Synergistic effect of hybrid nano-particles reinforced Al7150 metal matrix composites (A17150-hBN-B4C) for advanced aerospace applications Pagidi Madhukar, N Selvaraj, SK Gugulothu, Praveen Barmavatu Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2025 The performance of a hybrid metal matrix (HMM) composites relies on the dispersion of reinforcements. The present investigation presents a novel processing technique to fabricate high-performance Al7150 alloy with an even dispersion of hybrid nano-particulates. During the fabrication process, nano-sized reinforcements, boron carbide (B 4 C) and hexagonal boron nitride (hBN) were dispersed uniformly in Al7150 melt with the help of ultrasonic assisted stir casting method. Investigations were carried out to study the influence of hybrid nano-particulates weight percentage (wt.%) on the composite performance by varying it from 0 to 2 at an increment of 0.5 and with an equal reinforcement quantity. Phase identification and microstructural analysis were studied using XRD, EDX, OM and SEM, respectively. Microstructural investigations reveal the homogeneous dispersion of nano-particulates and grain refinement in the hybrid composites. XRD and EDX confirm the existence of the hBN, B4C and Al7150 elements in the hybrid composites. Further, mechanical testing was carried out using UTS for strength evaluation, fracture mechanism and hardness using a micro-hardness tester. Significant improvement in mechanical characteristics was noticed in the as-cast condition. Al7150-1.5% hybrid (B4C-hBN) nanocomposite revealed an 82.03% reduction in porosity, 25.4% enhancement in micro-hardness and 104.25% in tensile strength.
Influence of Silicon Nitride (Si3N4) on Mechanical and Dielectric Properties of a Novel Fused Silica Ceramic Composites Kishore Kumar Kandi, Gurabvaiah Punugupati, Pagidi Madhukar, C. S. P. Rao, Murthy Chavali Silicon, 2022 Porous fused silica (SiO2) ceramic composites were fabricated using a novel gel-casting process and the experiments were conducted using Response Surface Methodology (RSM) central composite with face centred design with a six-centre points approach. The process parameters of a gel-casting process such as solid loading (SL), monomer ratio (RM), monomer content (MC) and additive (Si3N4) were considered as input parameters and flexural strength (FS), porosity (Por.) and dielectric constant (DE) as response parameters. Single parameter and interaction parameter effects on responses were studied. The effectiveness of derived models was compared with Analysis of Variance (ANOVA) at a 95% confidence level. Statistical analysis proved that input parameters have a critical effect on responses. The derived RSM mathematical models have a higher R2 value (FS 97.62%, Por. 95.12% and DE 95.93%) which shows the critical relation between actual and predicted values. The optimal responses obtained were FS 86.173 MPa, Por. 39.767% and DE 6.949 corresponding parameters process parameters SL 47.95%, additive (Si3N4) 10.43 wt%, MC 15 wt% and RM 3.
Mathematical Models to Predict Flow Stress and Dynamically Recrystallized Grain Size of Deformed AA7150-5 wt% B4C Composite Fabricated Using Ultrasonic-Probe Assisted Stir Casting Process R. Seetharam, Pagidi Madhukar, G. Yoganjaneyulu, S. Kanmani Subbu, M. J. Davidson Metals and Materials International, 2022 Mathematical models are among the new approaches employed to predict the properties of any material under various conditions. Mathematical models are essential for not only understanding the material properties but also estimating the cost of design, product life, and failure criteria of the product. Therefore, in the current investigation, the hot deformation (HD) behaviour and microstructure alteration of deformed AA7150-5 wt% B4C composite was studied through a mathematical model. The new AA7150-5 wt% B4C composite was fabricated through an ultrasonic-probe assisted (20 KHz, 1000 W) stir casting process. The hot compression test was performed on a hydraulic press for various deformation temperatures (623–773 K) and strain rates (0.01–1 s− 1). Based on the outcome, it is inferred that the flow stresses and microstructures of AA7150-5 wt% B4C composite was significantly altered during the hot compression test under various deformation conditions. The constitutive and dynamically recrystallized grain (DRXed) models were developed as a function of various deformation conditions of deformed AA7150-5 wt% B4C composite, which was then applied to forecast the flow stress and grain size behaviour for different deformation conditions. The flow stress and DRXed grain size were obtained through the proposed constitutive and DRXed models are correlated with experimental results, with excellent accuracy. The models developed are reliable to predict the AA7150-5 wt% B4C properties for various conditions.
Process Parameter Trade-offs in Laser Powder Bed Fusion: A Multi-Objective Review on Surface Finish, Strength, Biological Performance, Modelling, Artificial Intelligence, and … B Das, N Sahoo, P Patel, A Ghosh, MDA Khan, AK Sinha, P Madhukar, ... Materials Today Communications, 115319 , 2026 2026
Artificial neural network-based prediction and microstructural insights of wear in Nb C-103 alloy for aerospace applications AS Kotha, P Madhukar, G Punugupati Journal of the Brazilian Society of Mechanical Sciences and Engineering 48 … , 2026 2026
Post-harvest grain storage: Methods, factors, and eco-friendly solutions P Madhukar, LM Pandey, US Dixit Food Control 174, 111236 , 2025 2025 Citations: 18
Synergistic effect of hybrid nano-particles reinforced Al7150 metal matrix composites (A17150-hBN-B 4 C) for advanced aerospace applications P Madhukar, N Selvaraj, SK Gugulothu, P Barmavatu Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2025 2025 Citations: 2
Laser-assisted machining of niobium alloy (C-103): effects of process parameters on cutting force and surface finish AS Kotha, P Madhukar, G Punugupati, CSP Rao, P Barmavatu, ... International Journal on Interactive Design and Manufacturing (IJIDeM) 19 (3 … , 2025 2025 Citations: 4
Manufacturing and Measuring Techniques for Graphene-Silicone-Based Strain Sensors: Peña-Consuegra, Pagnola, Useche, Madhukar, Saccone, and Marrugo J Peña-Consuegra, MR Pagnola, J Useche, P Madhukar, FD Saccone, ... JOM 75 (3), 631-645 , 2023 2023 Citations: 8
Optimization of process parameters for surface temperature in laser-assisted machining of Nb C103 alloy using taguchi method A Sankeerth, P Madhukar, G Punugupati, GB Veeresh Kumar, CSP Rao, ... Materials Express 13 (2), 401-406 , 2023 2023 Citations: 3
Influence of Reinforcement Particles on Dynamically Recrystallized Grain of Hot Upset Sintered Al-B 4 C Composites R Seetharam, SK Subbu, MJ Davidson, KR Ramkumar, P Madhukar Journal of Materials Engineering and Performance 31 (11), 9083-9096 , 2022 2022 Citations: 11
Effect of boron nitride (BN) on mechanical and dielectric properties of fused silica ceramic composites KK Kandi, G Punugupati, P Madhukar, CSP Rao Journal of the Korean Ceramic Society 59 (5), 565-577 , 2022 2022 Citations: 10
A Novel Gelcast SiO 2 -Si 3 N 4 -BN Ceramic Composites for Radome Applications KK Kandi, G Punugupati, M Pagidi, CSP Rao Silicon 14 (13), 8179-8192 , 2022 2022 Citations: 13
Influence of Silicon Nitride (Si 3 N 4 ) on Mechanical and Dielectric Properties of a Novel Fused Silica Ceramic Composites KK Kandi, G Punugupati, P Madhukar, CSP Rao, M Chavali Silicon 14 (13), 7503-7516 , 2022 2022 Citations: 7
Mathematical Models to Predict Flow Stress and Dynamically Recrystallized Grain Size of Deformed AA7150-5 wt% B 4 C Composite Fabricated Using Ultrasonic … R Seetharam, P Madhukar, G Yoganjaneyulu, SK Subbu, MJ Davidson Metals and Materials International 28 (4), 931-944 , 2022 2022 Citations: 15
Influence of ultrasonic vibration towards the microstructure refinement and particulate distribution of AA7150-B4C nanocomposites P Madhukar, V Mishra, N Selvaraj, CSP Rao, VK Gonal Basavaraja, ... Coatings 12 (3), 365 , 2022 2022 Citations: 20
Influence of ultrasonic vibration towards the microstructure refinement and particulate distribution of AA7150-B4C nanocomposites. Coatings. 2022; 12 (3) P Madhukar, V Mishra, N Selvaraj, CSP Rao, VK Gonal Basavaraja, ... Art , 2022 2022 Citations: 3
Influence of cutting parameters on laser assisted machining of C103 Nb alloy K Aravind Sankeerth, P Madhukar, G Punugupati, VK GB, CSP Rao Advances in Materials and Processing Technologies, 1-11 , 2022 2022 Citations: 1
Influence of TiC nano‐particulates on the physical and mechanical properties of AA7150‐TiC MMC: Fabricated by advanced novel process P Madhukar, N Selvaraj, GBV Kumar, CSP Rao, F Mohammad, ... Nano Select 3 (1), 78-90 , 2022 2022 Citations: 1
Investigation of the tribological characteristics of aluminum 6061-reinforced titanium carbide metal matrix composites GB Veeresh Kumar, R Pramod, R Hari Kiran Reddy, P Ramu, ... Nanomaterials 11 (11), 3039 , 2021 2021 Citations: 46
Effect of TiCnp on microstructure and mechanical behaviour of high-performance Al7150-TiC nanocomposites P Madhukar, N Selvaraj, GBV Kumar, CSP Rao, F Mohammad, M Chavali Materials Science and Engineering: B 265, 115034 , 2021 2021 Citations: 6
Enhanced performance of AA7150-SiC nanocomposites synthesized by novel fabrication process P Madhukar, N Selvaraj, CSP Rao, GBV Kumar Ceramics International 46 (10), 17103-17111 , 2020 2020 Citations: 36
Process Optimization of Digital Conjugate Surfaces: A Review P Madhukar, G Punugupati, N Selvaraj, CSP Rao Numerical Optimization in Engineering and Sciences: Select Proceedings of … , 2020 2020
MOST CITED SCHOLAR PUBLICATIONS
Production of high performance AA7150-1% SiC nanocomposite by novel fabrication process of ultrasonication assisted stir casting P Madhukar, N Selvaraj, R Gujjala, CSP Rao Ultrasonics Sonochemistry 58, 104665 , 2019 2019 Citations: 115
Fabrication and characterization two step stir casting with ultrasonic assisted novel AA7150-hBN nanocomposites P Madhukar, N Selvaraj, CSP Rao, GBV Kumar Journal of Alloys and Compounds 815, 152464 , 2020 2020 Citations: 99
Tribological behavior of ultrasonic assisted double stir casted novel nano-composite material (AA7150-hBN) using Taguchi technique P Madhukar, N Selvaraj, CSP Rao, GBV Kumar Composites Part B: Engineering 175, 107136 , 2019 2019 Citations: 92
Manufacturing of aluminium nano hybrid composites: a state of review P Madhukar, N Selvaraj, CSP Rao IOP Conference Series: Materials Science and Engineering 149 (1), 012114 , 2016 2016 Citations: 48
Investigation of the tribological characteristics of aluminum 6061-reinforced titanium carbide metal matrix composites GB Veeresh Kumar, R Pramod, R Hari Kiran Reddy, P Ramu, ... Nanomaterials 11 (11), 3039 , 2021 2021 Citations: 46
Enhanced performance of AA7150-SiC nanocomposites synthesized by novel fabrication process P Madhukar, N Selvaraj, CSP Rao, GBV Kumar Ceramics International 46 (10), 17103-17111 , 2020 2020 Citations: 36
Influence of ultrasonic vibration towards the microstructure refinement and particulate distribution of AA7150-B4C nanocomposites P Madhukar, V Mishra, N Selvaraj, CSP Rao, VK Gonal Basavaraja, ... Coatings 12 (3), 365 , 2022 2022 Citations: 20
Post-harvest grain storage: Methods, factors, and eco-friendly solutions P Madhukar, LM Pandey, US Dixit Food Control 174, 111236 , 2025 2025 Citations: 18
Mathematical Models to Predict Flow Stress and Dynamically Recrystallized Grain Size of Deformed AA7150-5 wt% B 4 C Composite Fabricated Using Ultrasonic … R Seetharam, P Madhukar, G Yoganjaneyulu, SK Subbu, MJ Davidson Metals and Materials International 28 (4), 931-944 , 2022 2022 Citations: 15
A Novel Gelcast SiO 2 -Si 3 N 4 -BN Ceramic Composites for Radome Applications KK Kandi, G Punugupati, M Pagidi, CSP Rao Silicon 14 (13), 8179-8192 , 2022 2022 Citations: 13
Microstructure studies of AA7150-hBN nanocomposites fabricated by ultrasonic assisted stir casting P Madhukar, N Selvaraj, G Punugupati, GB Veeresh Kumar, CSP Rao, ... Materials Research Express 6 (11), 116545 , 2019 2019 Citations: 13
Influence of Reinforcement Particles on Dynamically Recrystallized Grain of Hot Upset Sintered Al-B 4 C Composites R Seetharam, SK Subbu, MJ Davidson, KR Ramkumar, P Madhukar Journal of Materials Engineering and Performance 31 (11), 9083-9096 , 2022 2022 Citations: 11
Effect of boron nitride (BN) on mechanical and dielectric properties of fused silica ceramic composites KK Kandi, G Punugupati, P Madhukar, CSP Rao Journal of the Korean Ceramic Society 59 (5), 565-577 , 2022 2022 Citations: 10
Manufacturing and Measuring Techniques for Graphene-Silicone-Based Strain Sensors: Peña-Consuegra, Pagnola, Useche, Madhukar, Saccone, and Marrugo J Peña-Consuegra, MR Pagnola, J Useche, P Madhukar, FD Saccone, ... JOM 75 (3), 631-645 , 2023 2023 Citations: 8
Influence of Silicon Nitride (Si 3 N 4 ) on Mechanical and Dielectric Properties of a Novel Fused Silica Ceramic Composites KK Kandi, G Punugupati, P Madhukar, CSP Rao, M Chavali Silicon 14 (13), 7503-7516 , 2022 2022 Citations: 7
Effect of TiCnp on microstructure and mechanical behaviour of high-performance Al7150-TiC nanocomposites P Madhukar, N Selvaraj, GBV Kumar, CSP Rao, F Mohammad, M Chavali Materials Science and Engineering: B 265, 115034 , 2021 2021 Citations: 6
Fabrication of light weight metal matrix nanocomposites using ultrasonic cavitation process: a state of review P Madhukar, N Selvaraj, CSP Rao, SK Mishra Materials science forum 969, 882-888 , 2019 2019 Citations: 6
Laser-assisted machining of niobium alloy (C-103): effects of process parameters on cutting force and surface finish AS Kotha, P Madhukar, G Punugupati, CSP Rao, P Barmavatu, ... International Journal on Interactive Design and Manufacturing (IJIDeM) 19 (3 … , 2025 2025 Citations: 4
Optimization of process parameters for surface temperature in laser-assisted machining of Nb C103 alloy using taguchi method A Sankeerth, P Madhukar, G Punugupati, GB Veeresh Kumar, CSP Rao, ... Materials Express 13 (2), 401-406 , 2023 2023 Citations: 3
Influence of ultrasonic vibration towards the microstructure refinement and particulate distribution of AA7150-B4C nanocomposites. Coatings. 2022; 12 (3) P Madhukar, V Mishra, N Selvaraj, CSP Rao, VK Gonal Basavaraja, ... Art , 2022 2022 Citations: 3