(Brief Description / Abstract) :

Dr. RK Satapathy has a multi-disciplinary background with hands-on experience in several domains of Gas Turbine technology: from Design & Manufacturing to Certification & Engine Health Monitoring at operational bases. Aircraft accident investigation, Life revision of aero-engines, components and systems, Indigenization are some of his research interests. He led several projects& committees, both national and international, in Aeroengine Lifing, Indigenisation, Defect investigations, and Failure analysis. His professional career comprises 22+ years in HAL (Koraput) Engine factories, 10.5 years in Regional Centre for Military Airworthiness(RCMA, Koraput), DRDO as its Regional Director, and 3.5 yrs in DMRL, Hyderabad before joining DIAT on deputation. 

At HAL, he ledMiG-29 engine overhauling and overhauled more than 300RD-33 engines. During 1 ½ year tenure as Chief of Indigenisation at HAL, achieved the highest number of items indigenization. He was nominated by DRDO as a member of the Inter-Ministerial Committee on Aluminium Alloys for Defence and headed the Aluminium, Rolling, and Formability group at DMRL. 

Education:

• B. Sc Engg.(Metallurgical Engg),REC, Rourkela
• M.Tech.-Aircraft Production Engg.,IIT Madras
• Ph.D.-Engineering Sciences, AcSIR, CSIR, Ghaziabad

Professional Experience (Institution, Position and Period):

• Visiting Professor, DIAT (DU), Pune.  Oct. 2020 – Till date
• Sc-G, DMRL, DRDO, 2017- Sep 2020
• Regional Director, RCMA, Koraput, DRDO, 2006-2016
• MT, Technical-Chief Manager(Design), HAL, Koraput,1984-2006.

Research Domains:

• Aircraft accident investigation
• Lifing of aeroengines and systems
• Aerospace materials

Specific Projects:

• MiG29 Engine overhaul: overhauled more than 300 RD-33 engines in the absence of corresponding manufacturing project.
• Life enhancement of AI20D engines (AN32 A/c) from 6000 to 7000 hours. First of its kind study in the country.
• TBO life revision of Thrust Vector Nozzle (TVC) of SU30MKI from 500 to 850 h.
• Life enhancement of Ti-alloy 1st stage compressor disc (MiG27) from 800 to 1550 h &Life enhancement of Gas generator drum (MiG29).
• Indigenization of Integrated Engine Controllers of Su30MKI aircrafts.
• Engine health monitoring, mapping & monitoring additional station parameters on MiG27 engine with the support of CSIR & DRDO labs at HAL, Koraput.Off-Design Engine Modelling and performance parameter estimation with the help of NAL.
• Indigenization of 46 types of compressor and turbine blades of Mi8,Mi17 helicopters & AN 32 aircraft engines & Su-30 compressor blades by Cold Rolling using Indigenous materials Titan 31A & Super Nickel 718 from MIDHANI.
• Off Design Engine Modelling of Su-30 engine both in steady state and transients with the support of NAL, IIT, Kanpur & DRDO labs.
• Recycling, rejuvenation& casting yield improvement of imported Single Crystal blade/ alloy containing Rhenium.
• Development of CMAS resistant coating under Indian Conditions.
• Technical Consultancy to Indian Navy for Large NAB Propeller( 5.5 m dia& 21T weight) for Future Platform
• Consultancy to Indian Navy for TBO Life revision of Gas Turbine Generator GTG 1250-2E and Indigenization of it’s blades.

Research Collaborations:

Ph.D Thesis Supervision:

Experimental  investigation of Nickel base alloys for military gas turbine rotor blade- Dr Benudhar Sahoo ( Research in Progress), 2016 --  Mechanical  Engineering

M.Tech. Dissertation Supervision:

In 2013.

• Experimental Study on Effect of operating parameters on exit pattern factors of an annular combustor

In 2018

• Optimising the thickness combinations in Multi Layer Thermal Barrier Coatings on Ni-based Super alloys resulting in least Interfacial Stress.
• Characterization of Grain Boundary carbides and its effect on Creep behavior of a wrought Nickel based superalloy.

In 2021

• Decoding Indian Drone Policies from Operational Perspective-.
• Analysis and Implementation of Civil Drone Insurance in India
• Application Oriented Technical Evaluation of UAVs in India
• -UAS Traffic Management (UTM)-
• Real time Arbitrary Object Tracking for UAVs using Deep learning Algorithm

Summer/Winter Internships From other institutions Supervision:

Other Supervision:

Research Publications from 2010 to 2020:

Research Publications:

Journal Articles:

In 2020

• “Effectiveness of lanthanum zirconate and Yttriastabilised zirconia freestanding APS thermal barrier coatings against natural CMAS attack at high temperatures.” Materials at High Temperatures 37, no. 6 (2020): 416-424.

In 2019

• “Synthesis and Application of Nano structured Bi layer YSZ LZ Thermal Barrier Coating.” Defence Science Journal 69, no. 2 (2019): 185.

In 2018

• “Influence of Machining Process on Surface Integrity and Fatigue Life of a Turbine Rotor Blade” doi:10.1007/978-981-10-7197-3_53, Book chapter in “Advances in Structural Integrity”, 2018, pp.635-647
• “Creep life degradation and microstructure degeneration in a low-pressure turbine blade of a military aircraft engine.” Journal of Failure Analysis and Prevention 17(4): 529-538.doi:10.1007/s11668-017-0271-x

In 2018

• “Effect of aluminising on the low cycle fatigue life of a directionally solidified nickel-base alloy used for manufacturing turbine blade.” International Journal of Materials and Structural Integrity 12, no. 1-3 (2018): 58-75.

In 2016

• “Design point parameter estimation of a legacy twin spool turbojet engine for health monitoring.” J AeSI 68 (2016): 101-109.

In 2015

• “Analysis of a turbine blade failure in a military turbojet engine.”International Journal of Turbo & Jet-Engines 33, no. 2 (2015): 1–9.doi: 10 1515/tjj-2015-018
• “Effect of Operating Variables on the Performance of a Highly Loaded Annular Combustor.” International Journal of Turbo & Jet-Engines 32, no. 1 (2015): 85-95.

In 2013

• “Aero-thermodynamic modelling and gas path simulation for a twin spool turbo jet engine.” Gas Turbine India Conference, vol. 35161, p. V001T06A008. American Society of Mechanical Engineers, 2013. https://doi.org/10.13140/RG.2.1.1201.8401
• “Isothermal Fatigue Behavior of Two Nickelbase Alloys for Turbine Blades of Fighter Aircraft Engines.” Gas Turbine India Conference, vol. 35161, p. V001T08A005.  American Society of Mechanical Engineers, Dec 2013,doi: 10 1115/ GTINDIA2013-3682
• “Effect of shot peening on low cycle fatigue life of compressor disc of a typical fighter class aero-engine.” Procedia Engineering 55 (2013): 144-148.doi: 10.1016 /j.proeng.2013.03.233

Book Chapters:

Conference Papers:

Research/Review Submitted/Under Review:

• “Microstructural attributesto the Stability of ‘Brass’-Texture during Cold Rolling of AA7010 High Strength Aluminium Alloy”, APMC2020, 028, v1-Accepted
• “Modeling a twinspool legacy turbo jet engine for health monitoring application.” submitted to DSJ, OSJ 15428-final review

Any Publications Submitted/Under Review:

Invited Talks:

• Instrumentation in Aeronautics, KIIT, BBSR, 25th July, 2021
• General defects in Aluminium Components and causes, National Academy of DefenceProduction(NADP), Ambajhari, 28th July,2020
• Nano structured multilayered Thermal Barrier Coatings for Jet engine  application,  KIIT, BBSR, 20- 25 Jul, 2020
• Characterization of TBC – An application perspective, ICPCM, 12-14 Dec,2019, NIT Rourkela
• Failure-Analysis – A systems approach to Life revision of Aero-engines, 10th Dec, 2019,IIM, Jamshedpur Chapter
• Performance of Nano-structured YSZ-LZ Bi- layer TBC in Aero engines, 24thNov,ETRE, IREL, 2019
• Fundamentals of a TBC Design, NCIC 24-25th Jan, 2019, CSIR-IMMT Bhubaneswar

Patents:

Awards/Scholastic Achievements:

Government Funded Projects:

Any Other:

Level III qualification in NDT(Basic & Magnetic Testing) and has undergone a specialized course on “Solidification of Metals” at CALCOM, ESI, Switzerland. Cleared O & A level production engineering and management courses of HAL with Distinction. Completed special course on SQC/SPC & Design of Experiments conducted by ISI, Bangalore. Visited Defence Industries of Ukraine as a member of Defence delegation, Govt. of India. As Chairman of Aero Standardization Sub-committee, Directorate of Standardization, he made 15 Joint Service Specifications(JSS) and a Coating compendium. He received a commendation certificate & Titanium Medal from Scientific Advisor to Raksha Mantri.  He is a life member of Aeronautical Society of India, Indian Institute of Metals, Member of Indian Society of Failure Analysis, and American Society for Quality. 

• Board of Studies Member, Aerospace Engineering,KIIT  University Bhubaneswar