Research Projects

The Direct Metal Deposition (DMD) process of nickel-based super alloys, such as Inconel 738LC, waspalloy, K417G, and CM247LC, has applications in defense, aerospace, and energy sectors. However, these alloys exhibit a tendency for solidification-cracking. This project aims to develop non-dimensional criteria for predicting crack-vulnerable zones using thermal and misorientation signatures using a multiscale, multi-physics three-dimensional solidification model. Multi-scale numerical simulations have been used to quickly solve this problem, and recent research by satbhai et al. (satbhai 2023, IJHMT) has proposed novel macroscopic criteria for predicting the location of solidification-cracks. The project aims to develop a multi-scale, multi-physics computational tool/model for predicting solidification cracks and their orientation in the post-solidified zone during laser DMD and autogenous similar welding processes for nickel-based super alloys and stainless steel. The model will be validated by comparing computational results with experimental results. The first year will focus on developing a multi-scale, multi-physics computational model for the prediction of solidification-cracks using a transient three-dimensional coupled Finite Volume Method-Cellular Automata (FVM-CA) model.