Shalini Mohanty

Scopus Publications

Optimizing EDM of Gunmetal with Al2O3-Enhanced Dielectric: Experimental Insights and Machine Learning Models
Saumya Kanwal, Usha Sharma, Saurabh Chauhan, Anuj Kumar Sharma, Jitendra Kumar Katiyar, Rabesh Kumar Singh, Shalini Mohanty
Materials, 2025
This study investigates the optimization of electric discharge machining (EDM) parameters for gunmetal using copper electrodes in two different dielectric environments, which are conventional EDM oil and EDM oil infused with Al2O3 nanoparticles. A Taguchi L27 orthogonal array design was used to evaluate the effects of current, voltage, and pulse-on time on Material Removal Rate (MRR), Electrode Wear Rate (EWR), and surface roughness (Ra, Rq, and Rz). Analysis of Variance (ANOVA) was used to statistically evaluate the influence of each parameter on machining performance. In addition, machine learning models including Linear Regression, Ridge Regression, Support Vector Regression, Random Forest, Gradient Boosting, and Neural Networks were implemented to predict performance outcomes. The originality of this research is not only rooted in the introduction of new models; rather, it is also found in the comparative analysis of various machine learning methodologies applied to the performance of electrical discharge machining (EDM) utilizing Al2O3-enhanced dielectrics. This investigation focuses specifically on gunmetal, a material that has not been extensively studied within this framework. The nanoparticle-enhanced dielectric demonstrated improved machining performance, achieving approximately 15% higher MRR, 20% lower EWR, and 10% improved surface finish compared to conventional EDM oil. Neural Networks consistently outperformed other models in predictive accuracy. Results indicate that the use of nanoparticle-infused dielectrics in EDM, coupled with data-driven optimization techniques, enhances productivity, tool life, and surface quality.
Experimental Investigation of Al2O3 Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling
Sharad Yadav, Deepak Agarwal, Anuj Kumar Sharma, Rabesh Kumar Singh, Saurabh Chauhan, Shalini Mohanty
Micromachines, 2025
This paper investigates the use of Al2O3 nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder concentration, on the micro-channel fabrication performance in terms of TWR, MRR, depth, and width. A two-stage nested ANOVA is employed to understand the effect of powder concentration within different capacitance levels. The results show that the powder concentration significantly influences the system’s performance in conjunction with the capacitance. At low (100 pF) and high (1000 pF) capacitance, the addition of Al2O3 nano-powder increases the MRR, depth, and width but decreases TWR up to a concentration of 1.0 g/L. A desirability function analysis (DFA) tool identified the best overall performance from 14 experiments, revealing that 100 pF and 1 g/L yield the optimal outcomes.
Study on the Effect of Carbon-Fiber-Reinforced Composites on Tribological Properties
Shalini Mohanty, Adrian Murphy, Rashi Tyagi
Tribological Aspects of Additive Manufacturing, 2024
Polymer additive manufacturing (AM) has made significant progress in recent decades, but material properties, production speed, and part size constraints have limited it. As a result, it has mainly been used for rapid prototyping instead of the full-scale production of end-use components. Carbon fiber, however, offers several advantages, including low density, coefficient of thermal expansion, and high thermal conductivity. It can elevate polymer-based AM from simply achieving form and fit to achieving fit and function. Integrating carbon fiber into AM processes can lead to improved material characteristics, reduced production time compared to traditional subtractive methods, and decreased warping issues. This, in turn, allows for creating larger and more complex components. As a result, incorporating carbon fiber into various AM technologies has garnered increasing attention and interest within both academic and industrial circles. In the present chapter, a brief discussion on the effect of carbon fiber reinforcement on tribological properties of the additive manufactured CFRP composites is carried out.
Electroless Ni-P-MoS2 composite coating of Al-alloys: effect of surface textures and bath composition
Shalini Mohanty, Garima Singh, Suryank Dwivedi, Amit Rai Dixit, Rabesh Kumar Singh
Physica Scripta, 2023
The present work assesses the effect of textures and bath composition on Ni-P-MoS2 electroless composite coating. Aluminium alloys are subjected to textures (through electrical discharge machine) for using as substrate material in the present context of study. A comparison study is conducted to evaluate the effect of coatings on textured and non-textured surfaces prepared in two different baths (oxalic acid and hydrazine). Different surface characterization has been carried out including micro-hardness, surface roughness, topography, morphology, tribology through micro-scratch test, and composition analysis (using Energy Dispersive Spectroscopy) in the study. Results indicate that the textured coated surfaces impart better wear-resistant properties than those of coatings produced in non-textured ones. Moreover, the coating prepared using oxalic acid bath imparts better micro-hardness and tribological properties than those of hydrazine bath. The elemental presence of Mo, S, Ni and P was affirmed through EDS mapping, indicates transference of MoS2 particles on to the coated surfaces. The micro-hardness of different coated specimen prepared using oxalic acid bath range from 53.55 HV0.2 to 71.31 HV0.2 for non-textured samples and 70.47 HV0.2 to 113.52 HV0.2 for textured ones. It varied from 53.68 HV0.2 to 68.85 HV0.2 for non-textured surfaces and 63.03 HV0.2 to 98.27 HV0.2 for textured surfaces in hydrazine bath. The addition of MoS2 powder in the electroless bath account for the deposition of a tribo-adaptive layer on Al-alloys.
Metallic Coatings through Additive Manufacturing: A Review
Shalini Mohanty, Konda Gokuldoss Prashanth
Materials, 2023
Metallic additive manufacturing is expeditiously gaining attention in advanced industries for manufacturing intricate structures for customized applications. However, the inadequate surface quality has inspired the inception of metallic coatings through additive manufacturing methods. This work presents a brief review of the different genres of metallic coatings adapted by industries through additive manufacturing technologies. The methodologies are classified according to the type of allied energies used in the process, such as direct energy deposition, binder jetting, powder bed fusion, hot spray coatings, sheet lamination, etc. Each method is described in detail and supported by relevant literature. The paper also includes the needs, applications, and challenges involved in each process.
Effect of process parameters on the properties of β-Ti-Nb-based alloys fabricated by selective laser melting: A review
Shangavi Subramanian, Shalini Mohanty, KG Prashanth
Materials Today Proceedings, 2023
Selective laser melting of Inconel 718: Effect of thermal treatment on mechanical properties
Shalini Mohanty, Himanshu Singh Maurya, Konda Gokuldoss Prashanth
Materials Today Proceedings, 2023
Comparative study on electroless composite coatings of textured and untextured Al-substrates
Garima Singh, Shalini Mohanty, Rabesh Kumar Singh, Amit Rai Dixit, Anuj Kumar Sharma
Materials Today Proceedings, 2023
Electroless Ni-P-MoS2-Al2O3 Composite Coating with Hard and Self-Lubricating Properties
Shalini Mohanty, Naghma Jamal, Alok Kumar Das, Konda Gokuldoss Prashanth
Materials, 2022
The work aimed to produce Ni-P-MoS2-Al2O3 on Al-7075 alloys with multiple attributes through an electroless (EL) plating route. The effects of additives (MoS2 and Al2O3) in the EL bath on the surface morphology, topography, hardness, composition (phase and elemental), roughness, wettability, and coating thickness were evaluated. Results indicate a substantial enhancement in microhardness of the EL-coated surfaces by 70% (maximum hardness = ~316 HV) using powders, and 30% (244 HV) without powders. The maximum coating thickness and water contact angle obtained with powders were 6.16 μm and 100.46°, respectively. The coefficient of friction for the samples prepared using powders was 0.12, and for the base material it was 0.18. The compositional analysis through EDS and XRD suggested the incorporation of a hard and lubricious layer on the EL-coated surface owing to the presence of different phases of Al, Mo, P, Zn, O, and S. Therefore, the resulting coating surfaces impart hardness, self-lubrication, hydrophobicity, and wear resistance simultaneously.
Parametric analysis to enhance the printability in metal with electrochemical additive manufacturing
Mithilesh Singh, Shalini Mohanty, Alok Kumar Das
Materials Letters, 2022
Sustainable surface modification of Ti-alloy using powder mixed in bio-dielectrics through micro-electrical discharge coating process
Kiran P., Shalini Mohanty, Alok Kumar Das
Journal of Cleaner Production, 2022
Surface integrity of tribo-adaptive layer prepared on Ti6Al4V through μEDC process
Shalini Mohanty, Alok Kumar Das, Amit Rai Dixit
Surface and Coatings Technology, 2022
Surface modification through sustainable micro-EDM process using powder mixed bio-dielectrics
P Kiran, Shalini Mohanty, Alok Kumar Das
Materials and Manufacturing Processes, 2022
Selective surface modification of SS304 using hybrid powder-mixed EDC process
Abhishek Yadav, Shalini Mohanty, Suryank Dwivedi, Amit Rai Dixit
Surface Engineering, 2022
Experimental investigation of powder mixed micro-electrical discharge drilling on SS304 substrate
Sonakshi Hazra, Shalini Mohanty, Shakti Kumar, Ranjit Basak, Alok Kumar Das
Materials Today Proceedings, 2022
Surface integrity study of TiO2 based Sol-gel spin coatings on SS316L
Pankaj Kumar, Alok Kumar Das, Shalini Mohanty
Materials Letters, 2021
Influence of tool materials on surface modification using μEDC process
Shalini Mohanty, Alok Kumar Das, Amit Rai Dixit
Surface Engineering, 2021
Surface integrity and residual stress analysis of μEDM coated Ti-alloy miniature components
Shalini Mohanty, Alok Kumar Das, Amit Rai Dixit
Materials and Manufacturing Processes, 2021
Surface modification of high-performance alloys through microelectrical discharge machining processes
Shalini Mohanty, Alok Kumar Das, Amit Rai Dixit
Micro Electro Fabrication, 2021
Enhancement of Surface Properties of High Speed Steel Using Powder Mixed Micro-electrical Discharge Process
Shalini Mohanty, Partha Bhattacharyya, Alok Kumar Das, Amit Rai Dixit
Lecture Notes in Mechanical Engineering, 2021
Composite Coating on Aluminum-Based Alloys Through Ni-P Electroless Plating Route
Naghma Jamal, Shalini Mohanty, Sanu Raj, Alok Kumar Das
Lecture Notes in Mechanical Engineering, 2021
A concise review on improvement of tribological properties by electrical discharge coating process
Abhishek Yadav, Shalini Mohanty, Akash Nag, Amit Rai Dixit, Alok Kumar Das
Aip Conference Proceedings, 2020
Surface modification of titanium alloy using hBN powder mixed dielectric through micro-electric discharge machining
Deepak Sharma, Shalini Mohanty, Alok Kumar Das
Surface and Coatings Technology, 2020
A study on parametric optimization of Micro-electrical discharge coating process using response surface methodology
Shalini Mohanty, Brij Bhushan, Alok Kumar Das, Amit Rai Dixit
Materials Today Proceedings, 2020
Analysis and Prediction of Electrical Discharge Coating Using Artificial Neural Network (ANN)
R. Tyagi, S. Kumar, V. Kumar, S. Mohanty, A. K. Das, A. Mandal
Lecture Notes on Multidisciplinary Industrial Engineering, 2020
Production of hard and lubricating surfaces on miniature components through micro-EDM process
Shalini Mohanty, Brij Bhushan, Alok Kumar Das, Amit Rai Dixit
International Journal of Advanced Manufacturing Technology, 2019
Micro-electrical discharge coating of Titanium alloy using WS2 and Brass P/M electrode
Anusha Roohi Siddique, Shalini Mohanty, Alok Kumar Das
Materials and Manufacturing Processes, 2019
Electroless Ni–Al2O3–WS2 Composite Coating on Aluminum Substrate
Deepak Taye, Shalini Mohanty, Alok Kumar Das, Nirmal Kumar Singh
Transactions of the Indian Institute of Metals, 2019
Surface modification of Ti-alloy by micro-electrical discharge process using tungsten disulphide powder suspension
Shalini Mohanty, Vishnu Kumar, Alok Kumar Das, Amit Rai Dixit
Journal of Manufacturing Processes, 2019
A comparative study on machining of alsicp metal matrix composite using electrical discharge machine with and without nano powder suspension in dielectric
Shalini Mohanty, Subham S. Singh, B.C. Routara, B.K. Nanda, R.K. Nayak
Materials Today Proceedings, 2019
Micro-hardness Improvement of HSS Using Tungsten Tool Through Micro-electrical Discharge Process
S. Mohanty, Avijit Roy, Brij Bhushan, A. K. Das, Amit Rai Dixit
Lecture Notes on Multidisciplinary Industrial Engineering, 2019
A Study on the Effect of Polarity Change on Various Parameters on Ti6Al4V in Powder-Mixed Micro-EDM Using Multi-objective Grey Fuzzy Optimization
Deepak Sharma, Anusha Roohi Siddique, Vishnu Kumar, Shalini Mohanty, Alok Kumar Das
Lecture Notes on Multidisciplinary Industrial Engineering, 2019
Optimization of electrical discharge coating of WS2 and Cu powder mixture deposited through green compact electrode
Rashi Tyagi, Kshitij Pandey, Shalini Mohanty, Shakti Kumar, Alok Kumar Das, Amitava Mandal
Lecture Notes in Mechanical Engineering, 2019
Electroless Nickel–Phosphorus Plating on SS304 Substrate with Al2O3 and WS2 Powder Suspended in Electrolytic Solution
Divit Saini, D. Taye, S. Mohanty, H. Bishwakarma, A. K. Das, N. K. Singh
Lecture Notes on Multidisciplinary Industrial Engineering, 2019
Production of tungsten carbide nanoparticles through Micro-EDM and its characterization
H.N.S. Yadav, H. Bishwakarma, N. Kumar, S. Kumar, P.K. Singh, S. Mohanty, A.K. Das
Materials Today Proceedings, 2019
Surface alloying using tungsten disulphide powder mixed in dielectric in micro-EDM on Ti6Al4V
Shalini Mohanty, Vishnu Kumar, Rashi Tyagi, Shakti Kumar, Brij Bhushan, Alok Kumar Das, Amit Rai Dixit
Iop Conference Series Materials Science and Engineering, 2018
Multi-objective parametric optimization of nano powder mixed electrical discharge machining of AlSiCp using response surface methodology and particle swarm optimization
Shalini Mohanty, Ankan Mishra, B.K. Nanda, B.C. Routara
Alexandria Engineering Journal, 2018
Study of machining characteristics of Al-SiCp12% composite in nano powder mixed dielectric electrical discharge machining using RSM
Shalini Mohanty, B.C. Routara, B.K. Nanda, D.K. Das, A.K. Sahoo
Materials Today Proceedings, 2018
Experimental investigation of machining characteristics for Al-SiC12% composite in Electro-discharge machining
Shalini Mohanty, B.C. Routara, R.K. Bhuayan
Materials Today Proceedings, 2017
RSM and Fuzzy logic approaches for predicting the surface roughness during EDM of Al-SiCp MMC
R.K. Bhuyan, Shalini Mohanty, B.C. Routara
Materials Today Proceedings, 2017
A review on machining of metal matrix composites using nanoparticle mixed dielectric in electro-discharge machining
Shalini Mohanty, B.C. Routara
International Journal of Automotive and Mechanical Engineering, 2016

RECENT SCHOLAR PUBLICATIONS

Optimizing EDM of Gunmetal with Al 2 O 3 -Enhanced Dielectric: Experimental Insights and Machine Learning Models
S Kanwal, U Sharma, S Chauhan, AK Sharma, JK Katiyar, RK Singh, ...
Materials 18 (19), 4578 , 2025
2025
Citations: 2
Experimental Investigation of Al 2 O 3 Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling
S Yadav, D Agarwal, AK Sharma, RK Singh, S Chauhan, S Mohanty
Micromachines 16 (7), 725 , 2025
2025
Citations: 2
Study on the Effect of Carbon-Fiber-Reinforced Composites on Tribological Properties
S Mohanty, A Murphy, R Tyagi
Tribological Aspects of Additive Manufacturing, 97-108 , 2024
2024
Citations: 2
Electroless Ni-P-MoS 2 composite coating of Al-alloys: effect of surface textures and bath composition
S Mohanty, G Singh, S Dwivedi, AR Dixit, RK Singh
Physica Scripta 98 (10), 105951 , 2023
2023
Citations: 4
Thank You to Our Volunteer Reviewers
R Asthana
Journal of Materials Engineering and Performance 32 (18), 8027 , 2023
2023
Effect of process parameters on the properties of β-Ti-Nb-based alloys fabricated by selective laser melting: A review
S Subramanian, S Mohanty, KG Prashanth
Materials Today: Proceedings , 2023
2023
Citations: 15
Selective laser melting of Inconel 718: Effect of thermal treatment on mechanical properties
S Mohanty, HS Maurya, KG Prashanth
Materials Today: Proceedings , 2023
2023
Citations: 2
Metallic coatings through additive manufacturing: a review
S Mohanty, K Gokuldoss Prashanth
Materials 16 (6), 2325 , 2023
2023
Citations: 35
Comparative study on electroless composite coatings of textured and untextured Al-substrates
G Singh, S Mohanty, RK Singh, AR Dixit, AK Sharma
Materials Today: Proceedings 80, 233-240 , 2023
2023
Citations: 5
Electroless Ni-P-MoS 2 -Al 2 O 3 Composite Coating with Hard and Self-Lubricating Properties
S Mohanty, N Jamal, AK Das, KG Prashanth
Materials 15 (19), 6806 , 2022
2022
Citations: 8
Parametric analysis to enhance the printability in metal with electrochemical additive manufacturing
M Singh, S Mohanty, AK Das
Materials Letters 322, 132518 , 2022
2022
Citations: 5
Sustainable surface modification of Ti-alloy using powder mixed in bio-dielectrics through micro-electrical discharge coating process
P Kiran, S Mohanty, AK Das
Journal of Cleaner Production 362, 132375 , 2022
2022
Citations: 19
Surface modification through sustainable micro-EDM process using powder mixed bio-dielectrics
P Kiran, S Mohanty, AK Das
Materials and Manufacturing Processes 37 (6), 640-651 , 2022
2022
Citations: 54
Surface integrity of tribo-adaptive layer prepared on Ti6Al4V through μEDC process
S Mohanty, AK Das, AR Dixit
Surface and Coatings Technology 429, 127922 , 2022
2022
Citations: 30
Experimental investigation of powder mixed micro-electrical discharge drilling on SS304 substrate
S Hazra, S Mohanty, S Kumar, R Basak, AK Das
Materials Today: Proceedings 62, 270-275 , 2022
2022
Citations: 13
Selective surface modification of SS304 using hybrid powder-mixed EDC process
A Yadav, S Mohanty, S Dwivedi, AR Dixit
Surface Engineering 38 (1), 8-21 , 2022
2022
Citations: 21
Surface integrity study of TiO2 based Sol-gel spin coatings on SS316L
P Kumar, AK Das, S Mohanty
Materials Letters 303, 130553 , 2021
2021
Citations: 9
Influence of tool materials on surface modification using μEDC process
S Mohanty, AK Das, AR Dixit
Surface Engineering 37 (9), 1084-1097 , 2021
2021
Citations: 22
Micro Electro-Fabrication
T Saleh, MSM Ali, K Takahata
Elsevier , 2021
2021
Citations: 10
Enhancement of Surface Properties of High Speed Steel Using Powder Mixed Micro-electrical Discharge Process
S Mohanty, P Bhattacharyya, AK Das, AR Dixit
International Conference on Manufacturing Engineering and Materials, 361-370 , 2021
2021

MOST CITED SCHOLAR PUBLICATIONS

Surface modification of Ti-alloy by micro-electrical discharge process using tungsten disulphide powder suspension
S Mohanty, V Kumar, AK Das, AR Dixit
Journal of Manufacturing Processes 37, 28-41 , 2019
2019
Citations: 100
Multi-objective parametric optimization of nano powder mixed electrical discharge machining of AlSiCp using response surface methodology and particle swarm optimization
S Mohanty, A Mishra, BK Nanda, BC Routara
Alexandria Engineering Journal 57 (2), 609-619 , 2018
2018
Citations: 94
Surface modification of titanium alloy using hBN powder mixed dielectric through micro-electric discharge machining
D Sharma, S Mohanty, AK Das
Surface and Coatings Technology 381, 125157 , 2020
2020
Citations: 91
Surface modification through sustainable micro-EDM process using powder mixed bio-dielectrics
P Kiran, S Mohanty, AK Das
Materials and Manufacturing Processes 37 (6), 640-651 , 2022
2022
Citations: 54
A review on machining of metal matrix composites using nanoparticle mixed dielectric in electro-discharge machining
S Mohanty, BC Routara
International Journal of Automotive and Mechanical Engineering 13 (2), 3518-3539 , 2016
2016
Citations: 51
Micro-electrical discharge coating of Titanium alloy using WS 2 and Brass P/M electrode
AR Siddique, S Mohanty, AK Das
Materials and Manufacturing Processes 34 (15), 1761-1774 , 2019
2019
Citations: 48
Surface integrity and residual stress analysis of μEDM coated Ti-alloy miniature components
S Mohanty, AK Das, AR Dixit
Materials and Manufacturing Processes 36 (1), 48-58 , 2021
2021
Citations: 38
Metallic coatings through additive manufacturing: a review
S Mohanty, K Gokuldoss Prashanth
Materials 16 (6), 2325 , 2023
2023
Citations: 35
Production of hard and lubricating surfaces on miniature components through micro-EDM process
S Mohanty, B Bhushan, AK Das, AR Dixit
The International Journal of Advanced Manufacturing Technology 105 (5), 1983 … , 2019
2019
Citations: 31
Surface integrity of tribo-adaptive layer prepared on Ti6Al4V through μEDC process
S Mohanty, AK Das, AR Dixit
Surface and Coatings Technology 429, 127922 , 2022
2022
Citations: 30
Influence of tool materials on surface modification using μEDC process
S Mohanty, AK Das, AR Dixit
Surface Engineering 37 (9), 1084-1097 , 2021
2021
Citations: 22
Selective surface modification of SS304 using hybrid powder-mixed EDC process
A Yadav, S Mohanty, S Dwivedi, AR Dixit
Surface Engineering 38 (1), 8-21 , 2022
2022
Citations: 21
Sustainable surface modification of Ti-alloy using powder mixed in bio-dielectrics through micro-electrical discharge coating process
P Kiran, S Mohanty, AK Das
Journal of Cleaner Production 362, 132375 , 2022
2022
Citations: 19
Experimental investigation of machining characteristics for Al-SiC12% composite in Electro-discharge machining
S Mohanty, BC Routara, RK Bhuayan
Materials Today: Proceedings 4 (8), 8778-8787 , 2017
2017
Citations: 18
Study of machining characteristics of Al-SiCp12% composite in nano powder mixed dielectric electrical discharge machining using RSM
S Mohanty, BC Routara, BK Nanda, DK Das, AK Sahoo
Materials Today: Proceedings 5 (11), 25581-25590 , 2018
2018
Citations: 17
Surface alloying using tungsten disulphide powder mixed in dielectric in micro-EDM on Ti6Al4V
S Mohanty, V Kumar, R Tyagi, S Kumar, B Bhushan, AK Das, AR Dixit
IOP Conference Series: Materials Science and Engineering 377 (1), 012040 , 2018
2018
Citations: 16
RSM and Fuzzy logic approaches for predicting the surface roughness during EDM of Al-SiCp MMC
RK Bhuyan, S Mohanty, BC Routara
Materials Today: Proceedings 4 (2), 1947-1956 , 2017
2017
Citations: 16
Effect of process parameters on the properties of β-Ti-Nb-based alloys fabricated by selective laser melting: A review
S Subramanian, S Mohanty, KG Prashanth
Materials Today: Proceedings , 2023
2023
Citations: 15
Electroless Ni–Al 2 O 3 –WS 2 Composite Coating on Aluminum Substrate
D Taye, S Mohanty, AK Das, NK Singh
Transactions of the Indian Institute of Metals 72 (9), 2281-2292 , 2019
2019
Citations: 15
Experimental investigation of powder mixed micro-electrical discharge drilling on SS304 substrate
S Hazra, S Mohanty, S Kumar, R Basak, AK Das
Materials Today: Proceedings 62, 270-275 , 2022
2022
Citations: 13

Shalini Mohanty

RESEARCH INTERESTS

Scopus Publications

RECENT SCHOLAR PUBLICATIONS

MOST CITED SCHOLAR PUBLICATIONS