Pravansu S. Mohanty

Modelling of high-density laser-material interaction using fast level set method

A high-energy-density laser beam-material interaction process has been simulated considering a self-evolving liquid-vapour interface profile. A mathematical scheme called the level-set technique has been adopted to capture the transient liquid-vapour interface. Inherent to this technique are: the ability to simulate merger and splitting of the liquid-vapour interface and the simultaneous updating of the surface normal and the curvature. Unsteady heat transfer and fluid flow phenomena are modelled, considering the thermo-capillary effect and the recoil pressure. A kinetic Knudsen layer has been considered to simulate evaporation phenomena at the liquid-vapour interface. Also, the homogeneous boiling phenomenon near the critical point is implemented. Energy distribution inside the vapour cavity is computed considering multiple reflection phenomena. The effect of laser power on the material removal mode, liquid layer thickness, surface temperature and the evaporation speed are presented and discussed.

Multiple reflection and its influence on keyhole evolution

In laser drilling and keyhole welding, multiple reflection phenomena determine how the energy is transferred from the laser beam to the workpiece, and, most importantly, all other physics such as fluid flow, heat transfer, and the cavity shape itself depend on these phenomena. In this study, a multiple reflection model inside a self-consistent (or self-evolving) cavity has been developed based on the level set method and ray tracing technique. In the case of drilling, it is observed that the laser energy tends to concentrate near the center, where the effective intensity reaches a value two orders of magnitude higher than the original distribution. In keyhole welding, however, the maximum laser intensity is only around five times higher than the original during the entire process. Combined with the strong keyhole fluctuation, the redistributed intensity patterns are very dynamic. The intensity fluctuation drives the keyhole fluctuation, and the keyhole fluctuation, in turn, affects the intensity fluctuati...

Synthesis and characterization of Na0.44MnO2 from solution precursors

A simple, straightforward and less time consuming thermo-chemical conversion process was used to prepare submicron to micron size platelet/bar shaped single crystal powders of Na0.44MnO2 cathode material from an aqueous based solution precursor. Electrochemical characterization indicated a specific capacity close to the theoretical value (122 mA h g−1) with excellent cyclability.

A Numerical Method for Multiphase Incompressible Thermal Flows with Solid–Liquid and Liquid–Vapor Phase Transformations

ABSTRACT A numerical method for multiphase incompressible thermal flows with solid–liquid and liquid–vapor phase transformations is presented. The flow is mainly driven by thermocapillary force and vaporization. Based on the level set method and mixture continuum model, a set of governing equations valid for solid, liquid, and vapor phases is derived, considering phase boundary conditions as source terms in the transport equations. The vaporization process is treated as a source term in the continuity equation. The model developed is applied to the laser welding process, where the flow is coupled with optical phenomena. Formation and collapse of a laser-created hole is simulated.

Morphology and properties of poly vinyl alcohol (PVA) scaffolds: Impact of process variables

Successful engineering of functional biological substitutes requires scaffolds with three-dimensional interconnected porous structure, controllable rate of biodegradation, and ideal mechanical strength. In this study, we report the development and characterization of micro-porous PVA scaffolds fabricated by freeze drying method. The impact of molecular weight of PVA, surfactant concentration, foaming time, and stirring speed on pore characteristics, mechanical properties, swelling ratio, and rate of degradation of the scaffolds was characterized. Results show that a foaming time of 60s, a stirring speed of 1,000 rpm, and a surfactant concentration of 5% yielded scaffolds with rigid structure but with interconnected pores. Study also demonstrated that increased foaming time increased porosity and swelling ratio and reduced the rigidity of the samples.

Synthesis and Microstructural Evolution of Amorphous/Nanocrystalline Steel Coatings by Different Thermal-Spray Processes

Amorphous/nanocrystalline coatings are useful in high strength and wear-resistant applications. In the present study, the microstructural evolution of a nanocrystalline high performance steel coatings developed by different spray processes along with a novel “hybrid thermal spray” technique was studied. The hybrid-spray process combines arc and high-velocity oxy-fuel (HVOF) techniques, in which the molten metal at the arcing tip is atomized and rapidly propelled toward the substrate by HVOF jet. This so-called hybrid concept offers the benefits of productivity of electric arc spray combined with improved coating densities of HVOF. The microstructural characterization of the hybrid-spray coatings was performed by x-ray diffraction, electron microscopy, and differential scanning calorimetry, and then compared with coatings of the similar material developed by plasma-, HVOF-, and arc-spray processes individually. The HVOF- and plasma-spray coatings showed amorphous structures with very fine nanocrystals embedded, whereas hybrid- and arc-spray techniques yielded completely crystalline coatings with grain size in the range of several nanometers. The final microstructures in different spray processes could be attributed to the precursor materials employed, process temperatures, and cooling rates during the deposition process.

Robust uniform triangulation algorithm for computer aided design

This paper presents a new robust uniform triangulation algorithm that can be used in CAD/CAM systems to generate and visualize geometry of 3D models. Typically, in CAD/CAM systems 3D geometry consists of 3D surfaces presented by the parametric equations (e.g. surface of revolution, NURBS surfaces) which are defined on a two dimensional domain. Conventional triangulation algorithms (e.g. ear clipping, Voronoi-Delaunay triangulation) do not provide desired quality and high level of accuracy (challenging tasks) for 3D geometry. The approach developed in this paper combines lattice tessellation and conventional triangulation techniques and allows CAD/CAM systems to obtain the required surface quality and accuracy. The algorithm uses a Cartesian lattice to divide the parametric domain into adjacent rectangular cells. These cells are used to generate polygons that are further triangulated to obtain accurate surface representation. The algorithm allows users to control the triangle distribution intensity by adjusting the lattice density. Once triangulated, the 3D model can be used not only for rendering but also in various manufacturing and design applications. The approach presented in this paper can be used to triangulate any parametric surface given in S(u,v) form, e.g. NURBS surfaces, surfaces of revolution, and produces good quality triangulation which can be used in CAD/CAM and computer graphics applications.

High-speed visualization and plume characterization of the hybrid spray process

The hybrid spray process that combines arc spray with a high-velocity oxyfuel (HVOF)/plasma jet has recently demonstrated its effectiveness in deposition of functionally gradient coatings. This approach aims at exploiting the combined attributes of the arc-spray technique and the HVOF/air plasma spraying (APS) technique. This paper presents high-speed visualization and plume characterization of an arc/HVOF hybrid spray gun as well as a twin-wire arc-spray gun. The physics of atomization in the hybrid spray process is examined using a high-speed camera. A DPV/CPS-2000 (Tecnar, St-Bruno, QC, Canada) particle diagnostics sensor is used to measure particle velocity, temperature, size, and distribution. The influence of feed material, arc parameters, and HVOF parameters on the particle characteristics is presented. Differences in the in-flight characteristics between the hybrid and the twin-wire arc process are discussed aided by the observed atomization phenomena with the high-speed camera.

Impact of alginate concentration on the viability, cryostorage, and angiogenic activity of encapsulated fibroblasts

Cryopreservation or cryostorage of tissue engineered constructs can enhance the off-the shelf availability of these products and thus can potentially facilitate the commercialization or clinical translation of tissue engineered products. Encapsulation of cells within hydrogel matrices, in particular alginate, is widely used for fabrication of tissue engineered constructs. While previous studies have explored the cryopreservation response of cells encapsulated within alginate matrices, systematic investigation of the impact of alginate concentration on the metabolic activity and functionality of cryopreserved cells is lacking. The objective of the present work is to determine the metabolic and angiogenic activity of cryopreserved human dermal fibroblasts encapsulated within 1.0%, 1.5% and 2.0% (w/v) alginate matrices. In addition, the goal is to compare the efficacy of dimethyl sulfoxide (DMSO) and trehalose as cryoprotectant. Our study revealed that the concentration of alginate plays a significant role in the cryopreservation response of encapsulated cells. The lowest metabolic activity of the cryopreserved cells was observed in 1% alginate microspheres. When higher concentration of alginate was utilized for cell encapsulation, the metabolic and angiogenic activity of the cells frozen in the absence of cryoprotectants was comparable to that observed in the presence of DMSO or trehalose.

Entropy-based associative classification algorithm for mining manufacturing data

This paper presents a new associative classification algorithm for data mining. The algorithm uses elementary set concepts, information entropy and database manipulation techniques to develop useful relationships between input and output attributes of large databases. These relationships (knowledge) are represented using IF–THEN association rules, where the IF portion of the rule includes a set of input attributes features and THEN portion of the rule includes a set of output attributes that represent decision outcome. Application of the algorithm is presented with a thermal spray process control case study. Thermal spray is a process of forming a desired shape of material by spraying melted metal on a ceramic mould. The goal of the study is to identify spray process input parameters that can be used to effectively control the process with the purpose of obtaining better characteristics for the sprayed material. Detailed discussion on the source and characteristics of the data sets is also presented.