1. Automated Welding: Welding is one of the most important and sought after material joining methods in manufacturing industries. The trend is to achieve more and more degree of automation in the welding processes. Being a process of several complexities, the welding poses many challenges to the researcher. Our study is a comprehensive one in nature comprising of stress relieving through vibration, minimising the human intervention and associated errors by using robotic welding set-up, developing heat source models and analysis of micro structural changes in weldments. We plan to explore in the domain of multi-wire and multi-pass welding with maximum amount of automation incorporated. The study also covers the Quality Assurance in welding and current practices in inspection of welded components, and welding defects.

  2. Functionally Gradient Materials through Weld-Deposition: Functionally Gradient Materials (FGM) may have a controlled variation of the material matrix so as to obtain the desired distribution of the properties such as color, density, porosity, hardness, toughness etc. The objects built through Additive Manufacturing techniques are inhomogeneous or non-uniform, i.e., they are inherently anisotropic. When this inherent nature is carefully exploited, the anisotropy transforms into the desired distribution of the properties. Weld-deposition based Additive Manufacturing techniques offer unique advantages on that front due to their ability to control the properties of the deposited matrix through the control of process parameters like current, layer thickness etc. The present work focuses on obtaining a wide range of material properties by selecting filler wires with different properties and controlling the deposition rate of each of them separately.

  3. Micro Injection Molding: Demand for micro components has been increasing considerably in the recent years due to the advances in areas of micro fluidics, biotechnology, optical data communication, MEMS, NEMS etc. Micro components are mainly produced using plastics due to the relative ease of manufacturing. Injection Molding (IM) is one of the widely used processes for producing plastic components. However, Injection Molding technology cannot be used directly to produce micro - components as plastics behave differently when they flow through micro channels. The technology of micro injection molding (µIM) has emerged by considering these rheological effects when the fluid flows through micro channels. Research in the area of µIM is in developing phase. Even now, successful replication of micro - features is quite a task in µIM. It would be even more challenging when micro features are be replicated with out compromising much on the mechanical properties of the product. So, in this project we are making an attempt to produce the micro parts while improving the mechanical properties of the same.

  4. Rapid Prototyping & Manufacturing: Rapid Prototyping (RP), also known as Layered Manufacturing (LM), is a totally automatic process of manufacturing objects directly from their Computer Aided Designing (CAD) models. By using RP technology 3D models can be easily generated by layer by layer deposition process. In this process 3D objects are sliced into 2D layers, where it makes simple to construct a 3D model and ease of manufacture. The prototype is developed from the bottom of the base, thus a layer by layer deposition can be done, further the model is developed and it is cured or post processed.

  5. Sustainable machining process: Manufacturing industries are facing great challenges in developing an environmental friendly sustainable machining process. The strict rules framed by the organization like International Organization for Standardization (ISO) and Occupational Health and Safety Advisory Services (OHSAS) have made the industries and researchers to work in the direction of developing an environmental friendly sustainable machining process. The theme of sustainable machining process lies in the development of a process which will maximize the product quality without compromising on the environmental issues. This can be achieved by reducing the consumption of hazardous substances which are used in machining process. Some ways of achieving this goal is to reduce the use of cutting fluids, using environmental friendly cutting fluids, maximizing the cutting tool efficiency and by reducing the consumption of energy during cutting process.