Amit AroraIndian Institute of Technology Gandhinagar · Faculty of Materials Engineering
Amit Arora
PhD, The Pennsylvania State University
On sabbatical at University of North Texas, Denton.
About
65
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Introduction
Amit Arora currently works as Associate Professor of Materials Engineering, Indian Institute of Technology Gandhinagar, India. Amit does research in Materials Engineering and Manufacturing Engineering. Their most recent publication is 'Towards attaining dissimilar lap joint of CuCrZr alloy and 316L stainless steel using friction stir welding'.
Additional affiliations
January 2024 - December 2024
November 2011 - June 2021
March 2014 - September 2014
Education
August 2006 - September 2011
May 2004 - May 2005
July 2000 - May 2004
Publications
Publications (65)
4D printing refers to the additive manufacturing of a component by incorporating smart materials. The smart materials add the "4th dimension" to 3D-printing by altering the shape/functionality/configuration of the part in response to external stimulus such as heat, stress, pH, electric field, etc. In the current study, shape memory alloy (SMA) plug...
Mastication is an essential and preliminary step of the digestion process involving fragmentation and mixing of food. Controlled muscle movement of jaws with teeth executes crushing, leading towards fragmentation of food particles. Understanding various parameters involved with the process is essential to solve any biomedical complication in the ar...
Low-density polyethene (LDPE) is extensively used in single-end-use food packaging and contributes significantly to global waste plastic. This study addresses this challenge by introducing a sustainable approach to reclaim and valorise waste LDPE from milk packaging by converting them into 3D printing filaments. The process involves extruding shred...
The fabrication of compact heat exchangers with precisely designed micro- and mini-channels is crucial for enhancing the efficiency of thermal management systems. Friction stir channeling (FSC) emerges as a cost-effective advanced manufacturing process to create complex integral channels, offering channel shape and size flexibility. This review art...
Using the multi-principal element based high entropy alloy (HEA) concept, single-step ultra refinement and solid-state alloying of Cu with NiTi, Y, Fe, Cr, and Co were achieved simultaneously for the first time via friction stir processing (FSP). A bimodal microstructure with an average grain size smaller than 1.5 μm was attained. The microstructur...
The present study aims at identifying the critical Reynolds number for transition from laminar to turbulent in irregular shaped mini-channels. Numerical study including conjugate heat transfer and axial conduction is carried out using commercially available software ANSYS Fluent®. The channel of length 105 mm, width 4.5 mm, and height 2 mm is fabri...
The effect of energy density on different mechanical, microstructural and surface properties was examined for laser powder bed fusion of additively manufactured stainless steel 316L (AM SS316L). The energy density was varied by changing laser power from 80 to 180 W to print AM SS316L samples. The investigations include various mechanical tests and...
The spouted fluidized bed process is a multiphase heat and mass transfer flow. The process requires effective solid-gas and solid-solid interaction. Various numerical models have been developed to understand and optimize these interactions. However, most of these models have used spherical particle definition, whereas the actual particles are non-s...
Iron has been one of the most critical technotraditions that had lasting impact on social formation throughout the Iron Age and historical period. Iron was used in warfare and subsistence economy. Our knowledge on ancient iron smelting and working have generally been derived from ethnography and ethnohistory, which is by all means, time, region, an...
High-strength alloys can be efficiently welded utilizing laser beam welding because of their attributes, such as minimized fusion, heat-affected zone extensions, and minor deformation. Computational study of the laser material interaction process assists in analysing numerous process variables and their effect, which is challenging experimentally....
Direct ink writing (DIW) additive manufacturing is a versatile 3D printing technique for a broad range of materials. DIW can print a variety of materials provided that the ink is well-engineered with appropriate rheological properties. DIW could be an ideal technique in tissue engineering to repair and regenerate deformed or missing organs or tissu...
Achieving a specific solidification morphology during the directed energy deposition process can be key to desired properties of the deposited part. The careful control of thermal gradient and cooling rates can be utilized to achieve these grain morphologies. The heating of the build platform and post-deposition heat treatment are two ways in which...
In a 3D printed polymer composite, the orientation of the reinforcement, distribution, and porosity plays a major role in its mechanical properties. Here, we demonstrate a precise control of the orientation of the reinforcement by varying different printing conditions such as nozzle diameter and flow rates. The experimental observation reveals a di...
In the present scenario, global concern about the preservation of environment creates a necessity to mature more ecological manufacturing processes. In this context, cryogenic coolants i.e., liquid nitrogen (LN 2) and liquid carbon dioxide (LCO 2) are proved to be the prominent alternatives to conventional carbon-based flood coolant pollutants. How...
Low-density polyethylene (LDPE) is a soft thermoplastic with extensive application as a packing material such as plastic bags, dispensing bottles, milk pouches, etc. Many LDPE bags are used and dumped in landfills every year, leading to millions of tons of persistent waste. In addition, the recycling of LDPE is of no commercial interest due to its...
Continuous wave laser polishing is a promising technique for post-built smoothening of rough metallic surfaces produced by additive manufacturing. In laser polishing, a laser source melts a thin surface layer and redistributes the material resulting in a reduction of surface roughness. This paper develops a first principles-based three-dimensional...
The temperature distribution, geometry and size of the melt pool, and solidification parameters were computed using the heat transfer and material flow model for the directed energy deposition process. The thermal cycle and melt pool size were computed for different process parameters such as laser power, deposition speed, and laser beam radius acr...
Electron Beam Melting (EBM) is an emerging additive manufacturing technique for the fabrication of titanium alloy Ti-6Al-4V for orthopedic applications. Here, a hybrid manufacturing technique viz. EBM with Friction Stir Processing (FSP) has been proposed to enhance implant surface properties. The surface modification using FSP reduces the roughness...
Aluminum alloys find application in aerospace, automobile, and structural sectors. However, these alloys are susceptible to corrosion attack in chloride environments. Introducing a second species on the surface by surface composite fabrication can be a way to increase the corrosion resistance of the aluminum alloys. Here, we present corrosion studi...
There have been claims of early use of high-carbon steel in South India. Still, the antiquity, elemental composition and steelmaking process have not been explored adequately. The high carbon steel was known in the Iron Age or early historical period. However, the large-scale use of such steel was prevalent only in the medieval times. This article...
Many microslits are typically manufactured on quartz substrates and are used to improve their industrial performance. The fabrication of microslits on quartz is difficult and expensive to achieve using recent traditional machining processes due to its hardness, electrically insulating nature, and brittleness. The key objective of the current study...
Most aero-engine components and structures are subjected to life critical fatigue loads during service. Near-α titanium alloy IMI 834 is one candidate aero-engine material that is used as high-pressure compressor discs due to its superior fatigue strength and creep resistance. The effect of heat treatment on the microstructure and high-cycle fatigu...
There have been claims of early use of high-carbon steel in South India. Still, the antiquity, elemental composition and steelmaking process have not been explored adequately. The high carbon steel was known in the Iron Age or early historical period. However, the large-scale use of such steel was prevalent only in the medieval times. This article...
Polymer and polymer matrix composite materials are used in automotive applications owing to the high strength-to-weight ratio. However, the joining of polymer matrix composites is a challenging task due to the lower melting temperature, lower thermal conductivity, and agglomeration of reinforcements during fusion welding of these materials. Frictio...
Molybdenum-reinforced aluminum matrix surface composites have been fabricated using friction stir processing. The Mo reinforcement results in an increase in the hardness and a decrease in the grain size. The Mo particle size and its dependence on the tool rotational speed are important for fabrication of high-performance composites. However, the ef...
The study focuses on the effect of mono and combined addition of metallic and ceramic reinforcement particles on the microstructural and corrosion behavior of surface composites fabricated by friction stir processing. Molybdenum, possessing higher corrosion resistance compared to aluminum, is used as the metallic reinforcement, and boron carbide is...
Integral mini-channels fabricated in the metal substrate by friction stir channeling process are different from conventional mini-channels due to irregular shape, and large surface roughness. The effect of axial wall conduction on heat transfer in such mini-channels is significant, which could limit their utilisation as cooling channels in heat tra...
Composites have played a key role in revolutionizing the automobile, marine, and aerospace industries. There is a constant attempt for the development of low‐density composite materials with superior mechanical and corrosion‐resistant properties for elevated temperature applications. Herein, an attempt is made to develop a nature‐inspired unique al...
In this era, advanced non-conducting materials are gaining importance due to their superior properties. However, it is difficult to micro-machine these materials inefficiency and also economically still persists with currently used advanced non-traditional machining processes. Non-traditional machining processes are typically unfeasible for quartz...
A heat transfer numerical model is developed for friction stir welding of dissimilar materials Al 6061 and AZ31 alloy. Thermo-physical properties were experimentally determined for the stir zone and compared with the base alloys. Experimentally determined thermo-physical properties of the stir zone are not strictly the average values of the base al...
Additive manufacturing of titanium alloy Ti-6Al-4 V has significantly increased over the past few years, primarily due to its broad application over the conventional manufacturing process for complex and near net shape
production. However, difficulties arise while printing complex and huge structures and therefore, the components need a suitable jo...
Molybdenum (Mo), possessing higher hardness compared to aluminum (Al), is used for the surface hardness improvement in Al 1050 alloy. Al-Mo surface composites are developed using friction stir processing with different tool shoulder diameters. Single groove composite (SGC) and double groove composite (DGC) samples are processed with 22-, 20-, and 1...
The microstructure and corrosion behavior of as-cast and friction stir processed in-situ Al−TiB2 based composite in 3.5 wt.% sodium chloride solution were investigated. The microstructure was characterized using X-ray diffractometry, scanning electron microscopy and electron backscattered diffraction technique while corrosion behavior was evaluated...
In this study, an experiment is performed to investigate material flow and its implication on the channel formation in friction stir channeling process. X-ray Computed Tomography in combination with optical microscopy is used to analyse bulk material flow, geometry and various features of the fabricated channel. In addition, X-ray Micro Computed To...
High thermal and electrical conductivities, corrosion resistance and relatively good strength lead to use of copper and its alloys for several engineering applications. Copper alloys also find application in the nuclear industry for manufacturing storage canisters for spent nuclear fuel. Conventional fusion welding of copper and its alloys is diffi...
Joining different parts is one of crucial component of designing/engineering of materials. To current energy efficient low weight automotive and aerospace components are consisting of different class of materials such as metal, polymer and ceramics etc. Joining these component remains a challenge. Here, we demonstrate joining of metal (alumunium) a...
CuCrZr alloy (Cu-0.8wt-%Cr-0.1wt-%Zr) and 316L stainless steel (Fe-0.03wt-%C-16wt-%Cr-10wt-%Ni) plates were successfully friction stir lap welded resulting in significant mechanical mixing of the two matrix elements, Cu and Fe, in the stir zone. The severe mixing not only led to improved load bearing response but also leads to form Cu-rich and Fe-r...
Friction stir welding (FSW) of high melting point metallic (HMPM) materials has limited application due to tool wear and relatively short tool life. Tool wear changes the profile of the tool pin and adversely affects weld properties. A quantitative understanding of tool wear and tool pin profile is crucial to develop the process for joining of HMPM...
Eglin steel, an ultra-high-strength steel developed for various demanding applications, is a low-cost alternative to 4340 steel, in which nickel and cobalt additions are replaced by higher tungsten additions, thereby achieving comparable strength and ductility. Friction stir processing (FSP) was carried out on this steel under two heat input condit...
Eglin steel, an ultra-high-strength steel developed for various demanding applications, is a low-cost alternative to 4340 steel, in which nickel and cobalt additions are replaced by higher tungsten additions, thereby achieving comparable strength and ductility. Friction stir processing (FSP) was carried out on this steel under two heat input condit...
Joining of high strength materials using friction stir welding (FSW) is difficult due to severe tool wear and change in the shape/size of the tool. However, quantitative understanding of tool wear during FSW of high melting point metallic materials is very limited. Here we present quantitative wear analysis of H13 steel tool during FSW of CuCrZr al...
This paper is on the successful fabrication of Metal Matrix Composite (MMC) using an Aluminium plate and Molybdenum powder by Friction Stir Process (FSP). The aim was to produce a superficial MMC layer on the Al plate in order to increase the mechanical properties of the as received Al plate. A uniform dispersion of Mo particles in the Al matrix wa...
A framework is proposed to explain the dissolution and fragmentation of particles during friction stir welding and processing. Two major mechanisms dissolve the particle during the process: (i) thermally activated diffusion, and (ii) dislocation and grain boundary sweeping of atoms. We use a three-dimensional coupled viscoplastic flow and heat tran...
An assisted heating tool design was used to obtain better weld surface finish, and lower chip formation and material loss during friction stir welding (FSW) of thermoplastics. The welded coupons of polypropylene with various tool rotational speeds were tested under tensile loading to test the efficiency of the tool design. The proposed tool improve...
Tool and workpiece temperatures, torque, traverse force and stresses on the tools are affected by friction stir welding (FSW) variables such as plate thickness, welding speed, tool rotational speed, shoulder and pin diameters, pin length and tool material. Because of the large number of these welding variables, their effects cannot be realistically...
Friction stir welding is not used for hard alloys because of premature tool failure. A scheme is created that exploits th physical three-dimensional heat and mass flow models, and implements them into a fast calculation algorithm, which, when combine with damage accumulation models, enables the plotting of tool durability maps that define the domai...
The most important geometric parameter in the friction stir welding (FSW) tool design is the shoulder diameter, which is currently estimated by trial and error. Here, we report a combined experimental and theoretical investigation on the influence of shoulder diameter on thermal cycles, peak temperatures, power requirements, and torque during FSW o...
Although friction stir welding (FSW) is now widely used for the welding of aluminum and other soft alloys, premature tool failure limits its application to hard alloys such as steels and titanium alloys. The tool pin, the weakest component of the tool, experiences severe stresses at high temperatures due to both bending moment and torsion. It is sh...
Given the complexity and resource requirements of numerical models of friction stir welding (FSW), well-tested analytical models of materials flow, peak temperatures, torque, and weld properties are needed. Here an approximate analytical technique for the calculation of three-dimensional material flow during FSW is proposed considering the motion o...
Currently friction stir welding tools are designed by trial and error. Here we propose and test a criterion for the design of a tool shoulder diameter based on the principle of maximum utilization of supplied torque for traction. The optimum tool shoulder diameter computed from this principle using a numerical heat transfer and material flow model...
Structure and properties of steel welds are affected by their cooling rates in the 800 to 500°C range. The available cooling rate correlations are based mostly on heat conduction equation that ignores convective heat transfer and are inaccurate or empirical in nature and valid only for a limited range of welding conditions. Numerical heat and fluid...
Strains experienced by materials during friction stir welding (FSW) are important but scarce in the literature. Here we report the computed strains and strain rates during FSW of AA2524 from a three-dimensional coupled viscoplastic flow and heat transfer model. The strain rates are integrated along a streamline to estimate the accumulated strains e...
Investigations of heat transfer and fluid flow in the weld pool have become increasingly more realistic and useful in recent years because of advances in computational hardware and software. The goal of this paper is to provide an outline of the major impact of convective heat transfer calculations in advancing welding science and technology and th...
The torque, power requirement and stir zone geometry during friction stir welding of AA2524 aluminum alloy were modeled by solving the equations of conservation of mass, momentum and energy. The model predictions agreed well with the corresponding measured values for a wide range of welding speeds and tool rotational speeds when the heat transfer c...
The geometry of a weld pool affects its solidification behavior. Here we show that the welding parameters and material properties responsible for the formation of unusual, wavy fusion boundaries can be identified from heat and fluid flow calculations and confirmed by independent experiments. These parameters and properties can be expressed by dimen...