Pankaj Kaushik
@iitb.ac.in
Post-Doctoral Fellow
I.I.T. Bombay
RESEARCH, TEACHING, or OTHER INTERESTS
Mechanical Engineering, Industrial and Manufacturing Engineering, Metals and Alloys, Waste Management and Disposal
12
Scopus Publications
173
Scholar Citations
5
Scholar h-index
5
Scholar i10-index
Scopus Publications
- Comprehensive analysis of friction stir welding of high-temperature P22 steel and Al 5052 alloy: metallurgical mixing, mechanical properties, and failure mechanism
Pankaj Kaushik and Dheerendra Kumar Dwivedi
Springer Science and Business Media LLC - Investigating the influence of stress ratio variation on the crack growth rate in friction stir welded dissimilar aluminum alloys
Saurabh Tiwari, Sarthak Verma, and Pankaj Kaushik
Elsevier BV - Investigating Failure in Laser-Welded Joints of Microalloyed Steel: A Systematic Review
Dheeraj Kumar Saini and Pankaj Kaushik
Springer Science and Business Media LLC - Studies on Cold Metal Transfer Welding of Aluminum 5083 Alloy to Pure Titanium
Pankaj Kaushik, Ranjan Kumar, M. Manjaiah, and Ajith G. Joshi
CRC Press - Friction stir-assisted cladding: Solid-state recycling of machine shop scrap for sustainable metal production
Pankaj KAUSHIK
Materials Research Forum LLC
Abstract. The manufacturing industry, a cornerstone of modern economies, generates a substantial amount of waste in the form of manufacturing chips, which often end up as discarded byproducts. This waste not only poses environmental hazards but also represents a missed opportunity for resource efficiency and cost savings. This article explores the innovative use of friction stir-assisted cladding (FS-AC) as a sustainable and cost-effective solution for repurposing aluminum chips on a steel substrate without melting the material. The study investigates the mechanism of the FS-AC process, highlighting the conversion of metallic swarf into a feedstock material for cladding without entailing costly clad materials. Metallographic analysis demonstrates a uniformly clad layer with an average thickness of 0.95 mm. The study addresses challenges related to bonding at the clad layer-substrate interface and proposes further advanced characterization studies for diffusion analysis and coating-substrate bond strength. In conclusion, the FS-AC process presents a valuable method for recycling machine shop floor scrap, transforming it into useful feedstock material for cladding purposes, and that too in an energy-efficient manner. This proposed approach has promising potential for processing different material combinations for additive manufacturing and exploring functionally graded material development using metallic swarf. - Enhancing strength and metallurgical soundness of dissimilar Al-steel FSSW joints through novel exit hole refilling technique
Pankaj Kaushik and Dheerendra Kumar Dwivedi
Elsevier BV - Investigating the Effects of Induction Heating on Friction Stir Welding of Low-Carbon Steel
Pankaj Kaushik, Rajdev Singh, Arun Jena, and Dheerendra Kumar Dwivedi
Springer Nature Singapore - Heat generation and steel fragment effects on friction stir welding of aluminum alloy with steel
Pankaj Kaushik and Dheerendra Kumar Dwivedi
Informa UK Limited
ABSTRACT Joining two dissimilar materials, like aluminum and steel, has been a topic of great importance in modern engineering applications. Therefore, this research expounds on joining aluminum alloy (Al5052) with low-carbon mild steel using friction stir welding. A novel approach is employed that quantifies the discontinuities (steel debris and voids) in the weld stir zone using image analysis. Furthermore, a parametric investigation was conducted following a full factorial approach with three tool rotational and traverse speed levels, and a heat input factor (ω2/v) was derived through theoretical modeling of process parameters. The heat input factor was substantiated experimentally with thermal cycle measurements. Results revealed that both the ω2/v factor and the extent of discontinuities determined the soundness and strength of the weld joints. A low rotational speed of 386 revolutions/minute and moderate traverse speed of 140 mm/minute, having minimal discontinuities, rendered maximum joint strength of approximately 212 MPa. - Influence of hook geometry on failure mechanism of Al6061-galvanized steel dissimilar FSW lap joint
Pankaj Kaushik and Dheerendra Kumar Dwivedi
Springer Science and Business Media LLC - Al-steel dissimilar joining: Challenges and opportunities
Pankaj Kaushik and Dheerendra Kumar Dwivedi
Elsevier BV - Effect of tool geometry in dissimilar Al-Steel Friction Stir Welding
Pankaj Kaushik and Dheerendra Kumar Dwivedi
Elsevier BV - Induction preheating in FSW of Al-Steel combination
Pankaj Kaushik and Dheerendra Kumar Dwivedi
Elsevier BV
RECENT SCHOLAR PUBLICATIONS
- Comprehensive analysis of friction stir welding of high-temperature P22 steel and Al 5052 alloy: metallurgical mixing, mechanical properties, and failure mechanism
P Kaushik, DK Dwivedi
Welding in the World, 1-12 2025 - Investigating the influence of stress ratio variation on the crack growth rate in friction stir welded dissimilar aluminum alloys
S Tiwari, S Verma, P Kaushik
Engineering Failure Analysis 165, 108828 2024 - Investigating Failure in Laser-Welded Joints of Microalloyed Steel: A Systematic Review
DK Saini, P Kaushik
Transactions of the Indian Institute of Metals 77 (8), 1939-1957 2024 - Friction stir-assisted cladding: Solid-state recycling of machine shop scrap for sustainable metal production
P KAUSHIK, PP DATE
Materials Research Proceedings 41 (2024), 2822-2828 2024 - Heat generation and steel fragment effects on friction stir welding of aluminum alloy with steel
P Kaushik, D Kumar Dwivedi
Materials and Manufacturing Processes 39 (2), 161-173 2024 - Enhancing strength and metallurgical soundness of dissimilar Al-steel FSSW joints through novel exit hole refilling technique
P Kaushik, DK Dwivedi
Manufacturing Letters 38, 83-87 2023 - Significance of Tool Geometry and Double Hook Formation in Al-Steel Dissimilar Friction Stir Spot Joints
P Kaushik, DK Dwivedi
THE 76th IIW ANNUAL ASSEMBLY AND INTERNATIONAL CONFERENCE ON WELDING AND 2023 - Dissimilar metal joining of steel-aluminium alloy by friction stir welding
DK Dwivedi
Dissimilar Metal Joining, 269-285 2023 - Investigating the Effects of Induction Heating on Friction Stir Welding of Low-Carbon Steel
P Kaushik, R Singh, A Jena, DK Dwivedi
International Conference on Advances in Materials Processing: Challenges and 2022 - Influence of hook geometry on failure mechanism of Al6061-galvanized steel dissimilar FSW lap joint
P Kaushik, DK Dwivedi
Archives of Civil and Mechanical Engineering 22 (4), 149 2022 - Al-steel dissimilar joining: Challenges and opportunities
P Kaushik, DK Dwivedi
Materials Today: Proceedings 62, 6884-6899 2022 - Effect of tool geometry in dissimilar Al-steel friction stir welding
P Kaushik, DK Dwivedi
Journal of Manufacturing Processes 68, 198-208 2021 - Induction preheating in FSW of Al-Steel combination
P Kaushik, DK Dwivedi
Materials Today: Proceedings 46, 1091-1095 2021
MOST CITED SCHOLAR PUBLICATIONS
- Effect of tool geometry in dissimilar Al-steel friction stir welding
P Kaushik, DK Dwivedi
Journal of Manufacturing Processes 68, 198-208 2021
Citations: 85 - Induction preheating in FSW of Al-Steel combination
P Kaushik, DK Dwivedi
Materials Today: Proceedings 46, 1091-1095 2021
Citations: 23 - Al-steel dissimilar joining: Challenges and opportunities
P Kaushik, DK Dwivedi
Materials Today: Proceedings 62, 6884-6899 2022
Citations: 22 - Heat generation and steel fragment effects on friction stir welding of aluminum alloy with steel
P Kaushik, D Kumar Dwivedi
Materials and Manufacturing Processes 39 (2), 161-173 2024
Citations: 20 - Influence of hook geometry on failure mechanism of Al6061-galvanized steel dissimilar FSW lap joint
P Kaushik, DK Dwivedi
Archives of Civil and Mechanical Engineering 22 (4), 149 2022
Citations: 14 - Enhancing strength and metallurgical soundness of dissimilar Al-steel FSSW joints through novel exit hole refilling technique
P Kaushik, DK Dwivedi
Manufacturing Letters 38, 83-87 2023
Citations: 4 - Investigating the influence of stress ratio variation on the crack growth rate in friction stir welded dissimilar aluminum alloys
S Tiwari, S Verma, P Kaushik
Engineering Failure Analysis 165, 108828 2024
Citations: 3 - Investigating Failure in Laser-Welded Joints of Microalloyed Steel: A Systematic Review
DK Saini, P Kaushik
Transactions of the Indian Institute of Metals 77 (8), 1939-1957 2024
Citations: 1 - Dissimilar metal joining of steel-aluminium alloy by friction stir welding
DK Dwivedi
Dissimilar Metal Joining, 269-285 2023
Citations: 1