Sustainable Manufacturing of Advanced Materials

Gurudas Mandal, PhD is an Assistant Professor in the Department of Metallurgical Engineering, Kazi Nazrul University, West Bengal, India. He has published 20 technical research papers in reputed international journals, eight papers in conference proceedings, and nine book chapters. His research interests focus on alloy steel and cast iron, composite materials, magnetic materials, hydrogen energy, and archaeometallurgy. Swarup Kumar Ghosh, PhD is a Professor in the Department of Metallurgy and Materials Engineering, the Indian Institute of Engineering Science and Technology, Shibpur. West Bengal, India. He has published more than 100 research articles in reputed international journals and conference proceedings and has served as an investigator for nine sponsored projects. His research interests include structure-property correlations in ferrous and non-ferrous alloys, composite materials, crystallographic texture, and corrosion engineering. Snehanshu Pal, PhD is an Associate Professor in the Department of Metallurgy and Materials Engineering at the Indian Institute of Engineering Science and Technology, Shibpur. West Bengal, India. He has published more than 115 research articles in internationally reputed journals, three technical books, and edited one technical book. He has served as an investigator for five sponsored research projects and two industrial projects and has active research collaborations with esteemed universities across the globe. Sandip Kunar, PhD is an Assistant Professor in the Department of Mechanical Engineering, Aditya Engineering College, Andhra Pradesh, India. He has published more than 28 research papers in various reputed international journals, more than 24 research papers in national and international conference proceedings, 35 book chapters, and 13 books. He has also published two patents and been granted an additional two. His research interests include non-conventional machining processes, micromachining processes, advanced manufacturing technology, and industrial engineering.

• Preface xviiAcknowledgment xxi1 Introduction to Sustainability of Manufacturing and Materials Processing Technologies 1Sarthak Prasad Sahoo and Rahul Choudhary1.1 Introduction 21.2 Principles of Sustainable Manufacturing (SM) 31.3 Environmental Impacts of Traditional Manufacturing 51.4 Sustainable Materials Processing 61.5 Technological Innovations for Sustainability 81.6 Assessment Tools and Metrics 101.7 Real-World Examples of Sustainable Manufacturing Practices 111.8 Challenges and Future Directions 121.9 Conclusion 142 A Critical Review of Green and Sustainable Approaches in Advanced Materials Manufacturing 19Ajithkumar Sitharaj, Manoj Mohan Prasath V., Sandip Kunar, Ganesh N. and Arul Pandiyan2.1 Introduction 202.2 Foundations and Drivers of Green and Sustainable Manufacturing 212.3 Overview of Advanced Materials 252.4 Green Synthesis and Processing Techniques 272.5 Sustainable Manufacturing Technologies 302.6 Case Studies across Material Classes 332.7 Life Cycle Assessment (LCA) and Environmental Impact Analysis 342.8 Emerging Trends and Future Directions 362.9 Conclusion 373 Advanced High-Strength Steel Alloys for Sustainable Applications 43Indrajit Dey and Swarup Kumar Ghosh3.1 Introduction 443.2 Experimental Procedures 463.3 Results and Discussion 473.4 Conclusions 594 High-Performance Steels for Sustainable Manufacturing of Vehicles 65Ankita Bhattacharya, Ghanshyam Das and Swarup Kumar Ghosh4.1 Introduction 664.2 Properties and Characteristics of High-Performance Steels 674.3 High Strength Low Alloy Steel 754.4 Ultra-High Strength Steel 774.5 Galvanised Steel 794.6 Applications of High-Performance Steels 824.7 Benefits of High-Performance Steels 834.8 Challenges and Opportunities 844.9 Future Trends and Developments 854.10 Conclusions 855 Sustainable Manufacturing of Ferritic Stainless Steel: Experimental and Review 93Swarnendu Das, Nishant Kumar, Piyush Kumar, R. Rejeesh, A. Ghosh and S. Patra5.1 Introduction 945.2 Remedial for Ridging 955.3 Experimental Details 965.4 Results 985.5 Discussion 1045.6 Conclusion and Summary 1056 Sustainable Steel Processing Techniques: Minimising Waste and Energy Consumption 111Muralidhar Yadav and Swarup Kumar Ghosh6.1 Introduction 1126.2 Importance of Sustainable Steel Processing 1136.3 Sustainable Steel Processing Techniques 1146.4 Emerging Steelmaking Technologies 1226.5 Waste Minimization and Recycling 1226.6 Case Studies and Best Practices 1306.7 Recommended Future Directions for Sustainable Steelmaking 1316.8 Conclusions 1337 Minimizing Cr Loss during EAF Stainless Steel Making for Achieving Sustainability 137Subham Ranjan, Rinku Singroha, Sayantan Mukherjee and Sudipta Patra7.1 Introduction 1377.2 Description of the Pneumatic Injection 1397.3 Process 1417.4 Results 1417.5 Discussion 1447.6 Conclusion 1478 Bio-Inspired Steel Coatings for Corrosion Resistance and Sustainability 151Sneha Roy and Swarup Kumar Ghosh8.1 Introduction 1528.2 Bio-Inspired Coating Materials 1558.3 Fabrication and Characterization of Bio-Inspired Coatings 1588.4 Corrosion Resistance Mechanisms of Bio-Inspired Coatings 1628.5 Environmental Sustainability of Bio-Inspired Coatings 1638.6 Life Cycle Assessment (LCA) and Circularity 1658.7 Case Studies and Future Directions 1658.8 Emerging Trends and Future Outlook 1728.9 Conclusions 1739 Designing Advanced Materials Using Embedded Atom Method Interatomic Potential: A Review 179Sayak Bal and Snehanshu Pal9.1 Introduction 1799.2 Theoretical Foundations of EAM Potentials 1819.3 Development Methodologies 1839.4 Some Existing EAM Potentials 1869.5 Validation of EAM Potentials 1889.6 Recent Works and Future Directions in EAM Development 1899.7 Applications of EAM in Advanced Materials 1909.8 Conclusion 19110 Green Processing of Particles Dispersed Composite Materials 199Rudra Narayan Mohapatro, Sunita Routray and Ranjita Swain10.1 Introduction 20010.2 Background and Need for Green Processing 20010.3 Understanding Particles Dispersed Composite Materials 20110.4 Green Processing Approaches 20110.5 Role of Bio-Based and Waste-Derived Particles 20210.6 Benefits and Challenges 20310.7 Future Outlook and Applications 20410.8 Particles Composite Processing in Green Processing of Particles Dispersed Composite Materials 20410.9 Natural Fiber and Polymer Matrix Materials in Green Composites 20610.10 Chemical Treatment of Natural Fibers 20910.11 Strength Properties and Performance 21010.12 Sustainable Processing Techniques 21110.13 Applications and Future Directions 21210.14 Feasibility Studies on Investigating the Use of Industrial Waste Materials Reinforced Hybrid Composites 21310.15 Conclusion 21811 Advanced Multifunctional Ceramics: Foundations, Properties, Characterization, Processing and Emerging Trends 223Jagadeesha T. and Sandip Kunar11.1 Introduction 22411.2 Classification of Functional Ceramics 22611.3 Properties of Functional Ceramics 23011.4 Characterization of Functional Ceramics 23511.5 Fabrication Methods of Functional Ceramics 23911.6 Conclusions 24211.7 Future Research Opportunities 24212 Circular Economy-Driven Approaches in Sustainable Manufacturing of Advanced Materials 245Idhayaraja S., Ajithkumar Sitharaj, Ganesh N., Arul Pandiyan and Sandip Kunar12.1 Introduction 24612.2 Circular Economy Framework for Integrated Sustainable Production 24712.3 Sustainable Material Selection Strategies 25112.4 Additive Manufacturing for Circular Economy 25412.5 Digitalization Enabling Closed-Loop Production 25712.6 Conclusion 26113 Sustainable Additive Manufacturing: Innovations in Advanced Materials and Processing Techniques 267Manoj Mohan Prasath V., Ajithkumar Sitharaj, Karuppusamy R. and Sandip Kunar13.1 Introduction 26813.2 Overview of AM 27013.3 A Sustainable AM Technology 27813.4 Innovation in AM Technology 28313.5 Conclusion 28614 Semi-Solid Metal Casting: A Sustainable Approach for High-Performance Component Fabrication 293Arul Pandian Palanisamy, Ganesh Nataraj and Ajithkumar Sitharaj14.1 Introduction 29414.2 Fundamentals of Semi-Solid Metal Casting 29514.3 Process Routes and Materials 29614.4 Sustainability Aspects 29814.5 Mechanical and Microstructural Characteristics 29914.6 Applications in High-Performance Components 30114.7 Challenges and Limitations 30414.8 Conclusions 30615 Designing High-Performance Alloys for Sustainable Structural Applications Using Molecular Dynamics Simulations 311K. Vijay Reddy, Sunil Kumar Pathak, Shailesh Kumar Singh and Snehanshu Pal15.1 Introduction 31215.2 MD Simulation Setup 31415.3 Results and Discussion 31615.4 Conclusions 32016 Recyclable and Renewable Composite Materials in Additive Manufacturing 325Ganesh Nataraj, Ramesh Babu S., A. R. Ravikumar, Arul Pandian, Karthikeyan Rajendran and Ajithkumar Sitharaj16.1 Introduction 32616.2 Recyclable Composite Materials in Additive Manufacturing 32816.3 Renewable Composite Materials in Additive Manufacturing 33216.4 Processing and Characterization of Recyclable and Renewable AM Composites 33816.5 Applications for Recyclable and Renewable Composite Materials in AM 34216.6 Challenges and Future Outlook 34716.7 Conclusion 34817 Eco Friendly Bio Composites in Additive Manufacturing for Sustainable Applications 351Ganesh Nataraj, Ramesh Babu S., A. R. Ravikumar, Karthikeyan Rajendran, Arul Pandian and Ajithkumar Sitharaj17.1 Introduction 35217.2 Fundamentals of Bio Composites 35317.3 Additive Manufacturing: An Enabler of Sustainable Design 35817.4 Integration of Bio Composites in Additive Manufacturing 36117.5 Mechanical and Thermal Properties 36517.6 Sustainable Applications of Additively Manufactured Bio Composites 36917.7 Environmental Impact and Life Cycle Assessment (LCA) 37117.8 Challenges and Future Perspectives 37217.9 Conclusion 372References 373Index 377

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