Tarasankar DebRoy

About

Tarasankar DebRoy is a Professor of Materials Science and Engineering at Pennsylvania State University. His research focuses on computational materials processing, particularly the application of numerical transport phenomena and optimization in welding and additive manufacturing. He develops models that compute critical factors affecting metallurgical product quality, such as temperature and velocity fields, cooling rates, and solidification parameters, by solving tens of billions of equations efficiently. His models are uniquely structured for integration with genetic algorithms and other search engines, enabling bi-directional simulations that help tailor product attributes, optimize production variables, reduce defects, and improve overall product quality. Professor DebRoy has made significant contributions to the field, including developing the first rigorous numerical models of heat and fluid flow in 3D printing to reduce distortion and defects, and creating comprehensive models for laser-fired aluminum-silicon contact geometry in photovoltaic devices. He has pioneered models for controlling weld geometry and cooling rates during welding, estimating temperatures during laser welding, and understanding the role of surface active elements in steels. His work also includes a three-dimensional visco-plastic-flow and heat transfer model for friction stir welding. DebRoy is the founding editor of the 'Science and Technology of Welding and Joining' and has held various…

Research topics

• Computer Science
• Engineering
• Artificial Intelligence
• Materials science
• Metallurgy
• Mechanical engineering
• Manufacturing engineering
• Systems engineering
• Risk analysis (engineering)
• Industrial engineering

Selected publications

• Mechanistic models for additive manufacturing of metallic components

  Progress in Materials Science · 2020 · 501 citations

  Senior authorCorresponding

  Additive manufacturing (AM), also known as 3D printing, is gaining wide acceptance in diverse industries for the manufacturing of metallic components. The microstructure and properties of the components vary widely depending on printing process and process parameters, and prediction of causative variables that affect structure, properties and defects is helpful for their control. Since models are most useful when they can correctly predict experimental observations, we focus on the available mec…

  DOI

• Metallurgy, mechanistic models and machine learning in metal printing

  Nature Reviews Materials · 2020 · 456 citations

  1st authorCorresponding
  DOI

• Towards developing multiscale-multiphysics models and their surrogates for digital twins of metal additive manufacturing

  Additive manufacturing · 2021 · 135 citations

  Artificial intelligence (AI) embedded within digital models of manufacturing processes can be used to improve process productivity and product quality significantly. The application of such advanced capabilities particularly to highly digitalized processes such as metal additive manufacturing (AM) is likely to make those processes commercially more attractive. AI capabilities will reside within Digital Twins (DTs) which are living virtual replicas of the physical processes. DTs will be empowered…

  DOI

• Feedstocks and Processes for Additive Manufacturing of Metals and Alloys

  2026-02-06

  otherSenior author

  This chapter discusses commonly used additive manufacturing (AM) processes for metallic materials. It describes fabrication techniques for powder, wire, and sheet feedstocks. The chapter explains the effects of feedstock characteristics on AM processes and the qualities of the printed parts. In AM of metallic materials, a computer-aided design file specifies the part geometry. This file also helps to determine the orientation of the part within the build volume and the support structure that may…

  PublisherDOI

• Theory and Practice of Additive Manufacturing

  2026-02-06

  bookSenior author

  Theory and Practice of Additive Manufacturing Discover the ins and outs of additive manufacturing in this student-friendly textbook Also known as 3D printing, additive manufacturing is a process by which layers of material are added to create three-dimensional objects guided by a digital model. It has revolutionized the design and manufacture of customized products, facilitating the rapid, flexible production of a huge range of goods. It promises to revolutionize manufacturing engineering, short…

  PublisherDOI

Frequent coauthors

• Todd Palmer

  Pennsylvania State University

  45 shared

• T. Mukherjee

  43 shared

• A. De

  Indian Institute of Technology Bombay

  38 shared

• J. W. Elmer

  Lawrence Livermore National Laboratory

  36 shared

• Wei Zhang

  27 shared

• S. A. David

  25 shared

• H. K. D. H. Bhadeshia

  Queen Mary University of London

  23 shared

• Huiliang Wei

  Nanjing University of Science and Technology

  21 shared

Awards & honors

• Founding Editor, Science and Technology of Welding and Joini…
• Chair, Research and Development committee, American Welding…
• Chair 9th International Conference on Trends in Welding Rese…
• Co-Chair, 5th, 6th, 7th, 8th and 10th International Conferen…

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