PhD (National Institute of Technology Raipur)
M.Tech (National Institute of Technology Tiruchirappalli)
B.E. (Govt. Engineering College Raipur)
RESEARCH INTERESTS
Composite Materials, Machine Learning, Simulation and Modeliing
8
Scopus Publications
357
Scholar Citations
8
Scholar h-index
7
Scholar i10-index
Scopus Publications
A critical review on advanced functional bioceramics fabricated by SLA for precision implant applications Palivela Bhargav Chandan, Amrit Raj Paul, Mohit Kumar Sahu, Dinesh Kalyanasundaram, Suresh Kumar Bhargava Journal of Materials Research and Technology, 2026 The convergence of advanced bioceramics and stereolithography (SLA)-based additive manufacturing (AM) is redefining the design and fabrication of precision biomedical implants. Conventional ceramic processing routes, while mature, are fundamentally constrained in producing patient-specific geometries, hierarchical porosity, and functionally graded architectures essential for next-generation regenerative applications. SLA, a vat-photopolymerization technique, offers unparalleled resolution, geometric freedom, and microarchitectural control, enabling the fabrication of complex bio-ceramic constructs with tunable biological and mechanical performance. This review critically examines recent advancements in SLA-based manufacturing of functional bioceramics, including hydroxyapatite, β-tricalcium phosphate, zirconia, alumina, bioglass, and composite systems. Particular emphasis is placed on the interdependence between slurry formulation (solid loading, rheology, dispersant chemistry, photo initiator systems), photopolymerization dynamics, and post-processing strategies such as debinding and sintering. The manuscript systematically correlates printing parameters—including laser power, exposure energy, scanning speed, and layer thickness—with microstructural features, porosity, dimensional shrinkage, and mechanical integrity of the final constructs. Emerging innovations such as digital light processing (DLP), two-photon polymerization (TPP), multi-material printing, and AI-assisted process monitoring are also discussed in the context of improving reproducibility and clinical scalability. Furthermore, the biomedical relevance of SLA-fabricated bioceramics is analyzed through applications in bone tissue engineering, dental restorations, and craniofacial implants, highlighting the ability to engineer bioactivity, osteoconductivity, and controlled resorption profiles through architectural design and surface functionalization. Persistent challenges—including light scattering in highly loaded slurries, defect formation during thermal processing, and the balance between porosity and mechanical strength—are critically evaluated. By consolidating material science, processing optimization, and biomedical performance considerations, this review provides a strategic roadmap for advancing SLA-enabled bioceramic technologies toward reliable, high-performance, and clinically translatable precision implant systems.
Influence of copper interlayer on the interface characteristics of stainless steel–aluminium transitional structure in wire arc directed energy deposition Amrit Raj Paul, Manidipto Mukherjee, Mohit Kumar Sahu Rapid Prototyping Journal, 2024 Purpose The purpose of this study is to investigate the deposition of SS–Al transitional wall using the wire arc directed energy deposition (WA-DED) process with a Cu interlayer. This study also aims to analyse the metallographic properties of the SS–Cu and Al–Cu interfaces and their mechanical properties. Design/methodology/approach The study used transitional deposition of SS–Al material over each other by incorporating Cu as interlayer between the two. The scanning electron microscope analysis, energy dispersive X-ray analysis, X-ray diffractometer analysis, tensile testing and micro-hardness measurement were performed to investigate the interface characteristics and mechanical properties of the SS–Al transitional wall. Findings The study discovered that the WA-DED process with a Cu interlayer worked well for the deposition of SS–Al transitional walls. The formation of solid solutions of Fe–Cu and Fe–Si was observed at the SS–Cu interface rather than intermetallic compounds (IMCs), according to the metallographic analysis. On the other hand, three different IMCs were formed at the Al–Cu interface, namely, Al–Cu, Al2Cu and Al4Cu9. The study also observed the formation of a lamellar structure of Al and Al2Cu at the hypereutectic phase. The mechanical testing revealed that the Al–Cu interface failed without significant deformation, i.e. < 4.73%, indicating the brittleness of the interface. Originality/value The study identified the formation of HCP–Fe at the SS–Cu interface, which has not been previously reported in additive manufacturing literature. Furthermore, the study observed the formation of a lamellar structure of Al and Al2Cu phase at the hypereutectic phase, which has not been previously reported in SS–Al transitional wall deposition.
Solid State Processes for Fabrication of Aluminum Metal Matrix Composites for Automotive and Aircraft Applications Computational Optimization Modeling and Simulation for Engineering Applications, 2024
Experimental Investigation, Modeling, and Optimization of Wear Parameters of B4C and Fly-Ash Reinforced Aluminum Hybrid Composite Mohit Kumar Sahu, Raj Kumar Sahu Frontiers in Physics, 2020 Lightweight and high-wear performance materials are currently in demand for various advanced applications in areas such as aerospace and automobiles. These demands can be achieved by hybrid aluminum matrix composites (HAMCs), as they possess excellent mechanical and tribological properties which can be customized using more than one reinforcement. Boron carbide (8 wt.%) and fly-ash (2 wt.%) reinforced hybrid aluminum 7075 composite was successfully fabricated using a stir-casting route. Wear is a crucible phenomenon that occurs over the interaction of surfaces and affects the performance of the material. To investigate wear behavior of developed HAMC, dry sliding wear tests were conducted based on the central composite design, taking the specific wear rate as a response parameter. Modeling of wear parameters is crucial, as it helps to predict the value of the wear response at the given set of input parameters without performing experimentation. Response surface method (RSM) was used for the modeling of wear parameters to develop an empirical model of specific wear rate in terms of load, sliding speed, and sliding distance. The high value of the coefficient of determination (R2 = 0.9894) illustrates the goodness of fit of the developed model. Moreover, the optimal condition of wear parameters was determined as 20 N load, 1.5 m/s sliding speed, and 500 m sliding distance; the predicted value of specific wear rate in this set of parameters is 0.2 × 10−5 mm3/N-m. The validation test at optimal conditions was performed and the specific wear rate was found to be 0.205 × 10−5 mm3/N-m, which shows good agreement with the predicted value. The worn-out surface and debris were analyzed using scanning electron microscope (SEM) images and electron dispersive spectrums (EDS) to completely explore the mechanism of wear.
Multi-objective optimization of upsetting parameters of Al-TiC metal matrix composites: A grey Taguchi approach Mohit K Sahu, A Valarmathi, S Baskaran, V Anandakrishnan, Rupesh K Pandey Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture, 2014 This work is a novel attempt to identify the optimum process parameters in cold upsetting of Al–TiC metal matrix composites with multiple responses using grey Taguchi approach. The formation of barrel and workability are the important attributes that greatly influence the process of upsetting. Three independently controllable process variables, namely, aspect ratio, friction factor and load, each at four levels are considered to find their optimum levels which yields maximum barrel radius and workability simultaneously. Grey Taguchi analysis has been performed to optimize the levels of input parameters. Both the quality characteristics are improved significantly at the optimal process condition as verified by the confirmation test. The effect of individual process variables on the responses is determined using analysis of variance.
RECENT SCHOLAR PUBLICATIONS
A Robust Machine Learning Approach for Intelligent Ransomware Detection in Industrial Control Networks M Sahu International Journal of Emerging Research in Engineering and Technology 7 … , 2026 2026
Data Analytics Approaches for Effective Threat Identification in Cloud Databases M Sahu International Journal of Emerging Research in Engineering and Technology 7 … , 2026 2026
A COMPARATIVE STUDY OF GCC, CLANG, AND ICC: WHICH C COMPILER EXCELS? M Sahu, A Kumar Journal of Global Research in Mathematical Archives 12 (5) , 2025 2025
Inner Wellness Revolution: Scientific and Holistic Solutions for Anxiety, Stress, and Overthinking MK Sahu Shashwat Publication 1, 1-119 , 2025 2025
Solid State Processes for Fabrication of Aluminum Metal Matrix Composites for Automotive and Aircraft Applications AK Sinha, KR Rao, VK Soni, N Upadhyay, RS Parihar, MK Sahu Computational Optimization, Modeling, and Simulation for Engineering … , 2024 2024
Investigation of Mechanical Properties and Optimization of Forming Parameters of Al7075-B 4 C-Fly Ash Hybrid Aluminium Matrix Composite MK Sahu, RK Sahu Arabian Journal for Science and Engineering 47 (7), 8161-8176 , 2022 2022 Citations: 7
Mechanical properties of ramie polymer composites AK Sinha, S RUNGTA, D MISHRA, MK SAHU, R HIMTE, ... Adv Appl Math Sci 21, 5341 , 2022 2022 Citations: 2
Aluminum based hybrid metal matrix composites: a review of selection philosophy and mechanical properties for advanced applications MK Sahu, RK Sahu International Journal of Mechanical and Production Engineering Research and … , 2020 2020 Citations: 20
Experimental Investigation, Modelling and Optimization of Wear Parameters of B4C and Fly-Ash Reinforced Aluminium Hybrid Composite MK Sahu, RK Sahu Frontiers in Physics 8, 219 , 2020 2020 Citations: 39
Synthesis, microstructure and hardness of Al 7075/B4C/Fly-ash composite using stir casting method MK Sahu, RK Sahu materials today: Proceedings, Elsevier , 2019 2019 Citations: 35
Fabrication of aluminum matrix composites by stir casting technique and stirring process parameters optimization. Adv Cast Technol MK Sahu, RK Sahu, MK Sahu, RK Sahu 2018 Citations: 6
Fabrication of Aluminum Matrix Composites by Stir Casting Technique and Stirring Process Parameters Optimization MK Sahu, RK Sahu Advanced Casting Technologies, InTech Open 1, 111-126 , 2018 2018 Citations: 130
Optimization of Stirring Parameters Using CFD Simulations for HAMCs Synthesis by Stir Casting Process MK Sahu, RK Sahu Transactions of the Indian Institute of Metals, Springer 70 (10), 2563-2570 , 2017 2017 Citations: 60
Sanjay,“ D Mishra, M Sahu Quality Assurance in Higher Education: An Introduction”, NAAC , 2016 2016 Citations: 11
Skills Development Through Vocational Training Ambit of job opportunities through Vocational Training SB Harsh Dev Dubey, Pradeep Shrivastava, Mohit Kumar Sahu 2015
Geo-Exchange Leads to Green Balance in City S Khattar, A Mukherjee, MK Sahu, MNK Swamy 2015
Multi-objective optimization of upsetting parameters of Al–TiC metal matrix composites: A grey Taguchi approach MK Sahu, A Valarmathi, S Baskaran, V Anandakrishnan, RK Pandey Proceedings of the Institution of Mechanical Engineers, Part B: Journal of … , 2014 2014 Citations: 38
Genetic analysis of powdery mildew resistance in field pea ( Pisum sativum L.). AS Anjali Shrivastava, RL Pandey, M Sahu 2008
MOST CITED SCHOLAR PUBLICATIONS
Fabrication of Aluminum Matrix Composites by Stir Casting Technique and Stirring Process Parameters Optimization MK Sahu, RK Sahu Advanced Casting Technologies, InTech Open 1, 111-126 , 2018 2018 Citations: 130
Optimization of Stirring Parameters Using CFD Simulations for HAMCs Synthesis by Stir Casting Process MK Sahu, RK Sahu Transactions of the Indian Institute of Metals, Springer 70 (10), 2563-2570 , 2017 2017 Citations: 60
Experimental Investigation, Modelling and Optimization of Wear Parameters of B4C and Fly-Ash Reinforced Aluminium Hybrid Composite MK Sahu, RK Sahu Frontiers in Physics 8, 219 , 2020 2020 Citations: 39
Multi-objective optimization of upsetting parameters of Al–TiC metal matrix composites: A grey Taguchi approach MK Sahu, A Valarmathi, S Baskaran, V Anandakrishnan, RK Pandey Proceedings of the Institution of Mechanical Engineers, Part B: Journal of … , 2014 2014 Citations: 38
Synthesis, microstructure and hardness of Al 7075/B4C/Fly-ash composite using stir casting method MK Sahu, RK Sahu materials today: Proceedings, Elsevier , 2019 2019 Citations: 35
Aluminum based hybrid metal matrix composites: a review of selection philosophy and mechanical properties for advanced applications MK Sahu, RK Sahu International Journal of Mechanical and Production Engineering Research and … , 2020 2020 Citations: 20
Sanjay,“ D Mishra, M Sahu Quality Assurance in Higher Education: An Introduction”, NAAC , 2016 2016 Citations: 11
Investigation of Mechanical Properties and Optimization of Forming Parameters of Al7075-B 4 C-Fly Ash Hybrid Aluminium Matrix Composite MK Sahu, RK Sahu Arabian Journal for Science and Engineering 47 (7), 8161-8176 , 2022 2022 Citations: 7
Fabrication of aluminum matrix composites by stir casting technique and stirring process parameters optimization. Adv Cast Technol MK Sahu, RK Sahu, MK Sahu, RK Sahu 2018 Citations: 6
Mechanical properties of ramie polymer composites AK Sinha, S RUNGTA, D MISHRA, MK SAHU, R HIMTE, ... Adv Appl Math Sci 21, 5341 , 2022 2022 Citations: 2
A Robust Machine Learning Approach for Intelligent Ransomware Detection in Industrial Control Networks M Sahu International Journal of Emerging Research in Engineering and Technology 7 … , 2026 2026
Data Analytics Approaches for Effective Threat Identification in Cloud Databases M Sahu International Journal of Emerging Research in Engineering and Technology 7 … , 2026 2026
A COMPARATIVE STUDY OF GCC, CLANG, AND ICC: WHICH C COMPILER EXCELS? M Sahu, A Kumar Journal of Global Research in Mathematical Archives 12 (5) , 2025 2025
Inner Wellness Revolution: Scientific and Holistic Solutions for Anxiety, Stress, and Overthinking MK Sahu Shashwat Publication 1, 1-119 , 2025 2025
Solid State Processes for Fabrication of Aluminum Metal Matrix Composites for Automotive and Aircraft Applications AK Sinha, KR Rao, VK Soni, N Upadhyay, RS Parihar, MK Sahu Computational Optimization, Modeling, and Simulation for Engineering … , 2024 2024
Skills Development Through Vocational Training Ambit of job opportunities through Vocational Training SB Harsh Dev Dubey, Pradeep Shrivastava, Mohit Kumar Sahu 2015
Geo-Exchange Leads to Green Balance in City S Khattar, A Mukherjee, MK Sahu, MNK Swamy 2015
Genetic analysis of powdery mildew resistance in field pea ( Pisum sativum L.). AS Anjali Shrivastava, RL Pandey, M Sahu 2008
Publications
1. Investigation of Mechanical Properties and Optimization of Forming Parameters of Al7075-B4C-Fly Ash Hybrid Aluminium Matrix Composite.
2. Experimental Investigation, Modelling and Optimization of Wear Parameters of B4C and Fly-Ash Reinforced Aluminium Hybrid Composite
3.Optimization of Stirring Parameters Using CFD Simulations for HAMCs Synthesis by Stir Casting Process\Multiobjective optimization of upsetting
parameters of Al–TiC metal matrix composites: A grey Taguchi approach
4. Multiobjective optimization of upsetting parameters of Al–TiC metal matrix composites: A grey Taguchi approach
5.Synthesis, microstructure and hardness of Al 7075/B4C/Fly-ash composite using stir casting method
6.Aluminum Based Hybrid Metal Matrix Composites: A Review Of Selection Philosophy And Mechanical Properties For Advanced Applications
7.Mechanical Properties Of Ramie Polymer Composites: Review
8.Fabrication of Aluminum Matrix Composites by Stir Casting Technique and Stirring Process Parameters Optimization
9.Skills Development through Vocational Training
10.Geo-Exchange Leads toGreen Balan ce in City
RESEARCH OUTPUTS (PATENTS, SOFTWARE, PUBLICATIONS, PRODUCTS)
1. “A device to perform vehicle to vehicle communication to automate the safety and to enhance the driving Application
No. 202221036594 A, Publication Date : 02/12/2022, Issue No. 48/2022.
