I am a materials researcher specializing in advanced composite materials, additive manufacturing, and solid-state processing techniques for structural and biomedical applications. My research focuses on developing sustainable, high-performance composites through innovative reinforcement strategies, process optimization, and microstructural engineering.
My work integrates experimental fabrication (FDM, friction stir welding, powder metallurgy, squeeze casting, hot pressing), microstructural characterization (OM, SEM, XRD), and statistical optimization tools such as Response Surface Methodology (RSM), Taguchi methods, ANOVA, and Genetic Algorithms.
I have extensive experience in:
Polymer matrix composites for biomedical and tribological applications
Aluminum and magnesium matrix composites reinforced with ceramic and industrial/agro-waste particles
Friction stir welding of dissimilar alloys with particle incorporation
Wear behavior and mechanical performance evaluation
Sustainable materials development using recycled polymers and industrial waste
My research aims to bridge sustainability, performance optimization, and real-world engineering applications.
Sustainable Polymer Composites Bio-based and Hybrid Reinforced PLA Systems Fused Deposition Modeling (FDM) & Additive Manufacturing Optimization Friction Stir Welding (FSW) of Dissimilar Alloys Metal Matrix Composites (Al Mg) Surface Composites via Friction Stir Processing Tribology and Wear Behavior Analysis Microstructural Characterization & Phase Analysis Design of Experiments (RSM Taguchi CCD) Process Optimization using Statistical and AI-Based Methods Biomedical Composite Materials for Orthopedic Applications Waste-to-Value Reinforcement Strategies
Abstract Cold spray process (CSP) is a thermal spray technology in which coating (10–40 µm) is formed in the solid state by the impingement of power particles with supersonic velocity (200–1,200 m/s 2 ) on coupon employing compressed gas jet, below the melting point of coating powder. It is commonly referred as cold gas dynamic spray, high velocity powder deposition, kinetic spray and kinetic energy metallisation process. Using CSP, various engineering materials (metals, polymers and ceramics) and its composites can be deposited. It is unique and promising approach for obtaining surface coating and offers various technological benefits over thermal spray as kinetic energy is employed for deposition rather than thermal energy. This offers great benefits in additive manufacturing (AM) to develop a component denser, low oxide coating free of tensile residual stresses, and undesired chemical reactions compared to conventional AM and coating techniques. Cold spray additive manufacturing (CSAM) is the powerful and emerging technique in the field of AM to develop engineering components with improved performance covering broad range of functionalities of surface, subsurface and interfaces. There are few flaws in this technique; however, extensive research work is going in CSAM and repairing of components to meet the real-time applications. The main objective of this review article is to summarise the history, effect of process parameters on surface coating, research and development in CSP along with its implementation in AM, component repairing and biomedical, antimicrobial and electrical applications. A discussion on future trends in CSAM is also provided at the end part of this article.
In this work, the wear behavior of a novel AZ31 magnesium alloy reinforced with 5% yttria-stabilized zirconia (YSZ) composite was evaluated using a hybrid Response Surface Methodology (RSM) and Genetic Algorithm (GA) approach. The composite was fabricated using ultrasonic-assisted stir squeeze casting technique, ensuring homogeneous distribution of spherical YSZ particles, as validated by the scanning electron microscope integrated with energy dispersive spectroscope. Wear tests were carried out according to the ASTM standards using a pin-on-disc (POD) tribometer, with applied load (AL), sliding speed (SS), and sliding distance (SD) as the main parameters. An empirical wear rate regression model was developed using RSM/Box-behnken design, and Genetic Algorithm was deployed for parametric optimization, achieving a minimal wear rate of 0.0144 g/m under a load of 30 N, sliding speed of 260 rpm, and sliding distance of 400 m. Confirmation tests were performed to validate the GA predictions. The wear mechanisms were observed, showing reduced wear in GA-optimized samples due to optimized load distribution resulting minimized ploughing, grooving and delamination. This work highlights the efficacy of the hybridized RSM / GA for the wear performance in advanced magnesium alloy matrix composites.
The optimization of friction stir process (FSP) parameters plays a pivotal role in enhancing the mechanical properties of friction‐stirred hybrid surface composites (FSHSC), which are crucial for lightweight and high‐performance structural applications. This study introduces the use of the artificial bee colony algorithm (A BC A) for optimizing process parameters of yttria‐stabilized zirconia (YSZ) and alumina (Al 2 O 3 )‐reinforced FSHSC. A three‐factor, five‐level central composite design matrix based on response surface methodology is utilized to develop predictive models for ultimate tensile strength (UTS) and yield strength (YS). Analysis of variance confirms the robustness and reliability of the models, with high statistical significance ( p < 0.0001) and R 2 values of 0.9940 for UTS and 0.9938 for YS. A BC A identifies optimal parameters—tool rotational speed of 1001.543 rpm, tool transverse speed of 71.896 mm min −1 , and tool axial force of 7.23 kN—achieving UTS of 198.345 MPa and YS of 163.534 MPa. The study demonstrates that A BC A is a powerful tool for optimizing FSP parameters and improving hybrid composite performance. This methodology offers a framework for advancing the mechanical properties of composites, with significant implications for lightweight engineering applications.
Abstract The present research work is focused on analyzing the tribological and corrosion impacts of introducing a new metal/bioceramic (Ti/HA) compound into the matrix of the Mg–3Zn alloy. The hybrid composites were developed using the squeeze casting method. The density, microhardness, and microstructure of the developed composite materials were examined. A pin-on-disk tribology meter was used to conduct the tribological study under a phosphate-buffered saline (PBS) lubricating medium. Studies on electrochemical corrosion were carried out in the PBS medium. Incorporating hybrid Ti/HA particles into the Mg–3Zn alloy matrix significantly increased the density and microhardness of the composites. Optical microscopy demonstrates a refined grain size and uniform distribution of reinforced particles, showcasing improved structural integrity. Scanning electron microscopy analysis further confirms the α-Mg and β-Mg–Zn phases. According to the findings of wear tests, the Ti/HA inclusion in the Mg–3Zn (MZ0) matrix increased the resistance to wear behavior. Abrasion, delamination, oxide layer formation, and severe delamination features were observed at the worn surfaces. Abrasive wear happened along with all other wear mechanisms and served as a wear initiator. Potentiodynamic polarization experiments revealed that the corrosion resistance of hybrid composites was increased with the inclusion of 1.5 % HA.
The objective of this work is to examine the fire resistance of natural composite materials (NCM). The reinforcements used in this work are coir, cotton, Palmyra leaf stream, sisal fiber, and matrix selected for natural rubber resin (latex). The fibers as reinforcement and natural rubber as the matrix phase were considered, and then the composite was manufactured through the hand lay-up open mold method. The chemical compositions of specimens treated with inorganic flame retardant chemicals (Al(OH)3, Mg(OH)2, zinc borate, ZnO, and zirconium oxide). The selection of flame retardant chemicals is based on their high melting temperature, low toxicity, low smoke emission, low burning rate, easy availability, and low cost. The thermal analysis of the horizontal burn test, TGA, DSC, and cone calorimeter analysis was carried out to understand the material’s thermal stability. The important finding of this experimental work is to analyze the micro structural and thermal stability of various compositions of flame-retardant composite materials. In all aspects, the zinc-borate and zirconium oxide-added composites show more advantages in flame retardant properties compared to other composite materials.
Abstract In this work, the alumina (Al 2 O 3 ) particles-reinforced AZ61 magnesium (Mg) alloy surface composite was fabricated using friction stir processing (FSP) and groove reinforcement filling methods. The Mg alloy surface composites were developed with and without the addition of Al 2 O 3 reinforcing particles, and their mechanical performance was compared with each other and with unprocessed base metal (BM). The Al 2 O 3 powder was compressed into a groove of 4.5 mm depth that had been created in AZ61 Mg alloy plates. The volume fraction of Al 2 O 3 powder was increased to 5, 10, and 15 vol.% depending on the width of the groove. Results disclosed that the problem of cluster formation of reinforcing Al 2 O 3 particles was minimized by performing FSP in five number of passes. The ultimate tensile strength (UTS) and hardness of AZ61 Mg alloy were enhanced by 6.07 % and 22.23 % when it was subjected to FSP. This is primarily correlated to the significant refining of grains due to the severe plastic deformation associated with FSP. The 15 vol.%-FSPed Al 2 O 3 /AZ61 Mg alloy surface composite showed a higher UTS of 630 MPa and hardness of 300 HV. This is due to the integration of a greater quantity of Al 2 O 3 particles with substantial grain refining.
Herein, the mechanical and antibacterial properties of 3D printed polylactic acid (PLA) reinforced scaffolds incorporating hydroxyapatite (HA) and magnesium oxide (MgO) nanoparticles utilising various infill patterns (line, triangle, and cubic) were investigated. Scanning electron micrographs (SEM) demonstrated a uniform distribution of HA and MgO within the PLA, whereas X-ray diffraction (XRD) and Fourier Transform Infrared (FTIR) patterns confirmed the presence of the nanoparticles synthesised without compromising the crystallinity of the composite. The line pattern exhibited superior performance in surface hydrophilic properties, facilitating the interaction of bacteria with MgO nanoparticles. Mechanical tests indicated that the triangular pattern produced superior tensile, compressive, and flexural strength owing to its optimal load distribution and structural stability. Conversely, in vitro tests, including but not limited to inhibition zone measurements and live/dead cell imaging, the cubic pattern exhibited the most effective antibacterial activity, particularly against S. aureus bacteria. The cubic pattern, characterised by its increased surface area and improved wettability, facilitates bacterial interaction with MgO, which produces reactive oxygen species (ROS) that compromise cell membranes, ultimately leading to bacterial death. This study assessed the mechanical strength of the optimised components, determining that the triangular pattern was most suitable for load bearing implant applications, while the cubic pattern was effective for bacterial eradication.
Recent medical research is focusing on biodegradable and biocompatible magnesium-based alloy materials and composites for repairing damaged bone structures. Their rapid deterioration and poor antimicrobial properties prevent them from being used as implant materials. Hence, this study aims to develop novel nanocomposites (Mg/5% HA and Mg/5% HA/1% Ag np ) by innovative ultrasonic-aided squeeze-rheo casting to enhance the mechanical, corrosion, and biological properties of Mg-based composites, demonstrating their potential as biodegradable implants with a low implant/tissue infection risk. Herein, the fabrication process involved the application of 2 kW power and 20 kHz acoustic waves during ultrasonic treatment of the molten magnesium alloy to achieve uniform dispersion of HA and Ag np , followed by squeeze pressure to solidify the composite materials. The morphological and phase analysis reveals minimal Ag np aggregation, surface defects, and presence of primary Mg, HA, and Ag phases without intermetallic phase formation. Furthermore, potentiodynamic polarization study reveals that Ag np -reinforced nanocomposites have lower corrosion rate (0.82 mm/y) than pure Mg (1.15 mm/y) and Mg/HA (2.55 mm/y) composites in a simulated body fluid (SBF). Likewise, the contact angle testing and MTT assay demonstrated improved cell adhesion and proliferation properties of the nanocomposite. Also, the release of Ag+ ions during degradation inhibited colony-forming units of E. coli bacteria and disrupted its cell membrane, proving its bactericidal properties. Altogether, these novel nanocomposites (Mg/5% HA/1% Ag np ) may be suitable for biodegradable implants with a low implant/tissue infection risk.
Abstract This study aims to fabricate the hybrid yttria-stabilized zirconia (YSZ)/Al 2 O 3 surface composite on the AZ31 magnesium (Mg) alloy through friction stir processing (FSP). The base alloy center surface was turned to provide a 1 × 2 mm groove to fabricate the friction-stirred surface composite using the tapered cylindrical tool. The microstructural and mechanical behavior of the hybrid surface composite (FHSC) results were compared with the Al 2 O 3 -reinforced surface composite (FASC), the FSP-treated sample, and the base alloy. In terms of microhardness performance, the FHSC exhibits a 10% improvement over the FASC, a 32% improvement over the FSP treated alloy, and a 95% improvement over the base alloy. Additional FHSC samples exhibit improved impact resistance of around 30% over the FASC, 81% over the FSP treatment, and 226% over the base alloy. Furthermore, FHSC samples outperform FASC by about 15%, FSP-treated alloys by 59%, and base alloys by 95% in terms of tensile strength augmentation. This is due to the synergistic effects of both Al 2 O 3 and YSZ particles, which significantly strengthen the interfacial bonding between the matrix. This results in substantially enhanced interface adhesive behavior between the base alloy and ceramic particles and leads to enhanced mechanical characteristics.
AZ31 alloys are gaining considerable research interest owing to their commendable applications in automobile and aerospace applications because of their high strength-to-weight ratio to reduce the overall weight of the vehicle. However, these alloys are more susceptible to porosity and material shrinkage during casting, which in turn results in poor mechanical behavior. Ultrasonic-assisted squeeze casting is a non-traditional casting technique that involves the application of ultrasonic waves to distribute the reinforced particles homogenously in the melt, improving the integrity of the alloy composites by reducing agglomeration. While various materials have demonstrated the efficacy of these processing techniques, their potential for casting AZ31/10% SiC alloy composites remains unexplored. The present work aims to investigate the impact of three major process parameters, namely ultrasonic power (UP), squeeze time (ST), and stirring speed (SS), on the responses of porosity and microhardness, using the response surface methodology (RSM) central composite design (CCD) approach. The analysis of variance (ANOVA) technique is used to determine the most significant process parameter and to check the model’s adequacy. The analysis indicates that ultrasonic power has the highest F -value and is the most influential factor on porosity and microhardness. Microstructural studies reveal the composites’ structural morphology. Apart from identifying the optimal individual process parameters, the desirability approach was also deployed to carry out the multi-objective optimization. Further, empirical models were developed, and confirmatory tests were performed to validate the models. The observed confirmatory results indicate that the developed models have a good prediction tendency.
Abstract Friction stir processing (FSP) is a well-known method for improving metal alloys’ surfaces by producing surface composites with better mechanical properties. This study examines how the tool tilt angle affects the FSP region generation in an AZ31 magnesium (Mg) alloy reinforced with yttria-stabilized zirconia (YSZ) and alumina (Al 2 O 3 ). The effect of different tool tilt angles (T TA ) on the dispersion, integration, and distribution of YSZ and Al 2 O 3 in the Mg matrix was investigated. Optical microscopy, scanning electron microscopy (SEM), and Vickers hardness testing were used to extensively evaluate the microstructural and mechanical characteristics of the FSP-treated region. The findings show that the T TA has a major impact on the surface composite’s homogeneity and uniformity, with 2° T TA encouraging the best possible dispersion of YSZ/Al 2 O 3 and enhanced mechanical properties. T TA of 2° friction stirred surface hybrid composite (FSSHC) exhibits a greater hardness of 137 HV as compared to the FSP-treated (106 HV) and the base alloy (73 HV). This is due to the Orowan strengthening mechanism and also because FSSHC has the ability to withstand a load through the inclusion of YSZ/Al 2 O 3 particles, and the homogeneous distribution of YSZ/Al 2 O 3 particles among the recrystallized base alloy grains provides homogeneous reinforcement across the stirred region.
This research investigates the impact of various tool pin profiles on the tribological behavior of AZ31 magnesium alloy reinforced with 5 wt.% yttria-stabilized zirconia (YSZ) surface composite produced through friction stir processing (FSP). AZ31 plate filled with YSZ subjected to FSP using four distinguished tool profiles: plain cylindrical (PC), threaded cylindrical (TC), plain tapered cylindrical (PTC) and threaded tapered cylindrical (TTC). Dynamic recrystallization due to the FSP process contributed to fine grain structure refinement and uniform distribution of YSZ particles, resulting in improved hardness of AZ31/YSZ surface composites. The wear behavior was examined by means of a pin-on-disc tribometer under 15, 30, and 45 N applied loads. Results reveal that the FSPed AZ31/YSZ composites had higher wear resistance compared with those for as-received, and FSPed AZ31 alloy. Plain tapered cylindrical tool profile gave better outcomes which included defect free surface finish and optimal particle dispersion. It was shown that stronger YSZ particles inhibit material removal and increased refined grain structure, supported by a decrease in coefficient of friction from 0.49 for as received AZ31 alloy to 0.27 for FSPed AZ31/YSZ composites emphasizes the influence of FSP tool pin profiles in enhancing the hardness and tribological performance of surface composites.
To design, develop and study the substrate integrated waveguide using slot antennas with Yagi configurations and analyze its performance at s-band frequency. Compactness, light weight and improved performance are the major objective of this project. The main focus is towards achieving miniaturized form of waveguide based slot antenna suitable for mobile application and air-borne requirements.
The innovative development in materials engineering known as friction stir processed hybrid composites (FSPHC) provides unmatched performance and versatility for applications in the automotive and aerospace industries. The revolutionary potential of FSPHC in several industries is examined in this abstract. Through the technique of friction stir processing, FSPHC is able to combine the distinct qualities of several materials to create a material that is superior in terms of strength, lightweight design, and durability. FSPHC are being used more and more in the aerospace industry in structural parts like wing panels and fuselages, where their better mechanical qualities help to increase performance and fuel efficiency. Similar to this, FSPHC are essential to light weighting techniques in the automobile sector, which improve vehicle performance, fuel efficiency, and sustainability.
This study presents the fabrication and comparative assessment of biodegradation and biocompatibility behaviors of pure Mg, Mg/HA (Hydroxyapatite), Mg-Zn/HA, and Mg-Sn/HA composites with fixed 5 wt% HA and 1 wt% each of Zn and Sn, using novel ultrasonic-assisted rheo casting technology. Characterization techniques, including X-ray diffractometry and scanning electron microscopy integrated with energy dispersive spectroscopy, were employed to analyze phase formation, surface morphology, and elemental composition. Microhardness tests were conducted to assess indentation resistance, while in vitro corrosion performance was evaluated in simulated bodily fluid to compare degradation behavior. Results indicate a uniform distribution of reinforced particles within the matrix with minimal casting defects. Intermetallic phases MgZn and Mg 2 Sn precipitated along grain boundaries in Mg-Zn/HA and Mg-Sn/HA composites. The Mg-Sn/HA composite exhibited peak microhardness (94.8 HV) due to precipitation strengthening. In contrast, Mg-Zn/HA samples showed a low degradation rate (0.19 mm/yr) and H 2 gas evolution rate (0.035 ml/mm 2 ), attributed to uniform distribution of secondary phases and fine grains that mitigate galvanic cell formation and control degradation. Cell viability assay results demonstrated that Mg-Zn/HA composite outperformed all other samples, showing a 94% relative cell growth rate of osteosarcoma MG-63 cells after 2 h of incubation, attributed to strong apatite formation (rich in Ca and P) on the surface post-immersion, promoting cell proliferation.
Abstract Silicon carbide / Graphite and Alumina / Graphite reinforced AL6061 Hybrid metal matrix composites are fabricated by stir casting (liquid metallurgy) route. Four samples A,B,C,D with varying proportions in both matrix and reinforcements by fixing graphite proportion (5%) constant for all sampled are prepared. Mechanical properties of all the samples are compared with matrix material (AL6061). Scanning electron microscope is used to examine the microstructural characteristics of the composite samples. Mechanical test results exhibit 3.5% (sample C) increase in the hardness number than the base matrix. But, yield and ultimate tensile strength are reduced with all the reinforcements. Microstructural characterisation clearly depicts the presence of cracks, Agglomeration of reinforcements, cast defects on the surface of prepared composites which leads to poor yield and ultimate tensile strength.
ABSTRACT The limited load‐bearing capability of polylactic acid (PLA) restricts its use in biomedical applications such as orthopedic scaffolds, where mechanical robustness is essential. Reinforcing PLA with biofunctional natural fibers offers a sustainable route to overcome these limitations. In this study, Cissus quadrangularis (CQ), a fiber with high cellulose content and osteogenic potential, was employed as reinforcement for PLA to develop biodegradable composites. The composites were fabricated through melt extrusion followed by injection molding, and the effect of fiber content, extrusion temperature, and molding pressure on ultimate tensile strength (UTS) was systematically evaluated using a Taguchi L9 orthogonal design. Regression modeling revealed molding pressure as the most influential factor, and a Genetic Algorithm (GA) was integrated with the regression model to achieve global optimization of processing conditions. The optimized combination of 14.98 wt.% fiber, 160.9°C extrusion temperature, and 29.76 MPa molding pressure yielded a UTS of 43.05 MPa, closely matching experimental validation with < 1% error. Fractographic analysis confirmed effective fiber–matrix interaction under optimized conditions. This integrated Taguchi–GA framework highlights the significance of combining statistical design with metaheuristic optimization to enhance the performance of natural fiber composites and provides a pathway for designing mechanically robust PLA‐based biomaterials.
Influence of surface roughness on coefficient of friction of Titanium coated R19 Steel is investigated in this paper using Pin on Disc Apparatus. Wear properties of R19 Steel are evaluated because it is widely used in making the rail wheel and rail roads over the years. Titanium coating of 100nm thickness was deposited on the R19 Steel by Electron Beam Gun Physical Vapor Deposition method. Wear and friction parameters were evaluated using Pin on Disc apparatus. The Surface morphology plays an important role in affecting the wear rate. Non-contact surface roughness tester was used to examine the surface texture and measure the surface roughness of the specimens. The test was carried out in a pin on disc apparatus for Normal Load of 15N, Sliding Velocity of 3m/s and Time 5 min. The texture and the roughness parameters of the surface affect the coefficient of friction. The experimental values of roughness parameters of uncoated and coated disc and its effect on coefficient of friction are compared and validated. Results show that the Coefficient of friction decreases with lower value of R a . Lower values of frictional force and coefficient of friction results in lower wear rates.
Project Overview Magnesium-based alloys are emerging as next-generation biodegradable materials for orthopedic implant applications due …
Inviting collaborations in research, innovation, and academic publishing across materials science, advanced manufacturing, AI in engineerin…