Tarasankar DebRoy

Tarasankar DebRoy
  • Professor of Materials Science and Engineering
204 Steidle
(814) 865-1974


Professional Preparation

Indian Institute of Science, Bangalore, India: Ph.D., Department of Metallurgy, 1974, Professor K. P. Abraham, thesis advisor.

Imperial College of Science and Technology, London, England: Postdoctoral, 1974-77, Professor D. G. C. Robertson, advisor.

Massachusetts Institute of Technology, Cambridge, MA: Postdoctoral, 1978-79, Professors T. W. Eagar and J. Szekely, advisors.


(a) Pennsylvania State University: Assistant Professor, 1980 – 1984; Associate Professor, 1984-89; Professor of Materials Science and Engineering, since 1989.

(b) Founding Editor, Science and Technology of Welding and Joining, published by Maney, England. 1996-date.

(c) Chair, Research and Development committee, American Welding Society, 2007 to date.

(d) Chair 9th International Conference on Trends in Welding Research (2012), and Co-Chair, 5th, 6th, 7th, 8th and 10th International Conferences on Trends in Welding Research.

Other positions: Guest Professor, Production Technology Center (PTC), University West, Trollhattan, Sweden, January – February, 2013 and May 2014; Visiting Professor, African University of Science and Technology, Abuja, Nigeria, August 2010 and June 2011; Aditya Birla Chair, Department of Mechanical Engineering, Indian Institute of Science, Bangalore, India, Summer 2003;  Academic program Evaluator, School of Materials Science & Engineering, Shanghai Jiao Tong University, 2009; Member, ASM International-IIM Visiting Lecturer Selection Committee, 2000-2010; Member, Awards Committee, American Welding Society (AWS), 2000-date; Member, AWS Technical Papers Award Sub-committee, 2000 to date. 


Research focus: Computational materials processing, particularly the application of numerical transport phenomena and optimization in welding and additive manufacturing. Our models compute the most important factors that affect metallurgical product quality such as temperature and velocity fields, cooling rates and solidification parameters by solving tens of billions of equations quickly.

Uniqueness: Specially structured for integration with genetic algorithms and other search engines, these simulations can be made bi-directional, greatly expanding their utility by switching traditional input and output variables, tailoring product attributes, optimizing production variables, reducing defects and improving product quality. 

Examples of contributions:

(i) The first rigorous numerical model of heat transfer and fluid flow in 3D printing for reducing distortion and other common defects, customizing textures, selecting materials and reducing rejection rates of parts.

(ii) The first comprehensive numerical model for the calculation of laser fired aluminum-silicon contact geometry and dopant concentration fields during selective emitter formation in silicon based photovoltaic devices.

(iii) The first transport phenomena and genetic algorithm based bi-directional models to tailor both weld geometry and cooling rate during welding.

(iv) A novel experimental technique, now widely adopted, for estimating temperatures from vapor composition during laser welding.

(v) The first rigorous numerical model to understand and control the role of similar and dissimilar concentrations of surface active elements in steels.

(vi) The first three-dimensional visco-plastic-flow and heat transfer model for friction stir welding to understand the role of process variables and tool durability.

We work closely with many leading research and development groups worldwide. Our models and methodologies have been widely used in industries, government labs and universities both nationally and internationally.  Click below for more information.

Research     Publications     Citations    Models     Collaborations    Keynote & named lectures    Lectures in youtube  1  2

Awards and honors

Fulbright-FACEPE Distinguished Chair, 2012-2013, for teaching and research in Brazil.

Distinguished Visiting Fellowship, Royal Academy of Engineering, UK, 2011, tenable at Cambridge University for collaborative research.

Yoshiaki Arata Award, International Institute of Welding (IIW), Villepinte, France “given to a person who has realized outstanding achievements in welding science and technology, and its allied areas, and which have been recognized as a great contribution to the progress of welding engineering and related fields,”  2006.

Special Appreciation Award, College of Earth and Mineral Sciences, The Pennsylvania State University, “Tarasankar DebRoy is an outstanding faculty member who has served his profession and university diligently at all levels.  Professor DebRoy’s selfless contributions .... demonstrate an extraordinary level of commitment and service.... Dr. DebRoy founded and systematized the department’s professional recognition process.  The awards garnered through Tarasankar’s efforts have brought tremendous honor to the individuals, .... prestige for the department, the College and the University ....” 2005.

Honorary Membership Award, American Welding Society, “this award is presented to a person of acknowledged eminence in the welding profession or who is credited with exceptional accomplishments in the industry”, 2003.

ASM International Visiting Lectureship Award, ASM International, “for lectures in India based on qualifications of the lecturer,” 2003. 

The 57th Comfort A. Adams Lecture of American Welding Society. The Society describes this award as follows: “An award is made annually by the AWS Board of Directors to an outstanding scientist or engineer whose lecture presents some new and distinctive development in the field of welding,” 2000.

Fellow, American Welding Society “in recognition of outstanding and distinguished contributions that have enhanced the advancement of the science, technology and application of welding,” 1999.

Faculty Scholar Medal, The Pennsylvania State University, “for outstanding achievement in engineering”, maximum five Faculty Scholar Awards are made per year from among approximately 4200 Penn State faculty, 1997.

Fellow, ASM International, “for pioneering fundamental research in welding…and for leading efforts in the mathematical modeling of welding processes,” 1993.

Wilson Research Award, College of Earth and Mineral Sciences, The Pennsylvania State University, “for outstanding contributions to the understanding of weld pool surface phenomena,” 1993.

Adams Memorial Membership Award, American Welding Society, “for outstanding teaching,” 1992.

AWARDS FOR TECHNICAL PAPERS (shared with students and colleagues)

McKay Helm Award, American Welding Society, “for the best technical paper on the welding of steel published in the Welding Journal in the previous calendar year,” 2010 and 1994. (Two separate awards: 2010 award shared with R. Rai, T. A. Palmer and J. W. Elmer and 1994 award shared with K. Mundra)

Charles H. Jennings Memorial Award, American Welding Society, “for the most valuable paper published by a college student or faculty in Welding Journal during the previous calendar year,” 2007, 2006 and 1997 (Three separate awards; 2007 award shared with A. Kumar, 2006 award shared with A. De and 1997 award, shared with W. Pitscheneder, K. Mundra and R. Ebner).

William Spraragen Memorial Award, American Welding Society (AWS), “for the best research paper printed in the Welding Journal during the twelve month period ending with the December issue” 2005 and 2001 (Two separate awards; 2005 award shared with W. Zhang, T. A. Palmer and J. Elmer, and 2001 award shared with Z. Yang, J. Wong and J. Elmer).

Kenneth Easterling Best Paper Award, International Institute of Welding, Villepinte, France and Technical University of Graz, Graz, Austria, “for the best research paper presented at the 7th International Seminar on Mathematical Modeling of Welding,” Graz, Austria, 2003 (shared with A. Kumar, W. Zhang, and C. L. Kim).

Warren F. Savage Memorial Award, American Welding Society, “for innovative research resulting in a better understanding of the metallurgical principles related to welding,” 1998. (shared with K. Mundra, S. Babu and S. A. David).


(a) Thermochemical Processing: This three credit, senior level undergraduate course is concerned with physico-chemical aspects of high temperature extraction and processing of metals and alloys.

(b) Properties and Processing of Engineering Materials: This course serves as an introduction to the structure, processing, and properties of materials for undergraduate sophomore level engineering students.

(c) Computational Materials Science – Continuum Simulations: This graduate level course focuses on the simulations of transport of heat, mass and momentum, diffusion and structural changes.

Click here for more details of teaching