T. S. Prasanna Kumar

Bio: T. S. Prasanna Kumar is an academic researcher from Indian Institute of Technology Madras. The author has contributed to research in topics: Heat flux & Quenching. The author has an hindex of 11, co-authored 18 publications receiving 450 citations.

Heat flux transients at the casting/chill interface during solidification of aluminum base alloys

Abstract: Heat flow at the metal/chill interface of bar-type castings of aluminum base alloys was modeled as a function of thermophysical properties of the chill material and its thickness. Experimental setup for casting square bars of Al-13.2 pct Si eutectic and Al-3 pet Cu-4.5 pct Si long freezing range alloys with chill at one end exposed to ambient conditions was fabricated. Experiments were carried out for different metal/chill combinations with and without coatings. The thermal history at nodal locations in the chill obtained during the experiments was used to estimate the interface heat flux by solving a one-dimensional Fourier heat conduction equation inversely. Using the data on transient heat flux q, the heat flow at the casting/chill interface was modeled in two steps: (1) The peak in the heat flux curve qmax was modeled as a power function of the ratio of the chill thickness d to its thermal diffusivity a, and (2) the factor (q/qmax) X α0.05 was also modeled as a power function of the time after the solidification set in. The model was validated for Cu-10 pct Sn -2 pct Zn alloy chill and Al-13.2 pct Si and Al-3 pct Cu-4.5 pct Si as the casting alloys. The heat flux values estimated using the model were used as one of the boundary conditions for solidification simulation of the test casting. The experimental and simulated temperature distributions inside the casting were found to be in good agreement.

Estimation of multiple heat-flux components at the metal/mold interface in bar and plate aluminum alloy castings

Abstract: In the present investigation, a serial solution of the inverse heat-conduction problem (IHCP) is extended for Al-3 pct Cu-4.5 pct Si alloy square bars and rectangular plates cast in metal molds. The metal/mold interface was divided into three segments, viz., the half face, the quarter face, and the corner. The heat-flux transients during casting solidification were then estimated at these segments. Three configurations were considered, viz., (1) one boundary segment for the whole length on the interface, (2) two boundary segments delineating two heat-flux components, and (3) three boundary segments leading to three heat-flux components. In order to identify the most acceptable spatial distribution of interface heat flux, two types of analyses were performed on the results of the IHCP, viz., convergence of absolute error in the computed and the measured temperatures at the sensor locations and total heat energy transferred across the boundary from the casting to the mold. The error convergence at the thermocouple locations was more or less identical for all the three cases in both bars and plates. However, the total heat absorbed by the mold, in the case of the one-segment model in bars and the three-segment model in plates, was found to be a minimum. This indicated that the interface heat flux did not show any spatial distribution in the case of bars, while a distinct spatial distribution could be identified in the case of plates. The individual heat fluxes at the different interface segments for the plate casting showed a peak within 3 to 3.5 seconds of pouring, after which it reduced and reached stable values in about 200 seconds. The maximum heat flux occurred at the corner segment. The analysis of heat-flux gradients showed that the air gap initiated at the corner and spread toward the center.

A Benchmark Study on the Thermal Conductivity of Nanofluids

Abstract: This article reports on the International Nanofluid Property Benchmark Exercise, or INPBE, in which the thermal conductivity of identical samples of colloidally stable dispersions of nanoparticles or “nanofluids,” was measured by over 30 organizations worldwide, using a variety of experimental approaches, including the transient hot wire method, steady-state methods, and optical methods. The nanofluids tested in the exercise were comprised of aqueous and nonaqueous basefluids, metal and metal oxide particles, near-spherical and elongated particles, at low and high particle concentrations. The data analysis reveals that the data from most organizations lie within a relatively narrow band (±10% or less) about the sample average with only few outliers. The thermal conductivity of the nanofluids was found to increase with particle concentration and aspect ratio, as expected from classical theory. There are (small) systematic differences in the absolute values of the nanofluid thermal conductivity among the various experimental approaches; however, such differences tend to disappear when the data are normalized to the measured thermal conductivity of the basefluid. The effective medium theory developed for dispersed particles by Maxwell in 1881 and recently generalized by Nan et al. [J. Appl. Phys. 81, 6692 (1997)], was found to be in good agreement with the experimental data, suggesting that no anomalous enhancement of thermal conductivity was achieved in the nanofluids tested in this exercise.

Review of thermo-physical properties, wetting and heat transfer characteristics of nanofluids and their applicability in industrial quench heat treatment

Abstract: The success of quenching process during industrial heat treatment mainly depends on the heat transfer characteristics of the quenching medium. In the case of quenching, the scope for redesigning the system or operational parameters for enhancing the heat transfer is very much limited and the emphasis should be on designing quench media with enhanced heat transfer characteristics. Recent studies on nanofluids have shown that these fluids offer improved wetting and heat transfer characteristics. Further water-based nanofluids are environment friendly as compared to mineral oil quench media. These potential advantages have led to the development of nanofluid-based quench media for heat treatment practices. In this article, thermo-physical properties, wetting and boiling heat transfer characteristics of nanofluids are reviewed and discussed. The unique thermal and heat transfer characteristics of nanofluids would be extremely useful for exploiting them as quench media for industrial heat treatment.