Browsing by Author "Faisal, Nadimul Haque"

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    Application of thermal spray coatings in electrolysers for hydrogen production: advances, challenges, and opportunities
    (Wiley, 2022-10-14) Faisal, Nadimul Haque; Prathuru, Anil; Ahmed, Rehan; Rajendran, Vinooth; Hossain, Mamdud; Venkatachalapathy, Viswanathan; Katiyar, Nirmal Kumar; Li, Jing; Liu, Yuheng; Cai, Qiong; Horri, Bahman Amini; Thanganadar, Dhinesh; Sodhi, Gurpreet Singh; Patchigolla, Kumar; Fernandez, Carlos; Joshi, Shrikant; Govindarajan, Sivakumar; Kurushina, Victoria; Katikaneni, Sai; Goel, Saurav
    Thermal spray coatings have the advantage of providing thick and functional coatings from a range of engineering materials. The associated coating processes provide good control of coating thickness, morphology, microstructure, pore size and porosity, and residual strain in the coatings through selection of suitable process parameters for any coating material of interest. This review consolidates scarce literature on thermally sprayed components which are critical and vital constituents (e. g., catalysts (anode/cathode), solid electrolyte, and transport layer, including corrosion-prone parts such as bipolar plates) of the water splitting electrolysis process for hydrogen production. The research shows that there is a gap in thermally sprayed feedstock material selection strategy as well as in addressing modelling needs that can be crucial to advancing applications exploiting their catalytic and corrosion-resistant properties to split water for hydrogen production. Due to readily scalable production enabled by thermal spray techniques, this manufacturing route bears potential to dominate the sustainable electrolyser technologies in the future. While the well-established thermal spray coating variants may have certain limitations in the manner they are currently practiced, deployment of both conventional and novel thermal spray approaches (suspension, solution, hybrid) is clearly promising for targeted development of electrolysers.
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    Atomistic investigation on the structure-property relationship during thermal spray nanoparticle impact
    (Elsevier, 2013-12-31) Goel, Saurav; Faisal, Nadimul Haque; Ratia, Vilma; Agrawal, Anupam; Stukowski, Alexander
    During thermal spraying, hot particles impact on a colder substrate. This interaction of crystalline copper nanoparticles and copper substrate is modeled, using MD simulation. The quantitative results of the impacts at different velocities and temperatures are evaluated using a newly defined flattening aspect ratio. This ratio between the maximum diameter after the impact and the height of the splat increases with increasing Reynolds numbers until a critical value is reached. At higher Reynolds numbers the flattening aspect ratio decreases again, as the kinetic energy of the particle leads to increasing substrate temperature and, therefore, decreases the substrate resistance. Thus, the particle penetrates into the substrate and deforms less.
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    A comprehensive review of pre-and post-treatment approaches to achieve sustainable desalination for different water streams
    (Elsevier, 2023-09-09) Poirier, Kristofer; Lotfi, Mohsen; Garg, Kapil; Patchigolla, Kumar; Anthony, Edward J.; Faisal, Nadimul Haque; Mulgundmath, Vinay; Sahith, Jai Krishna; Jadhawar, Prashant; Koh, Liam; Morosuk, Tatiana; Al Mhanna, Najah
    Desalination is an energy intensive process requiring adequate pre- and post- treatment. The novelty of this paper is that it jointly reviews the technologies for pre-treatment, desalination and post-treatment and bridges the gap between them while comparing the treatment methods needed depending on the type of feed water including seawater, brackish water, municipal and industrial wastewater. Those different streams show wide variability, sometimes containing organics, oil or scaling precursors which require adequate treatment. Nowadays, membrane pre-treatment methods have become promising alternatives to conventional pre-treatment techniques thanks to their flexibility. Hybrid desalination technologies have shown great potential in reducing energy consumption. Moreover, desalination plants produce large quantities of brines which require post-treatment to reduce environmental impacts. Current research on post-treatment is looking into recovering salts, metals and potable water from brines to achieve zero liquid discharge (ZLD). Thermal-based ZLD technologies are capable of extracting those resources while membrane-based ZLD methods are mostly limited to pre-concentration and water recovery due to fouling issues. Several studies have shown that ZLD systems can lower the cost of water and increase profitability if crystals and water are recovered and sold for additional revenue.
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    Large-scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation
    (Springer, 2021-07-04) Faisal, Nadimul Haque; Sellami, Nazmi; Venturi, Federico; Hussain, Tanvir; Mallick, Tapas; Muhammad-Sukki, Firdaus; Bishop, Alex; Upadhyaya, Hari; Katiyar, Nirmal Kumar; Goel, Saurav
    Metamaterials, an artificial periodic two- or three-dimensional configuration can change propagation characteristics of electromagnetic waves (i.e., reflection, transmission, absorption). The current challenges in the field of metamaterial coatings are their manufacturing in large scale and large length scale. There is a clear need to enhance process technologies and scalability of these. Thermal spraying is a method used to deposit small to large scale coatings where the sprayed layer is typically formed by successive impact of fully or partially molten particles of a material exposed to various process conditions. This work aims to investigate the feasibility to manufacture large scale metamaterial coatings using the thermal spray technique and examine their response to solar radiation. Two types of coatings namely, Cr2O3 and TiO2 were deposited onto various substrates (e.g., steel, aluminium, glass, indium tin oxide (ITO) coated glass) with a fine wire mesh (143 µm and 1 mm aperture sizes) as the masking sheet to manipulate the surface pattern using suspension high-velocity oxy-fuel thermal spraying (S-HVOF) and atmospheric plasma-sprayed (APS) methods, respectively. Post deposition, their responses subjected to electromagnetic wave (between 250 nm to 2500 nm or Ultraviolet (UV)-Visible (Vis)-Infrared (IR) region) were characterised. The additional microstructural characterisation was performed using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), three-dimensional profilometry and optical spectroscopy. It is demonstrated that through novel application of thermal spray techniques, large scale manufacturing of metamaterial coating is possible, and such material can affect the electromagnetic wave propagation. Comparison between Cr2O3 and TiO2 coatings on aluminium substrates showed reduced three orders of reduced reflectance for Cr2O3 coatings (for 1 mm aperture size) throughout the spectrum. It was concluded that for a similar bandgap, Cr2O3 coatings on aluminium substrate will yield improved optical performance than TiO2 coating, and hence more useful to fabricate opto-electronic devices.
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    Nanoindentation of polysilicon and single crystal silicon: Molecular dynamics simulation and experimental validation
    (IOP Publishing, 2014-06-06) Goel, Saurav; Faisal, Nadimul Haque; Luo, Xichun; Yan, Jiwang; Agrawal, Anupam
    This paper presents novel advances in the deformation behaviour of polycrystalline and single crystal silicon using molecular dynamics (MD) simulation and validation of the same via nanoindentation experiments. In order to unravel the mechanism of deformation, four simulations were performed: indentation of a polycrystalline silicon substrate with a (i) Berkovich pyramidal and a (ii) spherical (arc) indenter, and (iii and iv) indentation of a single crystal silicon substrate with these two indenters. The simulation results reveal that high pressure phase transformation (HPPT) in silicon (Si-I to Si-II phase transformation) occurred in all cases; however, its extent and the manner in which it occurred differed significantly between polycrystalline silicon and single crystal silicon, and was the main driver of differences in the nanoindentation deformation behaviour between these two types of silicon. Interestingly, in polycrystalline silicon, the HPPT was observed to occur more preferentially along the grain boundaries than across the grain boundaries. An automated dislocation extraction algorithm (DXA) revealed no dislocations in the deformation zone, suggesting that HPPT is the primary mechanism in inducing plasticity in silicon.