Research focus: Computational materials processing, particularly the application of numerical transport phenomena and optimization in welding and additive manufacturing. Our models compute the most important factors that affect metallurgical product quality such as temperature and velocity fields, cooling rates and solidification parameters.

Uniqueness and examples of contributions: Specially structured for integration with genetic algorithms and other search engines, these simulations can be made bi-directional, greatly expanding their utility by switching traditional input and output variables, tailoring product attributes, optimizing production variables, reducing defects and improving product quality.

(i) The first rigorous numerical model of heat transfer and fluid flow in 3D printing for reducing distortion and other common defects, customizing textures, selecting materials and reducing rejection rates of parts.

(ii) The first comprehensive numerical model for the calculation of laser fired aluminum-silicon contact geometry and dopant concentration fields during selective emitter formation in silicon based photovoltaic devices.

(iii) The first transport phenomena and genetic algorithm based bi-directional models to tailor weld geometry and cooling rate.

(iv) A novel experimental technique, now widely adopted, for estimating temperatures from vapor composition during laser welding.

(v) The first rigorous model to understand the role of similar and dissimilar concentrations of surface active elements in steels.

(vi) The first three-dimensional visco-plastic-flow and heat transfer model for friction stir welding to understand the role of process variables and tool durability.

                     Publications     Citations    Models     Collaborations    Keynote & named lectures    Recent papers   YouTube lectures   1  2

Additive Manufacturing

Friction stir welding

Keyhole mode welding

Neural network

Reliability of heat and fluid flow calculations

Tailoring weld attributes using
Genetic Algorithm

Hydrogen, nitrogen and
oxygen in weld metal

Grain structure and topology (Monte Carlo)


Modeling weld defects

Weld surface profiles

Weld microstructures

Vaporization of alloying elements

Inclusions in weld metal

Sulfur, oxygen and weld geometry

Plasma in welding

Fillet welding

GTA and GMA welding

Spot welding

Electroslag welding

Gas stirred ladles

Tundish /AOD process simulation

Composites / solid state reactions