Somnath Chattopadhyaya

Indian Institute of Technology(Indian School of Mines University)

Friction surfacing is the most recent technology applied in surface engineering for developing surface materials. It is a solid-state technique employed to coat one material over another material in order to reconstruct the worn-out parts, to enhance protection from ware and corrosion, to develop mechanical features and composite materials.This is...

Energy auditing is crucial for both emerging and developed nations, focusing on aspects such as energy efficiency, quality and intensity. This becomes especially significant in the industrial sector, where major operating costs involve materials, machinery, personnel and energy. A key objective is identifying energy consumption in the Continuous Mi...

A novel approach for zero material loss (zero flash) and uniform cross-section during friction stir welding of dissimilar thickness Cu and Al alloys Sachindra Shankar a,*, Somnath Chattopadhyaya b, Kush P. Mehta c, Pedro Vilaça d a Department of Mechanical Engineering, Anurag University, Hyderabad, 500088, India b Department of Mechanical Engineeri...

Safety in conjunction with production is a reality achieved in underground mining, where roof or side falls can have devastating effects on operations. A precise understanding of the roof structure is crucial for designing effective support systems that mitigate ground-fall risks. A key finding underscores the significance of this understanding. Su...

The study investigates the high-temperature corrosion behaviour of Ni–Al coatings produced by the wire arc spraying technique on ASME SA T23 low alloy ferritic tube weldments prepared by shielded metal arc welding. The oxidation tests were conducted on coated and uncoated base metal and welded specimens at 900 °C. The samples were exposed to three...

The coal mining business is quickly expanding to meet the increasing demand for coal for power plants. They are introducing a variety of intricate and sophisticated equipment for the system’s mechanization and atomization. The mining industry spends a significant amount of money on this equipment. The equipment’s reliability, maintainability, and a...

Tunnel boring machine (TBM) has been in focus for the last few decades and is currently the most preferred excavation method for metro, hydro and irrigation tunnels. Tunnelling in hard and abrasive rock conditions, in particular, is adversely affected by a very low advance rate coupled with increased TBM disc cutter failures and cutterhead jamming,...

Laser-assisted manufacturing has been in the rise for advanced and additive manufacturing purposes. Recently, laser-induced forward transfer (LIFT) has emerged as a highly effective additive manufacturing technique with broad applications, being widely adopted in numerous fields. LIFT being a non-contact, one-step and high resolution , poses to be...

Friction surfacing (FS) is a coating technique inspired by friction stir welding. FS is a solid-state, thermo-mechanical process providing excellent wear and corrosion resistance properties. Frictional heating elevates the temperature of the consumable rotating tool (mechtrode) up to the softening of the material, the tool is traversed along the le...

The growing necessity of large aperture-based structures for many aerospace applications emphasizes the need to deploy large antenna structures in space. The space antennas should be light in weight and have low stowage volume, with efficient membrane packaging. The concept of additive manufacturing has been introduced to reduce weight as well as c...

Aluminum alloys are becoming increasingly popular due to their potential to offer superior durability while being lower in weight. Most industrial sectors, including transportation, aviation, marine, automotive, and others, have a strong interest in light-weight components, particularly in the transportation industry. Traditional joining techniques...

Electronic waste (e-waste is one of the fastest growing waste streams which contains valuable materials such as plastic, glass, and precious metals. This study investigates different recycling methods such as pyrometallurgy, hydrometallurgy, and bio-metallurgy process used to recover precious metals such as Au and Ag from e-waste based on the infor...

The preparation and characteristics of nanosheets mixed dielectric. Also, the machining performance is compared at different concentrations of nanosheets in the dielectric medium with conventional EDM. CTB and SDS surfactants are used for suspension and machining efficiency characterization. The addition of Nanosheets into deionized water improves...

The cold spraying, a solid-state deposition phenomenon relates to one of the thermal spray coating. It is an innovative coating technology mainly based on metals and ceramic particle's high-speed impact on different substrates in which solid powders are propagated towards a substrate. It is one of the promising technologies offering several technol...

Thin sheets of Ti-6Al-4V alloy of thickness 1 mm were butt welded using a pulsed Nd-YAG low-power laser setup. The goal of this research is to explore the influence of pulsation on the microstructure and mechanical properties. In addition to that, annealing at different temperatures has been performed to compare the results of pulsation and heat tr...

Acoustic emission (AE) evaluation is an important Nondestructive Testing technique. The technique is a whole field passive technique that detects defects that are growing during the application of force on the structure. At a certain threshold, AE starts emanating from the structure while the structure is stressed by tensile deformation. 18% Ni Mar...

In the present competitive landscape industry, individuals have emphasized fulfilling the consumer needs in available resources and limited constraints. However, the industry individuals face several problems in achieving operational efficiency. These problems include ergonomics issues, environmental waste, work processes waste, inobservance on the...

In this paper, three kinds of Ni–20Cr coatings were deposited on SA516 substrate steel by cold-sprayed coating technique. Physical properties (such as hardness, surface roughness, and residual stress) and slurry erosion behavior (with impingement angles of 30 ∘ and 90 ∘ ) of cold-sprayed substrates have been evaluated. Moreover, a scanning electron...

In the dynamic trend of production shop floor management, management team members are focusing to develop a novel model to control operational performance in industry 4.0. Several approaches are used in the present scenario to control operational performance, includes lean manufacturing, smart manufacturing, kaizen, digitalization, etc. The main ob...

In this work, a highly carbonated liquid has been utilized as a dielectric medium in the EDM process. The effect of the dielectric medium has been investigated and then, finally, compared with EDM oil. The outcomes have demonstrated that discharge energy density has escalated to fierce-extent, thus, removing a voluminous amount of material from the...

In the rapidly growing modern technology era, eco-friendly manufacturing technology is needed for the sustainable growth of society. Friction stir welding (FSW) is a joining technique that can be used to join lightweight materials like aluminum and magnesium alloys that can reduce the weight of automobile, aircraft and military vehicles to curb fue...

The present work deals with improvement of mechanical properties and refining the microstructure of low carbon steel (0.2%-C) after applying heat treatment techniques. For the purpose, five different samples were taken under study. First sample was kept in ‘as received’ condition and other four samples were undergone into heating process in an Indu...

Mold breakout is one of the significant problems in a continuous casting machine (caster). It represents one of the key areas within the steel production facilities of a steel plant. A breakout event on a caster will always cause safety hazards, high repair costs, loss of production, and shutdown of the caster for a short while. In this paper, a lo...

Affordable access to energy and power is vital for economic and human development, industrialization, and poverty alleviation. Over 20% of South Asia's population does not have access to power, resulting in immense economic growth and prosperity deprivation. The limited endowment of locally available energy resources; varied financial and technolog...

Globalization needs close collaboration in economic, social, political, cultural, education, and research to enhance collaborative socio-economic development, conservation of the environment, and transfer of knowledge and technology innovation across the continents. Cross country, intra-continental, and intercontinental research collaboration and r...

Dissimilar metals joining different alloys, thermoplastic and composites is a challenging task due to their dissimilar characteristics and material incompatibility. Friction Stir Welding (FSW) is a kind of fabrication method, which joins material below its melting point and emerges as an advanced technique for the welding of similar/dissimilar meta...

A limited amount of fossil fuel is not a sustainable solution for growing energy demand. Developing countries like Bangladesh face major challenges in meeting the energy demand of the countries that are being increasing day to day. This work aims to design and optimize a sustainable and cost-effective hybrid energy system for a rural area in Bangla...

Friction Stir Welding (FSW) is an eco-friendly solid-state fusion process that can be used to join two similar or dissimilar (different) materials which require strenuous effort to join by conventional welding processes. Friction Stir Welding (FSW) plays a vital role over conventional welding processes due to no hazardous fumes, less wastage, and l...

Solid-state welding refers to the joining of similar and dissimilar materials below their melting temperature. In this process, the weld formation occurs due to the intermolecular diffusion in which the interface molecules of workpieces flow from higher concentration regions to lower concentration regions due to applied pressure. The joints assembl...

The properties of the material surface are developed by different mechanical processes. Shot peening is used to develop compressive stress in the surface of the material and thereby improve fatigue life, hardness, and resistance due to stress corrosion of the material without changing the material composition. The surface is also modified by carbur...

The impact of single-slope solar still with and without flat-plate collector was evaluated experimentally and numerically. Experimental analysis was conducted for four different water depths (3, 6, 9, 12 cm) in on-sunshine hours between 11 AM to 5 PM in Bhopal (23.2599° N, 77.4126° E), India. The thermo efficiency was 51.31% for 3 cm water depth wh...

The extreme heat input in the submerged arc welding (SAW) process can result in significant heat affected zone. This can be controlled by limiting the heat input, say by using a shielding plate. The superior properties of Monel 400 have wide range of applications where corrosion is a concern. In this work, mild steel plates are welded with Monel 40...

The extreme heat input in the submerged arc welding (SAW) process can result in significant heat affected zone. This can be controlled by limiting the heat input, say by using a shielding plate. The superior properties of Monel 400 have wide range of applications where corrosion is a concern. In this work, mild steel plates are welded with Monel 40...

Temperature changes have significant effects on rock properties. The changes in properties vary for different rocks with different temperature ranges. Granite is an igneous type of rock that is common in India and is frequently used for construction and domestic purposes. Granite is mainly composed of quartz and feldspar and shows a considerable re...

Drilling Electro Chemical Discharge Machining (D-ECDM) Process is a new thermal based non-conventional machining process, having potential to machine electrically non-conductive hard and brittle materials by using a rotating tool electrode. In D-ECDM process the repeated piercing of rotating tool the terminal having ECD (electro Chemical discharge)...

Surface mining is the world's most costly industry due to its enormous expenses. Reduced production is forcing mining companies to automate their equipment, predominantly heavy earth mining machinery (HEMMs), for example, dump trucks, shovels, and dozers. The backbone of pit mining is the crawler dozer, commonly known as a dozer. Crawler dozers are...

It is about reliability and maintainability of Heavy Earth Moving equipment

In recent days, the utilization of lightweight alloys for various applications has been increased massively. Starting from the automobile industry, aerospace industry, and even in the biomedical field, there is a need for dissimilar precise joining of steel to other light alloys (magnesium alloy, aluminum alloy, titanium alloy). However, those allo...

“External magnetic-field (EMF)” has been proved as an additional process parameter like voltage and current affecting the weld arc form, molten metal-flow, microstructure, and characteristics of the weld joint. This article analyzed the research work that has been done to promote EMF application in welding and discussed the recent development trend...

In this work, a three-dimensional (3D) time dependent finite element method is used to simulate the thermo-mechanical behavior of laser welded joints. Laser welding of two dissimilar materials (AISI 316L and Ti6Al4V) of 2 mm thickness has been considered while modeling in COMSOL multiphysics with a coupling of heat transfer and solid mechanics modu...

This paper presents analysis and comparison into mechanical behaviour and microstructural attributes of postweld heat-treated AISI 1020 (0.21%-C) plates joined by the shielded metal arc welding (SMAW) process. The purpose of this work is to heat the welded samples uniformly so that a possible formation of austenite can be obtained, and hence, resid...

The present work deals with analysis of mechanical performance and microstructural appearance of quenched and tempered SS-304 welded joints made by MIG welding technique. Since welding involves a critical solidification and thereby lots of internal stresses. Hence, heat treatment becomes important for removing stresses. In the present work, two SS-...

Underground mining is a difficult area for miners to work. Miners must go to the working faces by walking, which is not only time consuming but also physically demanding. In mines, a man-rider chair lift system (MRCL) has been developed to alleviate the strain stresses caused by walking lengthy and uneven distances up to the working faces. All para...

In the present study, the industrial transesterification process of biodiesel production is replaced by a novel pretreatment and two-step homogenous acid–base catalyst method of production in order to increase its yield and to reduce its free fatty acid content. The produced Jatropha and Madhuca biodiesels were blended with 25%, 50% and 75% methyl...

In the present industry revolution, operations management teams emphasize implementing an efficient process optimization approach with a suitable strategy for achieving operational excellence on the shop floor. Process optimization is used to enhance productivity by eliminating idle activities and non-value-added activities within limited constrain...

Non-destructive testing (NDT) is effective in detecting surface as well as intrinsic faults in structures during production or in-service service life without destroying the originality of the test specimen. It is a tool that ascertains the viability of potential, behind sceptically for current and future use of material. The structural strength of...

Citation: Tripathi, V.; Chattopadhyaya, S.; Mukhopadhyay, A.K.; Sharma, S.; Li, C.; Singh, S.; Hussan, W.U.; Salah, B.; Saleem, W.; Mohamed, A.

The paper presents a comprehensive review on dissimilar friction stir welding (FSW) of Al to non-Al metallic materials, wherein the combination of Al–Mg, Al–Cu, Al-steel and Al–Ti are covered. The summary revealed that FSW is observed as one of the most feasible solutions in the family of welding in case of dissimilar materials combinations of Al t...

Tunnel boring machine (TBM) is a popular rock cutting machine for rapid construction of tunnels. This paper mainly dwells on the excess cutter wear and low penetration rates encountered while tunnelling through hard and abrasive rock in a head race tunnel being driven for hydel power generation. Wear prediction in disc cutters with its mechanism wa...

Nowadays, industries are emphasizing the implementation of a smart shop floor management method because of different types of problems faced in controlling the production activities in Industry 4.0. Several shop floor management methods are currently implemented in the present Industry 4.0 scenario, including lean manufacturing, logistics, Internet...

Friction stir welding of dissimilar thickness aluminum and copper alloys was carried out without offsets by placing the copper at different positions, with horizontal and inclined bed conditions. The influence of the copper plate positions and bed conditions on macro-structure, microstructure, and mechanical properties were investigated. Optical mi...

In industry 4.0, shop floor management teams are increasingly focused on developing an unprecedented strategy to avoid financial losses and address the challenges and problems encountered in operations management. In the present scenario, the management teams use various process optimization approaches for operational control, including lean manufa...

The outbreak of novel COVID-19 has severely and unprecedentedly affected millions of people across the globe. The painful respiratory distress caused during this disease calls for external assistance to the victims in the form of ventilation. The most common types of artificial ventilating units available at the healthcare facilities and hospitals...

This research reports the experimental outcomes of potentiodynamic analysis of the steel reinforcement in carbonated and uncarbonated high-volume fly-ash concrete powder solution extracts (CPSE). Different percentages of fly-ash content have been used to form a high-volume fly-ash concrete (0%, 20%, 40%, 50%, 60%, and 70%) with three different type...

The local residual stresses (tensile) generated on the surface of a component during its manufacturing (machining, welding) cause deterioration of its service life. To eliminate the negative effect of the stresses, the surface is treated using different methods (shot peening, laser shock peening, heat treatment, water jet peening). The application...

Earth pressure balance tunnel boring machines (EPBTBM) are used in soft or mixed ground conditions often encountered in tunneling operations. The performance of EPBTBM could be enhanced to a great extent by appropriate time management, proper maintenance and reduced unproductive times such as idle hours and breakdown hours using reliability analysi...

Roof bolt reinforcement of stratified carboniferous and fragile strata is a popular way of roof support in underground mines. The manifestation of strain energy of strata generated during coal winning generates convergence on established highways, the magnitude of which is exclusively determined by the strength, manner of beam construction, and tim...

COVID-19 pandemic created a global health crisis affecting every nation. The essential smart medical devices/accessories, quarantine facilities, surveillance systems, and related digital technologies are in huge demand. Healthcare, manufacturing industries, and educational institutions need technologies that allow working from a safe location. Digi...

Tungsten microtool electrode is one of the preferred tool electrodes in micro electrochemical machining (µECM) of hard to machine materials. During the pilot experiments with different types of electrolytes materials (such as NaOH, HNO3, NaBr, KOH, H2SO4, NaCl, NaNO3 and HCl), it has been found that KOH(Aq.) and NaOH(Aq.) electrolytes are suitable...

Three-dimensional finite element analysis has been carried out in order to study the response of retaining walls subjected to lateral earth pressure using ABAQUS/CAE. This study consists of analysis and design of cantilever, gravity type, and precast concrete retaining wall. It also shows comparative study such as distribution of stresses along wit...

Using a significant number of transverse hoops in the joint’s core is one recognized way for achieving the requirements of strength, stiffness, and ductility under dynamic loading in a column joint. The shear capacity of a joint is influenced by the concrete’s compressive strength, the anchoring of longitudinal beam reinforcement, the number of sti...

Overheating is a critical problem encountered with an electro hydraulically operated machine working in underground mines. Aggrandizement in the temperature of the hydraulic fluids is caused due to deficiencies in the components. Thermal instability of hydraulic power systems causes temperature transients, which not only mitigates machine productiv...