metal additive manufacturing, micro/nano-machining processes, precision and ultra-precision machining, modeling and analysis in the machining of “difficult to machine” materials, tribology of manufacturing processes, nano-tribology, surface coatings, nano-lubricants, advanced machining processes
From grain to chip: Influence of manufacturing route on micro-turning behaviour of Inconel 718 S. Vishnu, Basil Kuriachen, Jose Mathew Journal of Materials Research and Technology, 2026 The influence of manufacturing route on the microstructure and machinability of Inconel 718 (IN-718) remains an important consideration for precision micromachining applications. In this study, IN-718 produced by conventional forging and laser powder bed fusion (L-PBF) was subjected to identical standard heat treatments to establish comparable metallurgical conditions and enable meaningful comparison. Microstructural characterization was performed to examine grain morphology, phase evolution, and hardness response, followed by micro-turning experiments conducted at three cutting speeds (30-60 m/min) and feed rates (10-30 μm/rev) using uncoated tungsten carbide tools. Cutting force, surface roughness, and flank wear were evaluated to assess the combined effects of microstructure and machining parameters. The results show that L-PBF IN-718 exhibits finer grains and a larger relative increase in hardness after heat treatment, whereas forged IN-718 retains a coarser, equiaxed grain structure with higher absolute hardness. During micro-turning, forged IN-718 generated higher cutting forces, while L-PBF IN-718 achieved superior surface finish, particularly at lower cutting speeds and feeds. Although both materials exhibited similar dominant wear mechanisms, including abrasion, adhesion, and micro-chipping, their severity and morphology varied significantly with manufacturing route and cutting conditions. Overall, the findings demonstrate that manufacturing-induced microstructural characteristics strongly govern machinability and tool wear behaviour in micro-turning of IN-718. • Forged and L-PBF Inconel 718 were subjected to identical standard heat treatment to enable direct machinability comparison. • Forged IN-718 exhibited higher post-treatment hardness, while L-PBF IN-718 showed greater relative hardness improvement due to precipitation strengthening. • L-PBF IN-718 achieved superior surface finish at lower cutting speeds and feeds, whereas forged IN-718 generated higher cutting forces. • Distinct wear mechanisms were observed, with adhesion and micro-chipping dominating in L-PBF IN-718 and plowing and abrasion prevailing in forged IN-718.
Wear behaviour of deep cryogenically treated coated tool during end milling of XH67MBTHO Jayaram C Sasi, Jose Mathew, Allan George, Basil Kuriachen, P B Dhanish, George Oommen, C R Anoop Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology, 2026 XH67MBTHO is a Ni-based superalloy which finds usage in high temperature applications of aero engines. However, attributed to some of their inherent properties like strain hardening and poor thermal conductivity, tool life characteristics are adversely affected during the machining operations. The use of conventional TiAlN coated tools can address the tool wear issues faced during machining of similar Ni-based alloys. However, severe coating delamination, and significant adhesion wear mechanisms could negatively influence the effectiveness of the tools at dry lubricating conditions. The current study investigates the influence of a sustainable manufacturing technique through DCT (Deep Cryogenic Treatment) and its impact on coated tool inserts to address the tool wear issues under dry machining conditions. The DCT aids in the formation of η (eta) phase carbides, β-phase densification etc. Hence, the tool substrate develops significant wear resistance and fracture toughness in withstanding the contact stress at the machining interface. Notch wear, micro-crack formations, and built-up layer generations were observed to be major wear mechanism, and for treated tool (TT) it was less severe. Furthermore, the maximum reduction in average flank wear widths for treated tool was observed to be 26%, while the cutting force and surface roughness values were found to be reduced by 27%, and 24% respectively compared to untreated tool (UTT).
A Novel Seal Design to Enhance MR Brake Performance Deepak Kumar, G. A. Harmain, Gaurav Gaurav, K. P. Lijesh, Basil Kuriachen, Harish Hirani, Jibin T. Philip Transactions of the Indian Institute of Metals, 2023
Describing the Influence of Laser Cutting Parameters on a SiC Reinforced Al Alloy Metal Matrix Composite (MMC) Using Response Surface Methodology (RSM) Lasers in Engineering, 2022
Comparative Ambient and Elevated Temperature Wear Performance of an AlSi10Mg Alloy Fabricated by Selective Laser Melting (SLM) and Casting Lasers in Engineering, 2022
Precision beyond wear: A pulse-energy-based electro-thermal approach for tool wear compensation in μ-EDM of Ti6Al4V M Manikandan, S Vishnu, B Kuriachen, J Mathew Journal of Manufacturing Processes 168, 746-771 , 2026 2026
Microturning response of LPBF Inconel 718: effect of homogenization annealing S Vishnu, B Kuriachen, J Mathew MATERIALS AND MANUFACTURING PROCESSES 41 (7), 964-973 , 2026 2026
Influence of Post-Processing on the Microstructure and Tribological Response of Ti64 ELI Alloys under Dry and Simulated Body Fluid Environments M Adith, V Venugopal, PV Likhar, KA Babu, B Kuriachen Wear, 206732 , 2026 2026
Corrosion and Surface Integrity Enhancement of AISI H13 Tool Steel via Electrical Discharge Machining B Karthik, B Kuriachen, V Kumar Journal of Materials Engineering and Performance, 1-17 , 2026 2026
From Grain to Chip: Influence of Manufacturing Route on Micro-Turning Behaviour of Inconel 718 S Vishnu, B Kuriachen, J Mathew Journal of Materials Research and Technology , 2026 2026
Wear behaviour of deep cryogenically treated coated tool during end milling of XH67MBTHO JC Sasi, J Mathew, A George, B Kuriachen, PB Dhanish, G Oommen, ... Proceedings of the Institution of Mechanical Engineers, Part J: Journal of … , 2026 2026 Citations: 3
Residual stress evolution and fatigue response in friction stir welded AA5052: An experimental and numerical study of tool profile effects FR Anoop, PM Sutheesh, B Kuriachen Engineering Fracture Mechanics, 111940 , 2026 2026 Citations: 2
Influence of discharge energy on dimensional accuracy and surface morphology during the µ-EDM of Ti-6Al-4 V M Manikandan, B Kuriachen, J Mathew Materials and Manufacturing Processes, 1-16 , 2026 2026
Corrosion performance of CMT-based wire arc additive manufactured SS 304 L in acidic environment: Effect of anisotropy and heat treatment OS Sandeep, B Kuriachen Tribology International 214, 111366 , 2026 2026
Tool Pin Profile and B 4 C Reinforcement Influence on the Microstructural and Mechanical Characteristics of Friction-Stir-Welded Joints V Venugopal, B Kuriachen Journal of Materials Engineering and Performance 35 (6), 5400-5414 , 2026 2026
Surface Modification of Ti-6Al-4V with Surface Roughness, Wettability and Wear Analysis Using Titanium Carbonitride Powder-Mixed Electric Discharge Process NV Prajina, J Mathew, B Kuriachen Journal of Materials Engineering and Performance 35 (6), 5254-5269 , 2026 2026 Citations: 1
Parametric effect on microstructure evolution, grain size and mechanical behaviour of friction stir butt welding of AA6061-T6 alloy VP Singh, D Kumar, B Kuriachen Journal of Adhesion Science and Technology 40 (3), 357-381 , 2026 2026 Citations: 17
Machining of KhN67VMTYu Super Alloy A George, PB Dhanish, J Mathew, B Kuriachen, CR Anoop Advances in Aerospace and Energy, Volume II: Proceedings of International … , 2026 2026
Investigation on the tribological behavior of laser direct energy deposited SS304L-IN625 TV Cyril, J Joshy, N Tudu, B Kuriachen Tribology International 212, 110969 , 2025 2025 Citations: 3
Effect of TiAlSiN coatings in mitigating the tribological challenges during machining of XH67MBTHO–A nickel-based superalloy VV Balakrishnan, SM Kotian, B Kuriachen, AK Rai Tribology International 212, 110966 , 2025 2025 Citations: 2
Influence of process parameters on dimensional inaccuracies in µ-EDM of Ti–6Al–4V M Murugan, J Joshy, B Kuriachen, J Mathew Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2025 2025
Effect of process parameters and tool pin profiles on microstructural evolution and mechanical properties of friction stir welded AA5052 V Venugopal, VP Singh, B Kuriachen, MS Shamasundara Arabian Journal for Science and Engineering 50 (22), 18267-18283 , 2025 2025 Citations: 7
Microstructural, mechanical and wear behaviour of AA7075/ZrSiO 4 surface composite developed via multi pass friction stir processing SK Patel, B Kuriachen, S Lei Advances in Materials and Processing Technologies 11 (4), 2622-2652 , 2025 2025 Citations: 1
Influence of weld parameters on the tribocorrosion behaviour of friction stir welded AA5052 in the marine environment GS Anantharam, KB Bhole, B Kuriachen, SB Arya Tribology International 210, 110808 , 2025 2025 Citations: 1
A critical review on development of magnesium-based bio-implants surface composite through friction stir processing route SK Patel, L Shi, A Kumar, C Wu, S Mironov, M Zhou, X Liu, L Liu, Q Shi, ... Critical Reviews in Solid State and Materials Sciences, 1-86 , 2025 2025 Citations: 5
MOST CITED SCHOLAR PUBLICATIONS
Recent research progress in solid state friction-stir welding of aluminium–magnesium alloys: a critical review VP Singh, SK Patel, A Ranjan, B Kuriachen Journal of Materials Research and Technology 9 (3), 6217-6256 , 2020 2020 Citations: 339
Machinability of Inconel 718: A critical review on the impact of cutting temperatures K Mahesh, JT Philip, SN Joshi, B Kuriachen Materials and Manufacturing Processes 36 (7), 753-791 , 2021 2021 Citations: 200
Tribology of Ti6Al4V: A review JT Philip, J Mathew, B Kuriachen Friction 7 (6), 497-536 , 2019 2019 Citations: 199
Effect of powder mixed dielectric on material removal and surface modification in microelectric discharge machining of Ti-6Al-4V B Kuriachen, J Mathew Materials and Manufacturing Processes 31 (4), 439-446 , 2016 2016 Citations: 141
Transition from EDM to PMEDM–impact of suspended particulates in the dielectric on Ti6Al4V and other distinct material surfaces: a review JT Philip, J Mathew, B Kuriachen Journal of Manufacturing Processes 64, 1105-1142 , 2021 2021 Citations: 133
Mechanical and microstructural properties evolutions of various alloys welded through cooling assisted friction-stir welding: A review VP Singh, SK Patel, B Kuriachen Intermetallics 133, 107122 , 2021 2021 Citations: 92
Recent research progresses in Al-7075 based in-situ surface composite fabrication through friction stir processing: A review SK Patel, VP Singh, BS Roy, B Kuriachen Materials Science and Engineering: B 262, 114708 , 2020 2020 Citations: 89
Multiresponse optimization of micro-wire electrical discharge machining process B Kuriachen, KP Somashekhar, J Mathew The International Journal of Advanced Manufacturing Technology 76 (1), 91-104 , 2015 2015 Citations: 85
Parametric effect on dissimilar friction stir welded steel-magnesium alloys joints: a review VP Singh, SK Patel, N Kumar, B Kuriachen Science and Technology of Welding and Joining 24 (8), 653-684 , 2019 2019 Citations: 70
Investigations into the effect of process parameters on surface roughness and burr formation during micro end milling of TI-6AL-4V K Vipindas, B Kuriachen, J Mathew The International Journal of Advanced Manufacturing Technology 100 (5), 1207 … , 2019 2019 Citations: 68
The slurry abrasive wear behaviour and microstructural analysis of A2024-SiC-ZrSiO4 metal matrix composite SK Patel, B Kuriachen, N Kumar, R Nateriya Ceramics international 44 (6), 6426-6432 , 2018 2018 Citations: 65
Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V B Kuriachen, A Varghese, KP Somashekhar, S Panda, J Mathew The International Journal of Advanced Manufacturing Technology 79 (1), 147-160 , 2015 2015 Citations: 60
Experimental investigations into the effects of microelectric-discharge milling process parameters on processing Ti–6Al–4V B Kuriachen, J Mathew Materials and Manufacturing Processes 30 (8), 983-990 , 2015 2015 Citations: 58
Microstructural, mechanical and wear behavior of A7075 surface composite reinforced with WC nanoparticle through friction stir processing SK Patel, VP Singh, D Kumar, BS Roy, B Kuriachen Materials Science and Engineering: B 276, 115476 , 2022 2022 Citations: 46
Experimental investigations on the tribological performance of electric discharge alloyed Ti–6Al–4V at 200–600 C JT Philip, D Kumar, J Mathew, B Kuriachen Journal of Tribology 142 (6), 061702 , 2020 2020 Citations: 44
Friction stir processing of alloys with secondary phase particles: an overview SK Patel, VP Singh, B Kuriachen Materials and Manufacturing Processes 34 (13), 1429-1457 , 2019 2019 Citations: 44
Microstructural, mechanical and wear behavior of A7075 surface composite reinforced with WC and ZrSiO4 nanoparticle through friction stir processing SK Patel, VP Singh, BS Roy, B Kuriachen Journal of Manufacturing Processes 71, 85-105 , 2021 2021 Citations: 39
Underwater friction stir welding of marine grade aluminium alloys: A review V Venugopal, VP Singh, B Kuriachen Materials Today: Proceedings , 2023 2023 Citations: 38
Effect of heat treatment and electric discharge alloying on the lubricated tribology of Al–Si alloy fabricated by selective laser melting P Thasleem, D Kumar, ML Joy, B Kuriachen Wear 494, 204244 , 2022 2022 Citations: 38
Effect of eutectic silicon and silicon carbide particles on high stress scratching wear of aluminium composite for various testing parameters PK Yadav, G Dixit, S Dixit, VP Singh, SK Patel, R Purohit, B Kuriachen Wear 482, 203921 , 2021 2021 Citations: 37