Sagar Devaji Gaikwad

•Modeling, characteristics data acquisition and simulation of aluminum matrix composite (AMC) materials under thermo-mechanical loading. •Develop and optimize highly particle-reinforced AMC sheets using twin-roll casting and thermo-mechanical processing. •Develop thermo-fluid models to analyze melt flow, heat transfer, and temperature distribution. •Investigate process–microstructure–property relationships through material characterization and testing.

Simulative mapping of the electro-thermal battery behavior and development of the cooling system. •Characterized lithium-ion battery cells and developed electro-thermal models using equivalent-circuit and 3D FEM approaches in COMSOL Multiphysics. •Designed and simulated three cooling strategies for battery cells/modules and implemented PID controller to improve temperature uniformity and cooling performance.

•Characterized and studied lithium-ion battery cells. •Conducted electro-thermal simulation of lithium-ion battery cell (Equivalent circuit model and 3D FEM thermal model) using COMSOL Multiphysics. •Investigated temperature and current influences on battery behavior. •Validated simulation results with experimental data.

•Analyzed the thermo-mechanical behavior of Insulated Gate Bipolar Transistor (IGBT) power electronic modules with Direct Bonded Copper (DBC) substrates, considering multi-material interfaces and joining layers. •Performed thermal and mechanical FEM simulations using ANSYS to evaluate temperature distribution, thermally induced stresses, and thermal resistance across different material layers. •Evaluated and validated simulation results against experimental data and presented findings to project teams.

Main task: Flow simulation of automated vacuum suction blasting system. •Developed a 3D CAD model of an automated vacuum suction blasting system and performed multiphase CFD simulations using ANSYS Fluent to investigate the removal of CFRP material.