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Prof. Dr. Prateek Saxena
School of Engineering, Indian Institute of Technology Mandi, Kamand, Himachal Pradesh – 175005, India

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Research Keywords & Expertise

0 Additive Manufacturing
0 Composites
0 Manufacturing Systems
0 Industry 4.0
0 Sustainable manufacturing, sustainable products and processes, paper-based packaging products, advanced casting science and technologies

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Additive Manufacturing
Composites
Industry 4.0
Tooling and tooling process chains

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Journal article
Published: 18 May 2021 in Journal of Cleaner Production
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Additive Manufacturing has significantly developed over the years and is widely used in most industrial applications. Rapid Tooling refers to manufacturing the tools (moulds and dies) using Additive Manufacturing techniques. An essential application of Rapid Tooling is the 3D printing of sand moulds for castings. Metal casting is an energy-intensive process; and a lot of research has gone into the sustainability assessment of traditional sand castings. In this work, a robust decision-making approach is developed and implemented for sand mould manufacturing. Sustainability metrics for the mould production are formulated, and the conventional sand moulds are compared against the 3D printed sand moulds. A Multi-Criteria decision-making algorithm is implemented, and the effect of the batch size in the mould manufacturing is also studied. The discussed approach can help decision-makers choose the best mould manufacturing technique for the intended number of moulds to be manufactured.

ACS Style

Prateek Saxena; Emanuele Pagone; Konstantinos Salonitis; Mark R. Jolly. Sustainability metrics for rapid manufacturing of the sand casting moulds: A multi-criteria decision-making algorithm-based approach. Journal of Cleaner Production 2021, 311, 127506 .

AMA Style

Prateek Saxena, Emanuele Pagone, Konstantinos Salonitis, Mark R. Jolly. Sustainability metrics for rapid manufacturing of the sand casting moulds: A multi-criteria decision-making algorithm-based approach. Journal of Cleaner Production. 2021; 311 ():127506.

Chicago/Turabian Style

Prateek Saxena; Emanuele Pagone; Konstantinos Salonitis; Mark R. Jolly. 2021. "Sustainability metrics for rapid manufacturing of the sand casting moulds: A multi-criteria decision-making algorithm-based approach." Journal of Cleaner Production 311, no. : 127506.

Review article
Published: 13 May 2021 in CIRP Journal of Manufacturing Science and Technology
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Metal membrane technology is an environmentally promising method for separation technology. This green filtration technology has gained much attention than other approaches for desalination and water purification because of its high flux, simplicity in operation, space and energy savings, and no use of chemicals. In many filtration processes, frequently organic polymer membranes are used, but they have several stability concerns at higher temperatures and organic solvents’ contacts. Hence, many efforts are put into the manufacturing of high-temperature stability and solvent resistant metallic membranes. New developments in metal membrane materials have presented significant improvements in separation technologies. These improvements have led to the next-generation metal membrane-based separation. This review paper covers the significant aspects of the current research progress in the metal membrane separation technology, focusing on their manufacturing techniques, materials used, industrial applications, and establishing a relative comparison between them in terms of benefits and constraints. Existing work is further proposed to be an update and value addition to the earlier literature reviews.

ACS Style

Himanshu Singh; Prateek Saxena; Y.M. Puri. The manufacturing and applications of the porous metal membranes: A critical review. CIRP Journal of Manufacturing Science and Technology 2021, 33, 339 -368.

AMA Style

Himanshu Singh, Prateek Saxena, Y.M. Puri. The manufacturing and applications of the porous metal membranes: A critical review. CIRP Journal of Manufacturing Science and Technology. 2021; 33 ():339-368.

Chicago/Turabian Style

Himanshu Singh; Prateek Saxena; Y.M. Puri. 2021. "The manufacturing and applications of the porous metal membranes: A critical review." CIRP Journal of Manufacturing Science and Technology 33, no. : 339-368.

Conference paper
Published: 24 February 2021 in The Minerals, Metals & Materials Series
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COVID-19 has caused a global pandemic since December 2019. It has impacted not only the wellbeing of human society but also has been damaging to the global economy. This has imposed severe threats and challenges on businesses. The British government has launched aid schemes to combat the new scenarios developed as a result of the pandemic. This paper aims to assess the impact of COVID-19 on foundries in the UK. Recorded responses from a detailed survey of the British foundries were analysed and short- and long-term action plans for the foundries are suggested. The current status, challenges, and future direction of the UK foundries are discussed. An opinion for the use of additive technologies with business model innovation for the de-centralised foundries is presented.

ACS Style

Prateek Saxena; Pam Murrell; Tharmalingam Sivarupan; John Patsavellas; Konstantinos Salonitis; Mark R. Jolly. Impact of COVID-19 Pandemic on British Foundries. The Minerals, Metals & Materials Series 2021, 719 -726.

AMA Style

Prateek Saxena, Pam Murrell, Tharmalingam Sivarupan, John Patsavellas, Konstantinos Salonitis, Mark R. Jolly. Impact of COVID-19 Pandemic on British Foundries. The Minerals, Metals & Materials Series. 2021; ():719-726.

Chicago/Turabian Style

Prateek Saxena; Pam Murrell; Tharmalingam Sivarupan; John Patsavellas; Konstantinos Salonitis; Mark R. Jolly. 2021. "Impact of COVID-19 Pandemic on British Foundries." The Minerals, Metals & Materials Series , no. : 719-726.

Review
Published: 10 February 2021 in Additive Manufacturing
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3D sand mould printing using binder jet technology can enable many technical improvements in casting practice, including part consolidation, design of parts to optimise the consumption of materials and hazardous chemicals, and on-demand and flexible size part manufacturing near the customer. Incorporating artificial intelligence in optimising the design of moulds, printing process parameters, and solidification processes may help automate a production facility and reduce labour time. Elimination of hazardous chemicals from industrial use may be a challenge. Therefore, an alternative technology to fuse the sand particles during printing or an environmentally friendlier alternative option for the binders and other consumables should be utilised with the 3D sand printing process. Properties of parts produced using 3D printed sand moulds have the potential to be better than the properties of parts produced using traditional casting due to this technology's benefits. This technology is an enabling technology for traditional casting processes rather than a competing technology. It is causing a paradigm shift in casting design because of the mould geometries achievable by using additive manufacturing to produce the sand mould. This paper reviews the first twenty years of research and challenges in developing 3D sand printing processes as an innovation for sustainable manufacturing.

ACS Style

Tharmalingam Sivarupan; Nagasivamuni Balasubramani; Prateek Saxena; Devarajan Nagarajan; Mohamed El Mansori; Konstantinos Salonitis; Mark Jolly; Matthew S. Dargusch. A review on the progress and challenges of binder jet 3D printing of sand moulds for advanced casting. Additive Manufacturing 2021, 40, 101889 .

AMA Style

Tharmalingam Sivarupan, Nagasivamuni Balasubramani, Prateek Saxena, Devarajan Nagarajan, Mohamed El Mansori, Konstantinos Salonitis, Mark Jolly, Matthew S. Dargusch. A review on the progress and challenges of binder jet 3D printing of sand moulds for advanced casting. Additive Manufacturing. 2021; 40 ():101889.

Chicago/Turabian Style

Tharmalingam Sivarupan; Nagasivamuni Balasubramani; Prateek Saxena; Devarajan Nagarajan; Mohamed El Mansori; Konstantinos Salonitis; Mark Jolly; Matthew S. Dargusch. 2021. "A review on the progress and challenges of binder jet 3D printing of sand moulds for advanced casting." Additive Manufacturing 40, no. : 101889.

Review
Published: 01 January 2021 in Materials Letters
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Bio-engineering parts are widely used in hearing aid applications, dental applications, inhalation therapy blends, etc. Conventional tactile measurement techniques offer a limitation in the quality assessment of such parts due to the complex shape of the part and also due to their inability to measure internal features in a three-dimensional space. Industrial micro X-ray computed tomography (μXCT) is a robust characterization technique designed to maintain part quality, facilitate precision manufacturing, and reduce material waste due to part rejection. This paper highlights the limitations and challenges of conventional measurement techniques in the assessment of the quality of bio-engineering components. Capabilities of μXCT are presented and its application in the bio-engineering sector is discussed in this work.

ACS Style

Jitendra Singh Rathore; Prateek Saxena. Non-destructive quality assessment of bio-engineering parts using Industrial Micro X-ray Computed Tomography: A review. Materials Letters 2021, 287, 129252 .

AMA Style

Jitendra Singh Rathore, Prateek Saxena. Non-destructive quality assessment of bio-engineering parts using Industrial Micro X-ray Computed Tomography: A review. Materials Letters. 2021; 287 ():129252.

Chicago/Turabian Style

Jitendra Singh Rathore; Prateek Saxena. 2021. "Non-destructive quality assessment of bio-engineering parts using Industrial Micro X-ray Computed Tomography: A review." Materials Letters 287, no. : 129252.

Journal article
Published: 17 September 2020 in Designs
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Current frugal design practice is focused on the cost reduction of the product. Despite advancements in the domain of frugal Innovation, it is not systematized to develop products for all sets of users, including marginalized society. Many design researchers and engineers now dedicate time and knowledge to producing practical solutions to enhance the quality of life of the marginal community. The approach currently being adopted restricts the development of products intended for all segments of the users. In this paper, cumulative frequency distribution analysis and the Relative Importance Index is used to identify the essential attributes, which contribute to delivering actual frugal products in terms of functionality, usability, performance, affordability, accessibility, aesthetics, and robustness. The framework is beneficial to eradicate the discriminatory effect of being labeled as “Jugaad” users.

ACS Style

Ravindra Singh; Sumedha Seniaray; Prateek Saxena. A Framework for the Improvement of Frugal Design Practices. Designs 2020, 4, 37 .

AMA Style

Ravindra Singh, Sumedha Seniaray, Prateek Saxena. A Framework for the Improvement of Frugal Design Practices. Designs. 2020; 4 (3):37.

Chicago/Turabian Style

Ravindra Singh; Sumedha Seniaray; Prateek Saxena. 2020. "A Framework for the Improvement of Frugal Design Practices." Designs 4, no. 3: 37.

Conference paper
Published: 11 September 2020 in Blockchain Technology and Innovations in Business Processes
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Capabilities of additive manufacturing (AM) for rapid tooling are well known in recent times. Rapid sand moulds are advantageous over traditional sand moulds in terms of cost, manufacturing time, flexibility, etc. This paper identifies metrics related to mould manufacturing and categorises them into four categories (cost, time, quality and environmental sustainability). A methodology based on the deterministic Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) multi-criteria decision-making algorithm is used to map at high resolution the influence of such categories on to the decision-making space when comparing AM with conventional sand mould making. Results show that AM is almost always clearly advantageous overall (excluding some very limited corner cases) for the examined case.

ACS Style

Emanuele Pagone; Prateek Saxena; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping. Blockchain Technology and Innovations in Business Processes 2020, 345 -355.

AMA Style

Emanuele Pagone, Prateek Saxena, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping. Blockchain Technology and Innovations in Business Processes. 2020; ():345-355.

Chicago/Turabian Style

Emanuele Pagone; Prateek Saxena; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2020. "Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping." Blockchain Technology and Innovations in Business Processes , no. : 345-355.

Journal article
Published: 20 August 2020 in Journal of Manufacturing Processes
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Paper-based packaging products are a cheap and sustainable alternative to their plastic counterparts. The manufacturing process of paper molding is a relatively newer concept, and the tooling aspect remains somewhat unknown. The work done in this paper establishes a tool design approach for the molding of paper products. These products are also sometime referred to as the molded paper products (MPP). Functional requirements are identified and translated to process chains. The concept of non-deterministic and deterministic tooling is introduced. Tooling process chains based on micro-metal additive manufacturing are defined and implemented. The process chain is utilized to manufacture micro features of size 300 μm in a high aspect ratio. A comparative study on validation of tooling process chains is also discussed, and the suitability of rapid tooling over sintered tools is highlighted in this work.

ACS Style

Prateek Saxena; Giuliano Bissacco; Kenneth Ælkær Meinert; Filip Jakub Bedka. Mold design and fabrication for production of thermoformed paper-based packaging products. Journal of Manufacturing Processes 2020, 58, 311 -321.

AMA Style

Prateek Saxena, Giuliano Bissacco, Kenneth Ælkær Meinert, Filip Jakub Bedka. Mold design and fabrication for production of thermoformed paper-based packaging products. Journal of Manufacturing Processes. 2020; 58 ():311-321.

Chicago/Turabian Style

Prateek Saxena; Giuliano Bissacco; Kenneth Ælkær Meinert; Filip Jakub Bedka. 2020. "Mold design and fabrication for production of thermoformed paper-based packaging products." Journal of Manufacturing Processes 58, no. : 311-321.

Journal article
Published: 31 July 2020 in Polymers
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High-performance polymer composites are being increasingly favored for structural applications. For this purpose, efforts are being focused on exploring the potential of high-performance thermoplastics and thermosets. Cyanate ester (CE) resin is a special thermoset that can be used at up to 400 °C without any considerable degradation; however, its tribological properties are not at the adequate level. Hence, it is needed to use this polymer in composite form with the fibrous/particulate reinforcement to impart better tribological properties and mechanical strength via a strong fiber–matrix interface. Carbon fiber/fabrics are at the forefront as reinforcement for specialty polymers. The tribological and tensile properties of cyanate ester (CE) composites-filled graphite, polytetrafluoroethylene (PTFE), and MoS2 micron-sized fillers reinforced with carbon fibers (CF) are investigated experimentally in a block-on-ring setup at 100 N, for 10 h, and with a sliding distance of approximately 10,000 m, against a hardened polished 100Cr6 steel shaft and diamond-like-coated (DLC) 100Cr6 steel shaft. The tribological properties of the composites including the coefficient of friction and specific wear rate are enhanced especially with the incorporation of graphite fillers. The friction coefficient and wear rate of the graphite-based composite was decreased significantly at 5 wt.% of graphite concentration. Further, at the same concentration, the graphite-based composite showed superior tensile properties as compared to the reference system owing to better dispersion and adhesion between the fibers and matrix. Tensile tests are performed to characterize the fiber–matrix interfacial adhesion and other strength properties.

ACS Style

Ankur Bajpai; Prateek Saxena; Klaus Kunze. Tribo-Mechanical Characterization of Carbon Fiber-Reinforced Cyanate Ester Resins Modified With Fillers. Polymers 2020, 12, 1725 .

AMA Style

Ankur Bajpai, Prateek Saxena, Klaus Kunze. Tribo-Mechanical Characterization of Carbon Fiber-Reinforced Cyanate Ester Resins Modified With Fillers. Polymers. 2020; 12 (8):1725.

Chicago/Turabian Style

Ankur Bajpai; Prateek Saxena; Klaus Kunze. 2020. "Tribo-Mechanical Characterization of Carbon Fiber-Reinforced Cyanate Ester Resins Modified With Fillers." Polymers 12, no. 8: 1725.

Conference paper
Published: 30 June 2020 in Recent Advances in Computational Mechanics and Simulations
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Digitalization of the heat transfer in shell and tube type heat exchanger is what sets the foundation of the future of thermal industry. In traditional computational model design, a simulation model is validated with the experimental results. A digital twin is a virtual representation of the real system or processes and imbibes the validation of the model. The only difference is that the exchange of information is carried out in real time and is more reliable. A digital twin is not a static representation of the real space but rather a dynamic phenomenon connecting the two spaces. In the present analysis, a comparative finite element analysis of the shell and tube heat exchanger has been performed with an intention to enhance the effectiveness of the heat exchanger process. An approach toward development of the next generation of heat exchangers is discussed in this work.

ACS Style

Himanshu Singh; Utkarsh Mishra; Prateek Saxena; Ganesh Shetiya; Y. M. Puri. Digital Twin for Shell and Tube Heat Exchanger in Industry 4.0. Recent Advances in Computational Mechanics and Simulations 2020, 637 -644.

AMA Style

Himanshu Singh, Utkarsh Mishra, Prateek Saxena, Ganesh Shetiya, Y. M. Puri. Digital Twin for Shell and Tube Heat Exchanger in Industry 4.0. Recent Advances in Computational Mechanics and Simulations. 2020; ():637-644.

Chicago/Turabian Style

Himanshu Singh; Utkarsh Mishra; Prateek Saxena; Ganesh Shetiya; Y. M. Puri. 2020. "Digital Twin for Shell and Tube Heat Exchanger in Industry 4.0." Recent Advances in Computational Mechanics and Simulations , no. : 637-644.

Journal article
Published: 19 June 2020 in IEEE Journal of Photovoltaics
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The Cu $_2$ ZnSnS $_x$ Se $_{4-x}$ (CZTSSe) thin-film solar cells have attracted the attention of researchers due to its earth-abundant composition containing Copper, Zinc, Tin and Sulfur, and Selenide with 12.6% record efficiency (2013-IBM). A 3-D simulation analysis is presented here on the optical, electrical, and thermal characteristics of CZTSSe solar cell using COMSOL multiphysics 3-D simulation package. COMSOL is capable of calculating the optical–electrical–thermal models through electromagnetic wave, semiconductor, and heat transfer modules for a finely meshed structure. Using this capability, we have calculated the optical photogeneration rate of the a Mo/Mo(S,Se) $_2$ /CZTSSe/CdS/ZnO/ITO/air structure by inserting the refractive index and extinction coefficient of every layer in Wave optic module in COMSOL. We also calculated the total optical generation rate for two structures with and without Mo(S,Se) $_2$ layer at the junction of Mo and CZTSSe layers. The current–voltage curve, electric field profile, and the recombination rate of the cell has also been calculated by Semiconductor module coupled to wave optic module. The current–voltage characteristics show an improvement in $V_{\text{oc}}$ for the cell with Mo(S,Se) $_2$ layer (0.46 to 0.513 V) which was also suggested by IBM for a record cell efficiency. Finally, the thermal maps of the cell has been calculated by heat transfer module coupled to semiconductor module considering the Shockley–Read–Hall (SRH) recombination heat, Joule Heat, and conductive heat flux. The total heat flux magnitude of the cell was also mapped as a result out of these heat generation and cooling sources. The SRH heat is maximum within the depletion width at the CZTSSe/CdS interface, whereas the Joule heating is intensive at the Mo/Mo(S,Se) $_2$ /CZTSSe side. Interesting is to see that the heat is mainly conducted to environment from Mo side presented by the conductive heat map. The total heat flux is intensive at both top and bottom interfaces which means the heat is generated at both top and bottom sides of the cells and not only from the illuminated part.

ACS Style

Soma Zandi; Prateek Saxena; Mohammad Razaghi; Nima E. Gorji. Simulation of CZTSSe Thin-Film Solar Cells in COMSOL: Three-Dimensional Optical, Electrical, and Thermal Models. IEEE Journal of Photovoltaics 2020, 10, 1503 -1507.

AMA Style

Soma Zandi, Prateek Saxena, Mohammad Razaghi, Nima E. Gorji. Simulation of CZTSSe Thin-Film Solar Cells in COMSOL: Three-Dimensional Optical, Electrical, and Thermal Models. IEEE Journal of Photovoltaics. 2020; 10 (5):1503-1507.

Chicago/Turabian Style

Soma Zandi; Prateek Saxena; Mohammad Razaghi; Nima E. Gorji. 2020. "Simulation of CZTSSe Thin-Film Solar Cells in COMSOL: Three-Dimensional Optical, Electrical, and Thermal Models." IEEE Journal of Photovoltaics 10, no. 5: 1503-1507.

Journal article
Published: 01 June 2020 in Journal of Manufacturing Processes
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ACS Style

Prateek Saxena; Giuliano Bissacco; Kenneth Ælkær Meinert; Anna Danielak; Macarena Méndez Ribó; David Bue Pedersen. Soft tooling process chain for the manufacturing of micro-functional features on molds used for molding of paper bottles. Journal of Manufacturing Processes 2020, 54, 129 -137.

AMA Style

Prateek Saxena, Giuliano Bissacco, Kenneth Ælkær Meinert, Anna Danielak, Macarena Méndez Ribó, David Bue Pedersen. Soft tooling process chain for the manufacturing of micro-functional features on molds used for molding of paper bottles. Journal of Manufacturing Processes. 2020; 54 ():129-137.

Chicago/Turabian Style

Prateek Saxena; Giuliano Bissacco; Kenneth Ælkær Meinert; Anna Danielak; Macarena Méndez Ribó; David Bue Pedersen. 2020. "Soft tooling process chain for the manufacturing of micro-functional features on molds used for molding of paper bottles." Journal of Manufacturing Processes 54, no. : 129-137.

Journal article
Published: 29 May 2020 in Energies
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Sustainability is becoming more and more important as a decision attribute in the manufacturing environment. However, quantitative metrics for all the aspects of the triple bottom line are difficult to assess. Within the present paper, the sustainability metrics are considered in tandem with other traditional manufacturing metrics such as time, flexibility, and quality and a novel framework is presented that integrates information and requirements from Computer-Aided Technologies (CAx) systems. A novel tool is outlined for considering a number of key performance indicators related to the triple bottom line when deciding the most appropriate process route. The implemented system allows the assessment of alternative process plans considering the market demands and available resources.

ACS Style

Prateek Saxena; Panagiotis Stavropoulos; John Kechagias; Konstantinos Salonitis. Sustainability Assessment for Manufacturing Operations. Energies 2020, 13, 2730 .

AMA Style

Prateek Saxena, Panagiotis Stavropoulos, John Kechagias, Konstantinos Salonitis. Sustainability Assessment for Manufacturing Operations. Energies. 2020; 13 (11):2730.

Chicago/Turabian Style

Prateek Saxena; Panagiotis Stavropoulos; John Kechagias; Konstantinos Salonitis. 2020. "Sustainability Assessment for Manufacturing Operations." Energies 13, no. 11: 2730.

Short communication
Published: 03 March 2020 in Materials Letters
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In the current scenario, exploration of metal membranes has highly enhanced, and more efforts have been executed in its development and characterization. These breakthroughs have accelerated its applicability in the number of relevant sectors such as waste-water treatments, dairy processing’s, wineries, and biofuel refinement. This work inspects about recent findings and progress in the field of metal membranes, including its innovative manufacturing techniques and various applications, which have been reported in multiple research papers. The sintering technique is used generally for the preparation of metal membranes. Throughout this process, the resulting pore sizes are in the range of micrometers. Till now it is used for filtration of liquids to separate the solid particles. There is intense research work required for reducing the pore size of metal membranes using some cost-effective novel techniques, which will intensify its applicability in many green filtration technologies.

ACS Style

Himanshu Singh; Prateek Saxena; Yogesh Madan Puri. Materials selection and manufacturing of metal membranes for industrial applications. Materials Letters 2020, 269, 127557 .

AMA Style

Himanshu Singh, Prateek Saxena, Yogesh Madan Puri. Materials selection and manufacturing of metal membranes for industrial applications. Materials Letters. 2020; 269 ():127557.

Chicago/Turabian Style

Himanshu Singh; Prateek Saxena; Yogesh Madan Puri. 2020. "Materials selection and manufacturing of metal membranes for industrial applications." Materials Letters 269, no. : 127557.

Journal article
Published: 29 January 2020 in Materials Characterization
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Recycling metallic powders used in the additive manufacturing (AM) process is essential for reducing the process cost, manufacturing time, energy consumption, and metallic waste. In this paper, the focus is on pore formation in recycled powder particles of stainless steel 316L during the selective laser melting process. We have introduced the concept of optimizing the powder bed's printing area in order to see the extent of the affected powders during the 3D-printing process. X-ray Computed Tomography (XCT) is used to characterize the pores inside the particles. The results from image processing of the tomography (rendered in 3D format) indicate a broader pore size distribution and a higher pore density in recycled powders compared to their virgin counterparts. To elucidate on this, the Electron Dispersion spectroscopy (EDX) analysis and Synchrotron-based Hard X-ray Photoelectron Spectroscopy (HAXPES) were performed to reveal the chemical composition distribution across the pore area and bulk of the recycled powder particles. Higher concentrations of Fe, Cr, and Ni were recorded on the interior wall of the pore in recycled particles and higher Mn, S and Si concentrations were recorded in the outer layer around the pore area and on the surface of the recycled particle. The pore formation in recycled powder is attributed to out-diffusion of Mn, S and Si to the outer surface as a result of the incident laser heat during the AM process due to higher electron affinity of such metallic elements to oxygenation. HAXPES analysis shows a higher MnO concentration around the pore area which impedes the in-diffusion of other elements into the bulk and thereby helps to creates a void. The inside wall of the pore area (dendrites), has a higher concentration of Fe and Cr oxide. We believe the higher pore density in recycled powders is due, at least in part to composition redistribution, promoted by laser heat during the AM process. Nanoindentation analyses on both virgin and recycled powder particles shows a lower hardness and higher effective modulus in the recycled powder particles attributed to the higher porosity in recycled powders.

ACS Style

Nima E. Gorji; Prateek Saxena; Martin Corfield; Adam Clare; Jean-Pascal Rueff; Justin Bogan; Pierre G.M. González; Matthew Snelgrove; Greg Hughes; Robert O'Connor; Ramesh Raghavendra; Dermot Brabazon. A new method for assessing the recyclability of powders within Powder Bed Fusion process. Materials Characterization 2020, 161, 110167 .

AMA Style

Nima E. Gorji, Prateek Saxena, Martin Corfield, Adam Clare, Jean-Pascal Rueff, Justin Bogan, Pierre G.M. González, Matthew Snelgrove, Greg Hughes, Robert O'Connor, Ramesh Raghavendra, Dermot Brabazon. A new method for assessing the recyclability of powders within Powder Bed Fusion process. Materials Characterization. 2020; 161 ():110167.

Chicago/Turabian Style

Nima E. Gorji; Prateek Saxena; Martin Corfield; Adam Clare; Jean-Pascal Rueff; Justin Bogan; Pierre G.M. González; Matthew Snelgrove; Greg Hughes; Robert O'Connor; Ramesh Raghavendra; Dermot Brabazon. 2020. "A new method for assessing the recyclability of powders within Powder Bed Fusion process." Materials Characterization 161, no. : 110167.

Conference paper
Published: 28 January 2020 in The Minerals, Metals & Materials Series
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The concept of smart foundries aims at integrating and enabling smart technologies for digitalization of manufacturing operations. Foundries 4.0 refer to the inclusion of Industry 4.0 principles in traditional foundries. The casting process is known to be one of the most energy-intensive processes. Enabling sensor-based technologies, such as the Internet of Things (IoTs) for condition monitoring, can be an efficient means to bring down the energy costs. IoTs can also be implemented for real-time waste-monitoring. Embedded sensors can be utilized in determining excessive loads during the casting operation. This is very useful to identify overloading and in avoiding potential damage to the castings. Introduction of Additive Manufacturing can reduce cycle time and material consumption. This paper aims to introduce the concept of Foundries 4.0. The key focus is to highlight the integration of digital technologies in establishing foundries of the future. Challenges involved in the establishment of smart foundries are also discussed. A case-study discussing establishment of energy-efficient smart foundries is also presented in this work.

ACS Style

Prateek Saxena; Michail Papanikolaou; Emanuele Pagone; Konstantinos Salonitis; Mark R. Jolly. Digital Manufacturing for Foundries 4.0. The Minerals, Metals & Materials Series 2020, 1019 -1025.

AMA Style

Prateek Saxena, Michail Papanikolaou, Emanuele Pagone, Konstantinos Salonitis, Mark R. Jolly. Digital Manufacturing for Foundries 4.0. The Minerals, Metals & Materials Series. 2020; ():1019-1025.

Chicago/Turabian Style

Prateek Saxena; Michail Papanikolaou; Emanuele Pagone; Konstantinos Salonitis; Mark R. Jolly. 2020. "Digital Manufacturing for Foundries 4.0." The Minerals, Metals & Materials Series , no. : 1019-1025.

Journal article
Published: 06 January 2020 in Solar Energy
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A 3D simulation of optical photogenreation, electrical characteristics, and thermal/heat distribution across the structure of a perovskite solar cell with a reduced graphene oxide (RGO) contact is presented. COMSOL Multiphysics package has been used to solve the coupled optical-electrical-thermal modules for this hybrid cell where the RGO added as the bottom electrode instead of a conventional metallic contact to enhance the heat dissipation towards a higher device stability. The Wave Optic module, Semiconductor module, and Heat Transfer in Solid module were coupled and solved for the proper input parameter values taken from relevant literature. The optical photogeneration, current-voltage characteristics, electric-field and the thermal maps of the cell are presented. The RGO contact doesn’t significantly impact on the optical and electrical output of the cell, but it accelerates the heat dissipation. The heat is mainly generated across the cell from the light absorption, Shockley-Read-Hall non-radiative recombination, and Joule heating. Compared to the cell with the Au electrode, the RGO contacted cell is showing a minimized heat accumulation and gradient at the bottom junction of the RGO/Spiro interface which promises a thermal stability of the cell. The nan-radiative and joule heat distribution also show a moderated density for the RGO contacted cell which are assigned to the high heat conductivity of the RGO layer compared to traditional metallic electrodes. Our simulations results are of the rarely presented thermal simulations for such devices and prove the superiority of graphene over plane metallic contacts for heat dissipation and thermodynamic aspect of a solar cell.

ACS Style

Soma Zandi; Prateek Saxena; Nima E. Gorji. Numerical simulation of heat distribution in RGO-contacted perovskite solar cells using COMSOL. Solar Energy 2020, 197, 105 -110.

AMA Style

Soma Zandi, Prateek Saxena, Nima E. Gorji. Numerical simulation of heat distribution in RGO-contacted perovskite solar cells using COMSOL. Solar Energy. 2020; 197 ():105-110.

Chicago/Turabian Style

Soma Zandi; Prateek Saxena; Nima E. Gorji. 2020. "Numerical simulation of heat distribution in RGO-contacted perovskite solar cells using COMSOL." Solar Energy 197, no. : 105-110.

Journal article
Published: 27 September 2019 in IEEE Journal of Photovoltaics
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The heat dissipation has been rarely investigated in solar cells although it has a significant impact on their performance and reliability. For the first time, an extended three-dimensional (3-D) simulation of heat distribution in perovskite solar cells is presented here. We use COMSOL Multiphysics to investigate the temperature distribution in conventional perovskite solar cells through a coupled optical–electrical–thermal modules. Wave optics module, semiconductor module, and heat transfer in solid module are coupled in COMSOL Multiphysics package to perform the simulation in 3-D wizard. The electrical behavior, optical absorption, and heat conduction or convection are considered to gain insight into heat dissipation across the cell. The simulation results suggest that the heat produced in the cell is best dissipated from the metallic contact where the PbI $_2$ defect forms because of oxidation or decomposition of the perovskite layer at moisture exposure. The generated heat varies significantly from the front FTO contact to bottom metallic electrode. The more heat dissipation and accumulation is observed at the junction and electrode sides too. In our simulations, we consider the Joule heating, nonradiative recombination heating, and heat flux in every layer of the cell and calculate the carrier’s concentration, electric field distribution, Joule heating, Shockley–Read–Hall heating, total heat flux, and temperature distribution across the solar cell structure. The simulations reveal that the metallic contact must be selected as a highly heat conductive material in order to accelerate the heat dissipation on the bottom of the cell and to enhance the cell reliability against temperature increase under normal operation.

ACS Style

Prateek Saxena; Nima E. Gorji. COMSOL Simulation of Heat Distribution in Perovskite Solar Cells: Coupled Optical–Electrical–Thermal 3-D Analysis. IEEE Journal of Photovoltaics 2019, 9, 1693 -1698.

AMA Style

Prateek Saxena, Nima E. Gorji. COMSOL Simulation of Heat Distribution in Perovskite Solar Cells: Coupled Optical–Electrical–Thermal 3-D Analysis. IEEE Journal of Photovoltaics. 2019; 9 (6):1693-1698.

Chicago/Turabian Style

Prateek Saxena; Nima E. Gorji. 2019. "COMSOL Simulation of Heat Distribution in Perovskite Solar Cells: Coupled Optical–Electrical–Thermal 3-D Analysis." IEEE Journal of Photovoltaics 9, no. 6: 1693-1698.

Journal article
Published: 10 June 2019 in Journal of Cleaner Production
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The advancement in plastic and plastic based products in last two decades has imposed a serious threat to the environment. This has led to an increase in the demand and need for sustainable and biobased products. Paper and paper products are good alternatives to their plastic counterparts. A key element of paper industry is the raw material (wood,bamboo and nonwood agricultural residues such as bagasse, straws etc.) from which pulp is produced. The pulp is then utilized for production of paper. There are many pulping processes to prepare pulp of various qualities. For fine grade pulp, chemical pulping is used. The chemical pulp is produced by soda, kraft and sulphite pulping processes. However, for newsprint grade pulp, stone ground wood (SW), thermomechanical pulp (TMP), chemi-thermomechanical pulp (CTMP), Chemi-mechanical pulp (CMP) or refiner mechanical (RMP) corresponding pulping processes are employed. The method of pulp preparation (pulping process) consumes large amount of energy and chemicals. A new pulping process with electron irradiation using biowaste (Bagasse) as a raw material is discussed in this work. Bagasse pulping process is found to reduce about 50% of energy consumption during pulping process. The process is referred to as ‘ECTMP’ (Energy Efficient Chemi-Thermo Mechanical Pulping). The paper produced from aforesaid method reflected no loss of strength properties with respect of TMP reference pulps. Henceforth, preliminary calculation based on experimental results shows that the proposed bagasse ECTMP process explored the scope of energy savings of the order of 50%.

ACS Style

Shailesh Pathak; Prateek Saxena; Amiya Kumar Ray; Harald Großmann; René Kleinert. Irradiation based clean and energy efficient thermochemical conversion of biowaste into paper. Journal of Cleaner Production 2019, 233, 893 -902.

AMA Style

Shailesh Pathak, Prateek Saxena, Amiya Kumar Ray, Harald Großmann, René Kleinert. Irradiation based clean and energy efficient thermochemical conversion of biowaste into paper. Journal of Cleaner Production. 2019; 233 ():893-902.

Chicago/Turabian Style

Shailesh Pathak; Prateek Saxena; Amiya Kumar Ray; Harald Großmann; René Kleinert. 2019. "Irradiation based clean and energy efficient thermochemical conversion of biowaste into paper." Journal of Cleaner Production 233, no. : 893-902.

Journal article
Published: 29 May 2019 in Procedia Manufacturing
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Eco-friendly products have gained importance in recent years. The paper bottle is a sustainable packaging solution for carbonated beverages. The moulding process is a two-stage process. At first, pulp is poured in the forming mould and fibers are formed in the desired shape. Wet bottle is then transferred to the drying mould to remove bound water. The drying process makes use of an inflatable core, which not only prevents the shrinkage of fibers but also helps in attaining good fiber compaction. Preliminary investigations reported uneven fiber compaction in changing curvatures and sharp corners. A cause of uneven thickness distribution in the geometry is uneven compaction pressure during core expansion. A FEM approach is developed to predict the occurrence of non-conformities in the bottle. Hyperelastic core material is modelled using Mooney-Rivlin material model from the elastic strain density function. The model can be used to optimize the core shape, thus developing a robust tooling solution.

ACS Style

Prateek Saxena; Giuliano Bissacco. Assessment of the inflatable core assisted paper bottle moulding process. Procedia Manufacturing 2019, 33, 312 -318.

AMA Style

Prateek Saxena, Giuliano Bissacco. Assessment of the inflatable core assisted paper bottle moulding process. Procedia Manufacturing. 2019; 33 ():312-318.

Chicago/Turabian Style

Prateek Saxena; Giuliano Bissacco. 2019. "Assessment of the inflatable core assisted paper bottle moulding process." Procedia Manufacturing 33, no. : 312-318.