulation of heat and moisture interactions between air stream and the particles in a desiccant bed provide useful insight on the dynamics of the bed and performance characteristics. Current study introduces a mathematical model for the heat and moisture transfer in desiccant packed bed based on solid side resistance (SSR) model that will now consider heat conduction along the bed. Adsorption and desorption experimental tests have been carried out for validating both solid side resistance (SSR) and solid side resistance with axial heat conduction (SSR-AC) models. The models have been used to investigate the influence of various design parameters like air velocity, particle diameter, bed length and the number of units of mass transfer, on the significance of axial heat conduction. It has been found that increasing the particle diameter or increasing air flow velocity or decreasing the bed length will reduce the influence of axial heat conduction in the bed. Moreover, it has been found that the difference in the bed performance evaluated due to the absence of axial heat conduction in the bed is notably decreasing with the decrease in the number of transfer units of heat or mass. From this study, it is recommended to consider the axial heat conduction term when number of transfer units of mass and heat are greater than unity. © 2013 Elsevier Masson SAS. All rights reserved.Item Spatial dependence of heat flux transients and wetting behavior during immersion quenching of inconel 600 probe in brine and polymer media(Springer Boston, 2014) Ramesh, G.; Prabhu, K.Cooling curve analysis of Inconel 600 probe during immersion quenching in brine and polymer quench media was carried out. Thermal histories at various axial and radial locations were recorded using a high-speed data acquisition system and were input to an inverse heat-conduction model for estimating the metal/quenchant heat flux transients. A high performance smart camera was used for online video imaging of the immersion quenching process. Solution to two-dimensional inverse heat-conduction problem clearly brings out the spatial dependence of boundary heat flux transients for a Inconel 600 probe with a simple cylindrical geometry. The estimated heat flux transients show large variation on axial as well as radial directions of quench probe surface for brine quenching. Polymer quenching showed less variation in metal/quenchant heat flux transients. Shorter durations of vapor film, higher rewetting temperatures, and faster movement of wetting front on quench probe surface were observed with brine quenching. Measurement of dynamic contact angle showed better spreading and good wettability for polymer medium as compared to brine quenchant. The solid-liquid interfacial tension between polymer medium and Inconel substrate was lower compared with that of solution. Rewetting and boiling processes were nonuniform and faster on quench probe surface during immersion quenching in brine solution. For the polymer quench medium, slow rewetting, uniform boiling and repeated wetting were observed. © 2014 The Minerals, Metals & Materials Society and ASM International.Item Effect of preheated mixture on heat transfer characteristics of impinging methane-air premixed flame jet(Elsevier Ltd, 2015) Tajik, A.R.; Kuntikana, P.; Prabhu, S.V.; Hindasageri, V.Energy from spent flame or other low grade energy can be used to increase the temperature of the air before mixing with fuel. This would improve the heat transfer characteristics of the impinging flame jet. The studies on impinging flame jets reported in the literature are based on the fuel-air mixture at ambient temperature. In the present work, the inlet air for mixture is heated by an electrical heater. The heat flux distribution is estimated using an inverse heat conduction (IHCP) technique. The Nusselt number (Nu) and effectiveness (?) distributions are obtained by estimating the adiabatic wall temperature (Taw) by the analytical-numerical method. A circular burner of 13.5 mm is used for impingement on quartz plate of 3 mm thickness. Reynolds number (Re) varying from 500 to 2000 for the non-dimensional burner tip to impingement plate spacing (Z/d) of 2-6 and stoichiometric condition (Ø = 1.0) is considered for varying preheated condition. The effect of equivalence ratio is studied for Ø = 0.75 to 1.5 for Re = 1000 and Z/d = 4. By increase in preheat temperature, the stagnation point heat flux increases from 20% to 50% unless the inner premixed zone touches the impingement plate. CFD simulations are carried out in FLUENT software to explain the distribution of heat flux. © 2015 Elsevier Ltd. All rights reserved.Item Heat transfer and quench performance of aqueous CuO nanofluids during immersion quenching(Inderscience Publishers, 2016) Nayak, U.; Prabhu, K.The present work involves the assessment of quench performance of aqueous-copper oxide nanofluids. Distilled water-based copper oxide nanofluids of concentrations 0.01, 0.05, 0.1 and 1.0 vol.% were prepared by a two-step process. Cooling curves analysis was carried out using an inconel probe that was instrumented with thermocouples. The recorded temperature data during experiments was used to estimate spatiotemporal heat flux transients by solving inverse heat conduction problem. Quenching of probe in nanofluids resulted in longer vapour phase stage duration compared to distilled water. The addition of nanoparticles altered the peak flux and the time of its occurrence. Rewetting temperatures were found to be lower for nanofluids. The measured thermal conductivities and viscosities showed similar values for all quench media. © 2016 Inderscience Enterprises Ltd.Item Estimation of spatially dependent heat flux transients during quenching of inconel probe in molten salt bath(ASTM International, 2017) Pranesh Rao, K.M.; Prabhu, K.N.Several industrial heat treatment processes, such as martempering and austempering, require a quench bath to be maintained at a temperature ranging between 150°C–600°C. Molten salts, molten alkali, and hot oils are the preferred quenchants for these processes. Molten salts and molten alkali are preferred over hot oil because they possess properties like wide operating temperature range, excellent thermal stability, and tolerance for contaminants. In the present work, the performance of a molten potassium nitrate (KNO3) quench bath was analyzed with an Inconel probe that measured 60 mm in height and 12.5 mm in diameter. The probe was heated to 850°C and subsequently quenched in a bath maintained at 450°C. Cooling curves at different locations of the probe were recorded using the K-type thermocouples inserted into the probe. Spatially dependent transient heat flux at the metal/quenchant interface was estimated using inverse heat conduction technique. The existence of two stages of quenching—boiling stage and convection stage—was confirmed by analyzing the heat flux. The heat transfer coefficient was calculated based on heat flux obtained by the inverse method. The nonuniformity in heat transfer along the length of the probe was quantified by calculating the range of surface temperatures at each instance. The hardness distribution in an AISI 4140 steel was predicted using the temperature distribution in the Inconel probe and obtained using inverse method. Uneven distribution of hardness predicted in the probe was attributed to the nonuniform cooling of the probe during quenching. © © 2017 by ASTM International.