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My research interest centers on advanced manufacturing and materials processing while addressing both fundamental questions and technological & societal impacts. It combines theoretical insights with practical applications, with scientifically relevant problems, emphasizing interdisciplinary collaborations and perspectives.
Below are the brief thematic outline, scope and objectives of research topics:
1. Metal additive manufacturing: data-driven smart AM system, active process monitoring & control, energy-efficient alternate powders
Commercial AM systems presently offer little scope for fully customized instrumentation, making comprehensive process monitoring challenging. A more pressing difficulty lies in the inflexible architecture, restricted to expensive/limited material powders. Therefore, powder production of a specific alloy or emerging alloys in lieu of existing routes, and their processability for AM (using modular systems) can provide a wider solution.
Our research has paved the way for exploring alternate, inexpensive, and versatile routes to make metal/ ceramic powders based on solid-state abrasion[1][2]. These results have shown promises and have applications for making powders more efficiently and independent to material system. It also offers a solution to “powder bottleneck” issue in parlance to global AM industry, particularly to new and emerging alloys such as refractory-based superalloys & HEAs, and electrode materials for growing EV sector. In addition, the possibility of developing a state-of-the art AM system with flexing design architecture would provide a sustainable solution to AM acceptance in medium to small manufacturing sectors. Further, it can contribute towards industry 4.0 by enabling with IoT and AI/ML based process monitoring and decision-making to improve overall effectiveness/ efficiency.
2. Solidification dynamics: microstructure evolution during non-equilibrium cooling and growth of metals
Liquid metal solidification and growth exhibit a diverse array of intriguing morphologies. Given their fundamental implications in manufacturing processes such as metal 3D printing, casting and powder metallurgy, understanding their evolution during rapid solidification remains a subject of active investigation. Recent interest in EV batteries has fetched the attention to investigate this phenomenon.
Our work on phenomenological modeling of solidification in confined geometries such as spheres under homogeneous conditions using metal-analog organic materials has proved an innovative approach. It has far-reaching implications from in situ observations of microstructural development in metal AM to the morphological evolution in battery electrodes on the other [3] [4] . It poses an interesting multi-physics problem which can be studied by applying principles from thermodynamics, heat transfer and fluid mechanics coupled with experimental and numerical tools.
3. Surface mechanics in materials processing: leveraging chemo-mechanics, emergence of surface roughness
Processing materials with high strain-rate coefficient such as Al, Fe, Ni, Nb, Ta etc. are difficult despite being soft due to their unsteady mode of deformation resulting in residual surface strain, crack-like defects and roughness. Being structurally relevant materials, it is intriguing to investigate and find the solution to such issue.
Our ongoing research work has demonstrated the possibility of altering surface properties by leveraging mechanochemical effect during deformation. Preliminary results ushered the investigation by in situ observations during bending cracks dynamics under surface adsorbed monolayers. It has practical applications in semiconductor and MEMS industries. Further, the idea can be implemented to study and alter the surface roughness evolution in diverse range of material processing techniques from “single-event addition” like AM to “multi-event subtraction process” like grinding, milling etc[5] .
4. Mechanics of architected materials: materials for targeted and extreme conditions
Geometrically and microstructurally designed materials like meta-materials, cellular and topologically ar chitected materials poses significant demand in aerospace, energy, construction and biomedical sectors due to their tailored properties.
Our preliminary work had demonstrated the possibility of printing structures with targeted properties and their performance under extreme conditions[6] . We plan to envisage exploring the potential by designing using date-driven computational tools and ma ufacturing structures with tailored mechanical, electrical and magnetic properties using AM. Such materials have applications from aerospace structures, damage tolerant & shielding to microelectromechanical systems (MEMS) devices. The research can also be relevant in making efficient battery electrodes design to cater the need of emerging EV demand.
5. Recycling, remanufacturing, and sustainability: processing metal matrix composites (MMCs), natural materials for social good
Metallic or machining byproducts have become a potential environmental threat in recent times due to rapid industrial and consumer growth. Exploring alternate recycling methods is believed to play a crucial role in addressing solid waste management via innovative solutions, contributing towards the national carbon-neutrality goals. Also, processing biodegradable natural materials for applications such as water purification/ desalination can be another avenue.
Our works on preparation and processing of MMCs using machining/ grinding-based metal chips using laser/ conventional sintering or injection molding has the potential to address the concerning sustainability/circularity in manufacturing[7] . It can be a promising way to process such metallic waste to make products for low-end applications with the addition of reinforcement[8] . Work on bio-fiber based composites has shown potential for water filtration applications, which can significantly reduce the non-degradable plastic waste.
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