Preface xvii
Acknowledgment xxi

1 Introduction to Sustainability of Manufacturing and Materials Processing Technologies 1
Sarthak Prasad Sahoo and Rahul Choudhary

1.1 Introduction 2
1.2 Principles of Sustainable Manufacturing (SM) 3
1.3 Environmental Impacts of Traditional Manufacturing 5
1.4 Sustainable Materials Processing 6
1.5 Technological Innovations for Sustainability 8
1.6 Assessment Tools and Metrics 10
1.7 Real-World Examples of Sustainable Manufacturing Practices 11
1.8 Challenges and Future Directions 12
1.9 Conclusion 14

2 A Critical Review of Green and Sustainable Approaches in Advanced Materials Manufacturing 19
Ajithkumar Sitharaj, Manoj Mohan Prasath V., Sandip Kunar, Ganesh N. and Arul Pandiyan

2.1 Introduction 20
2.2 Foundations and Drivers of Green and Sustainable Manufacturing 21
2.3 Overview of Advanced Materials 25
2.4 Green Synthesis and Processing Techniques 27
2.5 Sustainable Manufacturing Technologies 30
2.6 Case Studies across Material Classes 33
2.7 Life Cycle Assessment (LCA) and Environmental Impact Analysis 34
2.8 Emerging Trends and Future Directions 36
2.9 Conclusion 37

3 Advanced High-Strength Steel Alloys for Sustainable Applications 43
Indrajit Dey and Swarup Kumar Ghosh

3.1 Introduction 44
3.2 Experimental Procedures 46
3.3 Results and Discussion 47
3.4 Conclusions 59

4 High-Performance Steels for Sustainable Manufacturing of Vehicles 65
Ankita Bhattacharya, Ghanshyam Das and Swarup Kumar Ghosh

4.1 Introduction 66
4.2 Properties and Characteristics of High-Performance Steels 67
4.3 High Strength Low Alloy Steel 75
4.4 Ultra-High Strength Steel 77
4.5 Galvanised Steel 79
4.6 Applications of High-Performance Steels 82
4.7 Benefits of High-Performance Steels 83
4.8 Challenges and Opportunities 84
4.9 Future Trends and Developments 85
4.10 Conclusions 85

5 Sustainable Manufacturing of Ferritic Stainless Steel: Experimental and Review 93
Swarnendu Das, Nishant Kumar, Piyush Kumar, R. Rejeesh, A. Ghosh and S. Patra

5.1 Introduction 94
5.2 Remedial for Ridging 95
5.3 Experimental Details 96
5.4 Results 98
5.5 Discussion 104
5.6 Conclusion and Summary 105

6 Sustainable Steel Processing Techniques: Minimising Waste and Energy Consumption 111
Muralidhar Yadav and Swarup Kumar Ghosh

6.1 Introduction 112
6.2 Importance of Sustainable Steel Processing 113
6.3 Sustainable Steel Processing Techniques 114
6.4 Emerging Steelmaking Technologies 122
6.5 Waste Minimization and Recycling 122
6.6 Case Studies and Best Practices 130
6.7 Recommended Future Directions for Sustainable Steelmaking 131
6.8 Conclusions 133

7 Minimizing Cr Loss during EAF Stainless Steel Making for Achieving Sustainability 137
Subham Ranjan, Rinku Singroha, Sayantan Mukherjee and Sudipta Patra

7.1 Introduction 137
7.2 Description of the Pneumatic Injection 139
7.3 Process 141
7.4 Results 141
7.5 Discussion 144
7.6 Conclusion 147

8 Bio-Inspired Steel Coatings for Corrosion Resistance and Sustainability 151
Sneha Roy and Swarup Kumar Ghosh

8.1 Introduction 152
8.2 Bio-Inspired Coating Materials 155
8.3 Fabrication and Characterization of Bio-Inspired Coatings 158
8.4 Corrosion Resistance Mechanisms of Bio-Inspired Coatings 162
8.5 Environmental Sustainability of Bio-Inspired Coatings 163
8.6 Life Cycle Assessment (LCA) and Circularity 165
8.7 Case Studies and Future Directions 165
8.8 Emerging Trends and Future Outlook 172
8.9 Conclusions 173

9 Designing Advanced Materials Using Embedded Atom Method Interatomic Potential: A Review 179
Sayak Bal and Snehanshu Pal

9.1 Introduction 179
9.2 Theoretical Foundations of EAM Potentials 181
9.3 Development Methodologies 183
9.4 Some Existing EAM Potentials 186
9.5 Validation of EAM Potentials 188
9.6 Recent Works and Future Directions in EAM Development 189
9.7 Applications of EAM in Advanced Materials 190
9.8 Conclusion 191

10 Green Processing of Particles Dispersed Composite Materials 199
Rudra Narayan Mohapatro, Sunita Routray and Ranjita Swain

10.1 Introduction 200
10.2 Background and Need for Green Processing 200
10.3 Understanding Particles Dispersed Composite Materials 201
10.4 Green Processing Approaches 201
10.5 Role of Bio-Based and Waste-Derived Particles 202
10.6 Benefits and Challenges 203
10.7 Future Outlook and Applications 204
10.8 Particles Composite Processing in Green Processing of Particles Dispersed Composite Materials 204
10.9 Natural Fiber and Polymer Matrix Materials in Green Composites 206
10.10 Chemical Treatment of Natural Fibers 209
10.11 Strength Properties and Performance 210
10.12 Sustainable Processing Techniques 211
10.13 Applications and Future Directions 212
10.14 Feasibility Studies on Investigating the Use of Industrial Waste Materials Reinforced Hybrid Composites 213
10.15 Conclusion 218

11 Advanced Multifunctional Ceramics: Foundations, Properties, Characterization, Processing and Emerging Trends 223
Jagadeesha T. and Sandip Kunar

11.1 Introduction 224
11.2 Classification of Functional Ceramics 226
11.3 Properties of Functional Ceramics 230
11.4 Characterization of Functional Ceramics 235
11.5 Fabrication Methods of Functional Ceramics 239
11.6 Conclusions 242
11.7 Future Research Opportunities 242

12 Circular Economy-Driven Approaches in Sustainable Manufacturing of Advanced Materials 245
Idhayaraja S., Ajithkumar Sitharaj, Ganesh N., Arul Pandiyan and Sandip Kunar

12.1 Introduction 246
12.2 Circular Economy Framework for Integrated Sustainable Production 247
12.3 Sustainable Material Selection Strategies 251
12.4 Additive Manufacturing for Circular Economy 254
12.5 Digitalization Enabling Closed-Loop Production 257
12.6 Conclusion 261

13 Sustainable Additive Manufacturing: Innovations in Advanced Materials and Processing Techniques 267
Manoj Mohan Prasath V., Ajithkumar Sitharaj, Karuppusamy R. and Sandip Kunar

13.1 Introduction 268
13.2 Overview of AM 270
13.3 A Sustainable AM Technology 278
13.4 Innovation in AM Technology 283
13.5 Conclusion 286

14 Semi-Solid Metal Casting: A Sustainable Approach for High-Performance Component Fabrication 293
Arul Pandian Palanisamy, Ganesh Nataraj and Ajithkumar Sitharaj

14.1 Introduction 294
14.2 Fundamentals of Semi-Solid Metal Casting 295
14.3 Process Routes and Materials 296
14.4 Sustainability Aspects 298
14.5 Mechanical and Microstructural Characteristics 299
14.6 Applications in High-Performance Components 301
14.7 Challenges and Limitations 304
14.8 Conclusions 306

15 Designing High-Performance Alloys for Sustainable Structural Applications Using Molecular Dynamics Simulations 311
K. Vijay Reddy, Sunil Kumar Pathak, Shailesh Kumar Singh and Snehanshu Pal

15.1 Introduction 312
15.2 MD Simulation Setup 314
15.3 Results and Discussion 316
15.4 Conclusions 320

16 Recyclable and Renewable Composite Materials in Additive Manufacturing 325
Ganesh Nataraj, Ramesh Babu S., A. R. Ravikumar, Arul Pandian, Karthikeyan Rajendran and Ajithkumar Sitharaj

16.1 Introduction 326
16.2 Recyclable Composite Materials in Additive Manufacturing 328
16.3 Renewable Composite Materials in Additive Manufacturing 332
16.4 Processing and Characterization of Recyclable and Renewable AM Composites 338
16.5 Applications for Recyclable and Renewable Composite Materials in AM 342
16.6 Challenges and Future Outlook 347
16.7 Conclusion 348

17 Eco Friendly Bio Composites in Additive Manufacturing for Sustainable Applications 351
Ganesh Nataraj, Ramesh Babu S., A. R. Ravikumar, Karthikeyan Rajendran, Arul Pandian and Ajithkumar Sitharaj

17.1 Introduction 352
17.2 Fundamentals of Bio Composites 353
17.3 Additive Manufacturing: An Enabler of Sustainable Design 358
17.4 Integration of Bio Composites in Additive Manufacturing 361
17.5 Mechanical and Thermal Properties 365
17.6 Sustainable Applications of Additively Manufactured Bio Composites 369
17.7 Environmental Impact and Life Cycle Assessment (LCA) 371
17.8 Challenges and Future Perspectives 372
17.9 Conclusion 372

References 373
Index 377