Soumya Sangita Nayak
Supervisor
Prof. Surjya K PalDr. Prakash Srirangam (WMG, UK)
Doctoral Research Problem
Numerical modeling of texture evolution in friction stir welding process techniqueResearch Statement
Grain orientation or texture affects all most of all properties of the material. The properties of the material ultimately affect the performance of that material in the final applications. In any kind of application, either casting material (component like turbine blade, gas turbine vanes etc.) or deformed material (either deep drawn/extruded/forged) or joined material (weld joint etc.) or any material which undergoes some kind of heat treatment processes (hardening, annealing etc.). In each case, texture is different. The aim in every case is to get the desired texture to fulfil the performance of that material. Here the research objective is to see the texture evolution in friction stir welding (FSW) process which is a solid state joining technique and now a day this process is used widely due to its huge advantages upon fusion welding process. Heat and deformation are the two major factors to produce the weld joint in this process which is produced by the FSW tool. Due to these two factors, alteration in crystallographic texture occurs in the material. Numerical modeling will better give an avenue to understand the FSW process and see the texture evolution in FSW as experimental investigation to see the texture evolution with electron back scatter diffraction in the whole sample is difficult and costly. Once the model will be built, it will be easier to see the control of the texture evolution by varying the FSW process parameters (tool welding speed, tool rotational speed, plunge depth, tool tilt angle) to get the desired properties (e.g. weld strength, corrosion resistance etc.)Industrial Application
Aerospace Industry
Ref:https://www.appropedia.org/Compositesin_the_Aircraft_Industry)
Publications
LinkQuick Links
- Email: soumyasangitanayak.nayak[at]gmail.com
- Research Gate
- Google Scholar
Pooja Sarkar
×Supervisor
Prof. Surjya K PalProf. Barbara Shollock (King's College, London)
Doctoral Research Problem
Implementation of Friction Stir Channeling (FSC) as a successful manufacturing process to fabricate cooling channels and to do their thermal analysis to elevate the heat transfer rate for the use in HEV/EV battery pack cooling.Research Statement
With the advancement of battery efficiency that can give more power, cooling of battery pack for EVs is becoming a challenge that has to be addressed by the heat exchanger manufacturer. Friction Stir Channeling (FSC), enables us to create a continuous integral channel inside a monolithic plate in a single pass. The aim of the present work is to create cooling channels of different profiles (linear, serpentine, helical or as required by the product to be cooled) by FSC and also to control the shape and size of the channel. This work also includes the hydraulic and thermal analysis of the channels produced for optimum heat transfer.Industrial Application
FSC cool plates in cooling Lithium ion battery pack
Ref:www.lianinno.comPublications
LinkQuick Links
- Email: sarkarpooja90[at]gmail.com
- Research Gate
Md Noorul Hoda
×Supervisor
Prof. Surjya K PalDr. Jinu Paul
Doctoral Research Problem
A Novel Method of Manufacturing of Cost Effective Graphene-Aluminum Metal Matrix Composite (Direct Exfoliation of Graphite into Graphene by Friction Stir Processing)Indusrial Application
Aluminum-graphene composite for Engine Block Cylinder Liner
Ref:www.enginebuildermag.com/2015/09/liners-and-sleeves/11932946497.htm
Publications
LinkQuick Links
- Email: hoda.mdnoorul[at]gmail.com
- Research Gate
Ranjan Kumar Vishwakarma
×Supervisor
Prof. Surjya K PalDr. Nilanjan Das Chakladar
Doctoral Research Problem
A Novel Method of applications of solid-state technology based on friction-stir processing (FSP) principles for metal matrix composites (MMCs)Research Statement
Materials with high specific strength and stiffness have demanded for various applications such as aviation, aerospace, defense, automotive etc. that mostly use on light weighting, better fuel efficiency, and higher pay load. Composite materials have received wide acceptance owing to their greater potential for use as components/products with high specific strength, stiffness, enhanced wear resistance, and better high temperature properties compared to monolithic metals and alloys. Friction stir processing (FSP) has emerged as an effective tool for grain refinement and microstructure modification. It has now been also demonstrated that FSP is an attractive method to process composites. A wide range of reinforcements that include ceramic and metallic particles, carbon nanostructures have been incorporated in metallic matrices by FSP. This process has proved its potential in fabricating both bulk and surface composites. Nanocomposites and hybrid composites have been also fabricated by FSP. A major concern in fabricating the metallic matrix composites (MMCs) has been the inhomogeneity of particle distribution. A number of tool designs have emerged in order to distribute the particles uniformly. It has also been demonstrated how the process parameters affect the microstructure and properties of the processed composites. FSP has been also found useful in homogenizing the microstructure of as-cast and other MMCs that suffer from microstructural inhomogeneity such as particle clustering.Industrial Application
Cost reduction in FSW of high melting point materials like copper alloys through enhancement of tool life by Direct Metal Laser DepositionRef:https://images.app.goo.gl/L7ZNtafKB7dQNEaH6Publications
LinkQuick Links
- Email: ranjan5790[at]gmail.com
Rishabh Swarnkar
×Supervisor
Prof. Surjya K PalDoctoral Research Problem
Fabrication and microstructural evaluation of high ductile tube through friction stir extrusion (FSE) processResearch Statement
FSE is a severe plastic deformation (SPD) based novel technique. It has been used to consolidate and extrude bulk material, chips, and powdered metal into bulk wire and tube. In this process, a rotating cylindrical flat-faced tool is inserted into the die containing bulk billet or chips with a predefined feed rate. The friction at the tool specimen surface softens the material and is forced to flow radially outward similar to back extrusion. For the wire and rod, the softened material flows through the hole of the tool, and in the case of the tube, the softened material flows through the clearance in between the tool and die. The stirring action of the tool causes the SPD to lead to refined microstructure. It can be used as a solid-state recycling technique for chips and scraps. The process is highly energy efficient as compared to the conventional recycling technique and the permanent material loss is also low, due to reduced oxidation as the material does not reach the melting temperature. On the second side, the fine-grained microstructure pours additional advantages of high corrosion resistance as well as high ductility at room temperature. This extrusion method opens a new door for recycling the scraps and convert them into a finished and semifinished product. The finished product can be utilized in automobile, aerospace, and structural applications. Thus the objective of the work is to successfully extrude the high ductile seamless tubes through the FSE process.Industrial Application
Tubular Chassis
Ref:https://grabcad.com/library/tubular-chassis-2Publications
LinkQuick Links
- Email: rishabhswarnkar17@gmail.com
Souvik Karmakar
×Supervisor
Prof. Surjya K PalDoctoral Research Problem
Evaluation of mechanical and microstructural properties of multi-layered metal structure fabricated through friction stir deposition-based additive manufacturingResearch Statement
The fabrication of large-scale metal products through conventional fusion-based additive manufacturing (AM) is one of the most challenging areas in the modern manufacturing industry. Porosity, compositional inhomogeneity, hot cracking, and residual stress are the major drawbacks, out of which some are inevitable unless the fabrication environment is inert or controlled. In contrast, friction stir surfacing-based additive deposition is a newly developed solid-state manufacturing technology that combines the advantages of friction stir welding (FSW) and AM. It is a green, energy-efficient technology and can deposit metal layer by layer in an open atmosphere. The capability to deposit a higher thickness layer with a single pass, isotropic mechanical properties, etc. can find applicability in various manufacturing fields where metal AM is needed in large-scale product fabrication. Applications include adding rib stiffeners, flanges, and features on the thin plate to strengthen them in structural engineering component manufacturing. The process can be applied for repairing operations at the desired location to eliminate the defects like cracks, wear, and pitting.Industrial Application
Structural components: Rib features in aircraft panels
Ref:https://www.scirp.org/journal/paperinformation.aspx?paperid=67584Publications
LinkQuick Links
- Email: souvik96.mit[at]gmail.com
- Google Scholar
- Research Gate
Kranthi Kumar
×Supervisor
Dr. Siddharth TamangProf. Surjya K Pal
Doctoral Research Problem
Fabrication and Multi-sensor-based monitoring of bimetallic structures by Cold Metal Transfer Wire Arc Additive Manufacturing.Research Statement
Bimetallic structures have significant importance due to enhanced individual material properties and site-specific functionalities. It can be applicable to numerous industries. Fabricating bimetallic structures using traditional manufacturing techniques presents significant challenges due to disparities in thermomechanical properties present between two materials this will lead to the formation of various intermetallic compounds resulting in the deterioration of structure’s strength. Wire Arc Additive manufacturing using Cold Metal Transfer (CMT) as heat source has less input and it have great impact on fabricating bimetallic structures and improve the strength of the structure. The use of multi-sensor-based monitoring system will allow for real time detection and identification of defects and reducing the defects by changing different process parameters. It will be highly beneficial for the construction of industrial components.Industrial Application
Automobile body
Ref:https://www.motortrend.com/news/cadillac-ct6-aluminum-construction-saves-198-pounds-compared-to-steel/?galleryimageid=780e278d-778f-4ebb-bb91-17d2cd0d0be4&test=controlPublications
LinkQuick Links
- Email: kranthigaddam1234[at]gmail.com
- Research Gate
Dr. Ramkumar Kesharwani
×Supervisor
Dr. Sushanta K PandaProf. Surjya K Pal
Doctoral Research Problem
Friction stir welding and deep drawing of aluminum tailored blanks for light weight automotive applicationsResearch Statement
The invention of friction stir welding had created good scopes of replacing steels by some aluminum alloys (particularly 5XXX series) in the fabrication of tailor welded blanks. However, there was very limited information available in open literature regarding formability (in particular, drawability) performance of tailor-made aluminum friction stir welded blanks. Therefore, two mostly used aluminum alloys, namely AA5754-H22 and AA5052-H32 with dissimilar gauge (2.0 and 2.5 mm) were initially friction stir welded using optimized parameters, to be ensured to get its maximum weld strength. Subsequently, the fabricated optimized aluminum tailor friction stir welded blanks (TFSWBs) were examined for its formability in terms of limiting drawing ratio (LDR) in a laboratory scale standard deep drawing test. The obtained results were found to be very close to that of the base metals; however, for further improvement in the LDR, a new die (named as modified conical tractrix die, MCTD) was designed, developed and tested by using the fabricated optimized TFSWBs. Significant improvement in the LDR was observed once using MCTD. Moreover, a finite element model of the LDR test was developed and validated using the experimental results with impressively high accuracy. This model was used to analyze the strain evolution pattern during the drawing of the fabricated TFSWBs, which revealed a new and more pronounced reason behind the improvement in the LDR obtained with MCTD.Indusrial Application
Automotive industry: Fabrication of body-in-white, fuel tank, door and floor panel etc.Publications
LinkQuick Links
- Email: ramkumar31kesharwani[at]gmail.com
- Research Gate
- Google Scholar
Dr. Kanchan Kumari
×Supervisor
Prof. Surjya K PalDoctoral Research Problem
Novel Twin Tool Based Friction Stir Welding of Aluminum AlloysResearch Statement
Most of the research woks in FSW have been conducted using the traditional single tool system. This leads to non-unifrom temperature distribution across the weld plates. FSW also requires heavy clamping force abd high downward force to maintain the contact between the tool and the workpiece intact. To tackle this, a twin tool has been indignenously develeoped and farbicated. This consists of two tools rotating in opposite directions and moving simulateneously. The tool system requires less clamping force as the two tools counter each other. It disrupts and fragments the residual oxide layer remained in the first weld region by the follower tool, thus, enhancing the weld quality. Good quality welds can be achieved with higher welding speeds.Publications
LinkQuick Links
- Email: kanchan.1087[at]gmail.com
- Research Gate
Dr. Rahul jain
×Supervisor
Prof. Surjya K PalProf. Shiv B Singh
Doctoral Research Problem
Numerical modeling and validation of friction stir welding with different tool configurationsResearch Statement
Study of material flow mechanism, forces and defect formation during FSW process are important as it could help in proper selection of process parameter and pin design. Their experimental study is exhaustive due to lots of post weld analyses. Numerical modeling could be an efficient method to study the material flow and defect formation. This will reduce the cost associated for material and development of infrastructure. In the current research work two different three-dimensional thermo-mechanical models are developed to simulate FSW.(a) A three dimensional thermo-mechanically coupled model was developed based on Lagrangian theory. The developed model is used to model FSW for AA2024 and AA6061 aluminum alloys. For AA2024 material, the model is validated with the forces and spindle torque data obtained from the literature. Two different pin shapes viz. conical and threaded conical are compared in terms of forces, material flow, material velocity, effective strain and strain rate. Threaded conical pin produced higher deformation and vertical flow of the material among the two. For AA6061 material, in-house experiments are performed to validate the model with temperature, force and spindle torque. Three different pin shapes, namely, cylindrical, triflat and square are compared. For flat pin surfaces bulk material flow is prominent, while shearing or layer by layer material flow is more prominent for cylindrical pin. Distribution of the material is uniform across the stirred region for the triflat pin while it is stretched towards the advancing side for the square pin.
(b) Prediction of defect using Lagrangian model is difficult as void cannot be introduced in it. Therefore, another model based on coupled Eulerian Lagrangian is developed to predict the defect formation. The defect prediction is based on volume of fluid principle. Effect of tilt angle on defect formation is studied and simulation predicted defect is compared with the experiments. The developed model accurately predicted the defective as well as defective weld.
Indusrial Application
1. The developed model will help industry to pick the efficient tool geometry that will produce higher weld strength.2. The model developed based on coupled Eulerian Lagrangian method can predict the defective or non-defective weld based on input process parameter.
3. This will reduce a lot of experimental requirement to come up with optimized process parameters.
Publications
LinkQuick Links
- Email: rahul[at]iitbhilai.ac.in
- Research Gate
- Google Scholar
- Personal Website
Dr. Raju Prasad Mahto
×Supervisor
Prof. Surjya K PalDoctoral Research Problem
Friction Stir Lap Welding of AA6061-T6 and AISI304 in Air and Underwater Media: Mechanical Studies and Material CharacterizationsResearch Statement
The joining of dissimilar materials such as AA6061-T6 and AISI34 has the potential for tailoring the properties of a structure. However, because of the differences in the mechanical and metallurgical properties of AA6061-T6 and AISI304, there exist several challenges in fabrication. Friction stir welding (FSW) is an advanced solid-state welding technique having the potential to produce a sound weld between aluminum and steel substrates. Microstructure, intermetallic compounds (IMC), crystallographic texture, corrosion, and weld defects are the main factors controlling the mechanical and metallurgical properties of the welds. These factors rely on process parameters and weld media. Scanty literature is available on the effect of process parameters on the FSW of AA6061-T6 and AISI304 in air and water media.Indusrial Application
Sub-frame of Honda Accord
Ref:http://world.honda.com/automobiletechnology/FSW/topic7/20.03.2018
Publications
LinkQuick Links
- Email: rajukec1[at]gmail.com
- Research Gate
- Google Scholar
Dr. Abhishek Sharma
×Supervisor
Dr. Jinu PaulDoctoral Research Problem
Development of friction based solid-state processing strategies for the surface modification of Aluminium alloysResearch Statement
Solid state friction based strategies has the potential for locally enhancing the properties of various aluminium alloys for demanding applications within the automotive industry. The research aimed to increase the wear resistance of the aluminium alloys through impregnating various carbonaceous reinforcements such as Graphite, Graphene and CNTs through solid state friction stir processing and friction surfacing methodologies. Additionally, the novel powder metallurgy assisted friction surfacing technique is developed which facilitates the impregnation of amorphous materials on the substrate through friction surfacing.
Industrial Application
Hardfacing of the knife by FS
Publications
LinkQuick Links
- Email: abhi.foundry[at]iitkgp.ac.in
- Research Gate
- Google Scholar
Dr. Debasish Mishra
×Supervisor
Prof. Surjya K PalDoctoral Research Problem
Industry 4.0 based, monitoring and control of friction stir welding processResearch Statement
Applying digitization techniques to FSW is expected to improve the overall quality of the process. Integrating the machine with several sensors will provide a set of values of physical parameters which could be analyzed to monitor the process in real time and control it as required.
Publications
LinkQuick Links
- Email: debsmishra02[at]gmail.com
- Research Gate
- Google Scholar
Dr. Vyas Mani Sharma
×Supervisor
Dr. Vikranth RacherlaProf. Surjya K Pal
Doctoral Research Problem
Fabrication of open-celled copper foam using friction sinteringResearch Statement
Metal foams have received considerable attention due to their low density, high strength to weight ratio, large compressive deformations at constant flow stress, high gas permeability, and large surface area. Sintering and dissolution process (SDP), sintering with blowing agents, direct gas blowing, sintering with hollow spheres, reaction sintering, investment casting, etc., can be used to create metal foams. While most methods listed above result in closed-cell foams, SDP results in open-cell foams. While closed-cell foams are used in structural applications, open-cell foams are used in the heat exchanger, sound absorption, catalysis, boiling, and filtration applications. Metal foam can be fabricated on a friction stir welding machine using friction sintering process.Industrial Application
Multifunctional heat exchanger (University of Virginia)
Ref:https://www2.virginia.edu/ms/research/wadley/thermal-management.html
Publications
LinkQuick Links
- Email: vyasmani742014[at]gmail.com
- Research Gate
Dr. Omkar Mypati
×Supervisor
Prof. Surjya K PalDr. Prakash Srirangam (WMG, UK)
Doctoral Research Problem
Fabrication of electronic components by friction stir welding in the Li-ion battery packsResearch Statement
With the increasing rate of pollution and globalization, industries are adopting innovative technologies that can be probable solutions towards these concerns. Electric vehicles (EVs) are one such example among these innovations. EVs consist of powerful batteries consisting of micro-thickness tabs and interconnected with busbars. They are intended to obtain a high current source by means of these battery packs. Copper (Cu) and aluminum (Al) are two such metals which are being widely used in this area owing to their high thermal conductivity. The joining of this sheets through conventional fusion welding techniques will not be feasible because of the high amount of temperature involved with these methods. Hence, advanced solid state welding techniques i.e. friction stir welding (FSW) was emerged. Thus, research on µ-friction stir welding (µ-Friction Stir Welding) process was become a necessity. As these materials (Al-Cu) have similar FCC crystal structure, it is very difficult to examine the diffusion mechanisms, so a molecular dynamics study is a potentially useful approach to studying the joining mechanisms.Industrial Application
Battery cells and packs with electrode tabs for electric vehicles
Ref:https://link.springer.com/article/10.1007/s40430-018-1542-5
Publications
LinkQuick Links
- Email: omkar.mypati[at]gmail.com
- Research Gate
- Google Scholar
Dr. Abhijit Sadhu
×Supervisor
Prof. A K NathProf. Surjya K Pal
Doctoral Research Problem
Development of tools for friction stir welding of high melting point materials using direct metal laser deposition techniqueResearch Statement
Friction stir welding (FSW) is a solid state welding process originally developed for joining of low melting point alloys like Al & Mg alloys, which are otherwise difficult to be joined by the conventional fusion welding processes. Further, it offers superior property in the welded joints as it does not involve melting. This inspired extending the application of FSW to high melting point materials like Cu, Fe, Ti and their alloys. One of the major problems of FSW of these materials is the tool wear. This necessitates the development of tool materials having high strength, toughness and wear resistance at elevated temperatures. One possible solution could be the coated tools having hard coating on tough base material. H13 tool steel is one of the most commonly used tool material in FSW of low melting point materials like Al and Mg alloys. However, high temperature involved during FSW of high strength and high melting point materials like Cu alloys leads to increased tool wear. Therefore, the current study focuses on direct metal laser deposition (DMLD) of Stellite-6, a hardfacing alloy having high temperature wear resistance property on H13 tool steel for the fabrication of tools for friction stir welding of copper alloys.Indusrial Application
Cost reduction in FSW of high melting point materials like copper alloys through enhancement of tool life by Direct Metal Laser Deposition
Ref:http://www.iter.org
Publications
LinkQuick Links
- Email: sadhu.abhi4all[at]gmail.com
- Research Gate
Md Perwej Iqbal
×Supervisor
Prof. Surjya K PalDr. Parthasarathi Mandal (The University of Manchester, UK)
Doctoral Research Problem
Development of an integrated thermo-mechanical and metallurgical model of friction stir welding of pipesResearch Statement
Friction stir welding (FSW) has been successfully used to weld materials in various joint configurations such as butt, lap, and T, and recently it is being employed for joining of pipes. Industries like thermal power, hydro power, petroleum refineries, smelting plants, and rolling industries use pipelines for transportation of various fluids. There is an emerging need for establishing proper installation methodology and working of these pipes. The fabrication of these pipes is mostly being performed by using the fusion welding techniques, however, making use of FSW to fabricate them will not only be cost-effective but also will be environmental friendly. Further, an integrated thermo-mechanical and metallurgical model for FSW of pipes will be useful to predict various thermal properties such as strain, strain rate, temperature of the weld, mechanical properties such as force, torque, and metallurgical properties such as distribution of grain boundary, average grain size etc. In addition to the above, making use of modeling techniques prior to experiments optimizes the process, and increases the amount of process innovation.Industrial Application
FSW can be directly implement to join the aluminum tubular bus-bars for HV substations and pipelines industries
Ref:https://www.123rf.com/stockphoto/pipe_welding.html?sti=ljt4ct9kw1yq24im9s|&mediapopup=33311652
Publications
LinkQuick Links
- Email: iqbal.iitkgp[at]gmail.com
- Research Gate
- Google Scholar
Dr. Debolina Sen
×Supervisor
Prof. Surjya K PalDr. Sushanta K Panda
Doctoral Research Problem
Fabrication of friction stir welded aluminium tubes and their formability performanceResearch Statement
Tubular components made of aluminium are widely used as structural components in automobile and aerospace industries because of its low cost, higher energy absorption capability and better corrosion resistance. The tubular components can be manufactured by extrusion as well as different welding processes. The extrusion process is very expensive and is limited to fabrication of small diameter tubes. Hence for manufacturing tubes with large diameter to thickness ratio, welding is the possible solution. Fusion welding techniques create a lot of detrimental intermetallics and defects in the joints thus decreasing the quality of the tubes. Friction stir welding (FSW) process is an advanced welding technique where the welding takes place in its solid state i.e. without melting. Hence the joint formed is near to homogeneous in nature which enhances the joint properties and quality of the tubes. Tubular components which are employed in critical areas, needing good mechanical and metallurgical properties and can withstand failure can be manufactured by FSW. FSW of curved surfaces has got many challenges. Thus the objective of this research is to successfully weld tubular components using FSW process and study the forming properties of the welded tubes.Industrial Application
Wheel rims
Ref:https://spinoff.nasa.gov/Spinoff2008/ip_4.html
Publications
LinkQuick Links
- Email: debolinasen90[at]gmail.com
- Research Gate
Dr. Ananta Dutta
×Supervisor
Prof. Surjya K PalDr. Sushanta K Panda
Doctoral Research Problem
Fabrication of Aluminium Honeycomb Sandwich Structure using Friction Stir WeldingResearch Statement
Objective of this work is to manufacture aluminium honeycomb sandwich panel using corrugation forming and Friction Stir Welding processes. This work aims to reduce the possibility of damages like core collapse, interface debonding etc. due to manufacturing errors. To make this process well-suitable for industrial implementation to fabricate aluminium honeycomb panels in a cost-effective and time-efficient way is the key target of this work.Industrial Application
High speed train body
Ref:http://aluminium-honeycomb-panels.com/news/Application-of-Aluminium-Honeycomb-Panel.html
Publications
LinkQuick Links
- Email: ad26[at]iitkgp.ac.in
- Google Scholar
- Research Gate