Engineering, Mechanical Engineering, Materials Science, Surfaces, Coatings and Films
16
Scopus Publications
249
Scholar Citations
8
Scholar h-index
7
Scholar i10-index
Scopus Publications
Unveiling Relationship Between Crack Evolution Through Long-Term Ageing and Mechanical Properties of Cold-Sprayed Ni-Base Superalloys: Experimental Characterization and Evidence Through Finite Element Modeling Malar Vadani, Sanjay Raj, Chandan Mondal, Wen Sun, Shanta Chakrabarty, Sabeur Msolli, Adrian Wei‐Yee Tan, Ayan Bhowmik Advanced Engineering Materials, 2026 This work examines the effects of prolonged heat‐treatment on the microstructure and mechanical characteristics of cold spray (CS) IN718. The heat treatment reduced coating porosity from 3% to 0.8%. The ageing treatment results in a synergistic effect of precipitation hardening from intermetallic phases and carbides, with a simultaneous reduction in the work‐hardened microstructure through recovery, manifested as reduced dislocation density in the coating. The as‐sprayed coatings exhibit reduced cohesive strength and toughness, along with a significant anisotropy in tensile characteristics, which is a primary objective of the study. The causes of the mechanical anisotropy in the CS coatings have been elucidated. The postprocessing resulted in an increase of ≈120% in cohesive strength and ≈75% in ductility of the coating due to the aforementioned alterations in microstructures. The tensile response of the coatings in both as‐sprayed and heat‐treated conditions has been analysed using numerical modelling, which utilizes crack widths and their densities within the coating. The model clearly shows that cracks perpendicular to the loading affect tensile strength. The model agrees with experimental tensile strength data and accurately predicts crack widths and densities in each anisotropic direction. The finite element models reveal an empirical connection between tensile strength and crack size.
On the Joining of High-Strength Dissimilar Inconel 600 and SS316L Materials by Friction Stir Welding with Improved Mechanical Properties and Localized Corrosion Resistance Sanjay Raj, Pankaj Biswas, Malar Vadani, Ajaykumar Yadav, K. S. N. Vikrant, Ayan Bhowmik Advanced Engineering Materials, 2025 The present work thoroughly investigates the friction stir welding of dissimilar high‐strength materials Inconel 600 (IN600) and SS316L and its effect on welded microstructure, mechanical, and corrosion properties. The microstructure and crystallographic textures of the nugget zone are investigated using the electron backscattered diffraction technique and transmission electron microscopy. The mechanical properties of the joints are evaluated using hardness and tensile testing and the electrochemical behavior of the joints is also investigated. The microstructural examination reveals a high degree of material plastic flow, both IN600 and SS316L, in the weld zone with uniform distribution of fine M23C6 carbides. The weld zone comprises a dynamically recrystallized fine‐grained structure of γ‐Fe and γ‐Ni that results in improved mechanical properties and high weld efficiency (≈95%) of the joints. The fine microstructure in the weld zone is characterized by a high dislocation density in these low stacking fault materials. The electrochemical results show that the corrosion resistance of the cross‐sectional region is higher than the top surface region and lower than the base IN600. The combined effect of grain refinement, high degree of material intermixing, and distribution of fine carbide precipitates cumulatively is found responsible for the improved corrosion resistance of the nugget zone.
Design and Development of FSW Tool for Carbon-Manganese Steel S Raj, P Jayant Kumar Reddy, P Biswas All India Manufacturing Technology, Design and Research conference, 165-178 , 2026 2026 Citations: 1
Unveiling Relationship Between Crack Evolution Through Long‐Term Ageing and Mechanical Properties of Cold‐Sprayed Ni‐Base Superalloys: Experimental Characterization and … M Vadani, S Raj, C Mondal, W Sun, S Chakrabarty, S Msolli, AWY Tan, ... Advanced Engineering Materials, e202501848 , 2025 2025 Citations: 1
Enhanced Microstructure and Properties of HVAF-Sprayed IN718 Coatings by Flame Treatment S Kumari, S Raj, NN Gosvami, D Kumar, A Bhowmik Journal of Thermal Spray Technology 34 (7), 2841-2857 , 2025 2025 Citations: 1
Modification of superficial microstructure of D2205 duplex stainless steel for improvement of mechanical properties and biocompatibility of surfaces by laser shock peening A Sahu, M Tewari, V Apuroop, S Raj, S Rai, N Maharjan, BS Kumar, ... Applied Surface Science, 164568 , 2025 2025 Citations: 5
Mechanical and Tribological Properties of High Velocity Air Fuel-Sprayed IN625 and IN718 Coatings S Kumari, S Raj, N Babu, M Prashanth, S Junaid, S Govindarajan, ... Journal of Thermal Spray Technology 34 (6), 2405-2413 , 2025 2025 Citations: 3
Exploration of value-added soybean oil cake based carbon quantum dots for in-vitro biomedical applications S Raj, GD Thomas, JJ Vijaya, AJPP Winston, KM Mohamed, K Akash, ... JOURNAL OF MOLECULAR STRUCTURE 1322 , 2025 2025 Citations: 1
Overcoming the strength-ductility trade-off in zirconium using twin boundary engineering GB Reddy, R Kapoor, A Bhowmik, A Sarkar, BK Kumawat, S Raj Materials Science and Engineering: A 921, 147602 , 2025 2025 Citations: 8
On the Joining of High‐Strength Dissimilar Inconel 600 and SS316L Materials by Friction Stir Welding with Improved Mechanical Properties and Localized Corrosion Resistance S Raj, P Biswas, M Vadani, A Yadav, KSN Vikrant, A Bhowmik Advanced Engineering Materials, 2400767 , 2024 2024 Citations: 3
Quantitative analysis of deformation characteristics and corrosion properties of high energy laser shock peened Ni-based superalloy AB Yarramilli Vamsi Apuroop , Sanjay Raj, Malar Vadani, Msolli Sabeur, Pooja ... Surface and Coatings Technology , 2024 2024 Citations: 10
Experimental investigation of the effect of induction preheating on the microstructure evolution and corrosion behaviour of dissimilar FSW (IN718 and SS316L) joints S Raj, P Biswas Journal of Manufacturing Processes 95, 143-159 , 2023 2023 Citations: 39
Effect of induction preheating on microstructure and mechanical properties of friction stir welded dissimilar material joints of Inconel 718 and SS316L S Raj, P Biswas CIRP Journal of Manufacturing Science and Technology 41, 160-179 , 2023 2023 Citations: 46
High-frequency induction-assisted hybrid friction stir welding of Inconel 718 plates S Raj, P Biswas Journal of Manufacturing Science and Engineering 144 (4), 041014 , 2022 2022 Citations: 34
Friction Stir Welding of Heat-Treated Inconel 718 Alloy, and Its Mechanical and Microstructural Analysis S Raj, P Biswas Recent Advances in Manufacturing Processes and Systems: Select Proceedings … , 2022 2022 Citations: 2
Mechanical and microstructural characterizations of friction stir welded dissimilar butt joints of Inconel 718 and AISI 204Cu austenitic stainless steel S Raj, P Biswas Materials Characterization 185, 111763 , 2022 2022 Citations: 30
Investigations on the effect of sheets positioning in advancing & retreating side for dissimilar FSW of DH36 steel and aluminum alloy 6061 P Pankaj, A Tiwari, LN Dhara, S Raj, P Biswas Journal of the Institution of Engineers (India): Series C 103 (1), 5-20 , 2022 2022 Citations: 26
Friction stir welding of Inconel-718 alloy using a tungsten carbide tool S Raj, P Pankaj, P Biswas Journal of Materials Engineering and Performance 31, 2086–2101 , 2021 2021 Citations: 35
Microstructure and mechanical characterisation of friction stir welded Inconel 718 alloy S Raj, P Pankaj, P Biswas Recent Advances in Mechanical Engineering: Select Proceedings of ICRAME 2020 … , 2021 2021 Citations: 2
Significance of Activation Energy in Process Metallurgy S Raj 2013 Citations: 2
MOST CITED SCHOLAR PUBLICATIONS
Effect of induction preheating on microstructure and mechanical properties of friction stir welded dissimilar material joints of Inconel 718 and SS316L S Raj, P Biswas CIRP Journal of Manufacturing Science and Technology 41, 160-179 , 2023 2023 Citations: 46
Experimental investigation of the effect of induction preheating on the microstructure evolution and corrosion behaviour of dissimilar FSW (IN718 and SS316L) joints S Raj, P Biswas Journal of Manufacturing Processes 95, 143-159 , 2023 2023 Citations: 39
Friction stir welding of Inconel-718 alloy using a tungsten carbide tool S Raj, P Pankaj, P Biswas Journal of Materials Engineering and Performance 31, 2086–2101 , 2021 2021 Citations: 35
High-frequency induction-assisted hybrid friction stir welding of Inconel 718 plates S Raj, P Biswas Journal of Manufacturing Science and Engineering 144 (4), 041014 , 2022 2022 Citations: 34
Mechanical and microstructural characterizations of friction stir welded dissimilar butt joints of Inconel 718 and AISI 204Cu austenitic stainless steel S Raj, P Biswas Materials Characterization 185, 111763 , 2022 2022 Citations: 30
Investigations on the effect of sheets positioning in advancing & retreating side for dissimilar FSW of DH36 steel and aluminum alloy 6061 P Pankaj, A Tiwari, LN Dhara, S Raj, P Biswas Journal of the Institution of Engineers (India): Series C 103 (1), 5-20 , 2022 2022 Citations: 26
Quantitative analysis of deformation characteristics and corrosion properties of high energy laser shock peened Ni-based superalloy AB Yarramilli Vamsi Apuroop , Sanjay Raj, Malar Vadani, Msolli Sabeur, Pooja ... Surface and Coatings Technology , 2024 2024 Citations: 10
Overcoming the strength-ductility trade-off in zirconium using twin boundary engineering GB Reddy, R Kapoor, A Bhowmik, A Sarkar, BK Kumawat, S Raj Materials Science and Engineering: A 921, 147602 , 2025 2025 Citations: 8
Modification of superficial microstructure of D2205 duplex stainless steel for improvement of mechanical properties and biocompatibility of surfaces by laser shock peening A Sahu, M Tewari, V Apuroop, S Raj, S Rai, N Maharjan, BS Kumar, ... Applied Surface Science, 164568 , 2025 2025 Citations: 5
Mechanical and Tribological Properties of High Velocity Air Fuel-Sprayed IN625 and IN718 Coatings S Kumari, S Raj, N Babu, M Prashanth, S Junaid, S Govindarajan, ... Journal of Thermal Spray Technology 34 (6), 2405-2413 , 2025 2025 Citations: 3
On the Joining of High‐Strength Dissimilar Inconel 600 and SS316L Materials by Friction Stir Welding with Improved Mechanical Properties and Localized Corrosion Resistance S Raj, P Biswas, M Vadani, A Yadav, KSN Vikrant, A Bhowmik Advanced Engineering Materials, 2400767 , 2024 2024 Citations: 3
Friction Stir Welding of Heat-Treated Inconel 718 Alloy, and Its Mechanical and Microstructural Analysis S Raj, P Biswas Recent Advances in Manufacturing Processes and Systems: Select Proceedings … , 2022 2022 Citations: 2
Microstructure and mechanical characterisation of friction stir welded Inconel 718 alloy S Raj, P Pankaj, P Biswas Recent Advances in Mechanical Engineering: Select Proceedings of ICRAME 2020 … , 2021 2021 Citations: 2
Significance of Activation Energy in Process Metallurgy S Raj 2013 Citations: 2
Design and Development of FSW Tool for Carbon-Manganese Steel S Raj, P Jayant Kumar Reddy, P Biswas All India Manufacturing Technology, Design and Research conference, 165-178 , 2026 2026 Citations: 1
Unveiling Relationship Between Crack Evolution Through Long‐Term Ageing and Mechanical Properties of Cold‐Sprayed Ni‐Base Superalloys: Experimental Characterization and … M Vadani, S Raj, C Mondal, W Sun, S Chakrabarty, S Msolli, AWY Tan, ... Advanced Engineering Materials, e202501848 , 2025 2025 Citations: 1
Enhanced Microstructure and Properties of HVAF-Sprayed IN718 Coatings by Flame Treatment S Kumari, S Raj, NN Gosvami, D Kumar, A Bhowmik Journal of Thermal Spray Technology 34 (7), 2841-2857 , 2025 2025 Citations: 1
Exploration of value-added soybean oil cake based carbon quantum dots for in-vitro biomedical applications S Raj, GD Thomas, JJ Vijaya, AJPP Winston, KM Mohamed, K Akash, ... JOURNAL OF MOLECULAR STRUCTURE 1322 , 2025 2025 Citations: 1