About
Ajai Sankar Kavunkara Thadayil
Postgraduate Researcher
UCD
Ajai Sankar is a PhD researcher at I-Form and is also affiliated with the EPSRC-SFI Advanced Metallic Systems CDT at University College Dublin (UCD). His research is at the forefront of metal additive manufacturing, composites, and nanomaterials. Ajai completed his postgraduate degree in Materials Science with distinction from the University of Manchester, establishing a strong foundation for his current research interests.
His research interests span metal additive manufacturing, materials characterization, microstructure studies, and the innovative use of nanomaterials like graphene to create practical, real-world applications. Ajai’s industrial background as a materials consultant and engineer brings a wealth of practical experience to his academic work. He has successfully managed projects involving a wide array of materials, including metals and nanomaterials, enriching his research with valuable practical insights.
Technical Summary
Additive manufacturing, particularly Laser Powder Bed Fusion (PBF-LB), has emerged as a revolutionary technique for fabricating complex structures, such as lattice components, using materials like Ti-6Al-4V. This project aims to investigate the synergistic effects of Hot Isostatic Pressing (HIP) combined with intricate lattice structures on porosity control. The focus is on studying the microstructural characteristics and fatigue performance of Ti-6Al-4V components. The study encompasses a comprehensive characterization of the microstructure using advanced techniques such as X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), Electron Backscatter Diffraction (EBSD), X-ray CT, and optical microscopy and mechanical tests to evaluate the material’s fatigue performance and overall structural integrity.
The primary objective is to contribute to the forefront of materials science and additive manufacturing by introducing innovative approaches. This includes advanced characterization techniques to analyse microstructural features and mechanical properties, the integration of nanotechnology by incorporating novel nano-reinforcements into materials design to enhance properties, and topology optimization using lattice structures and other cutting-edge design strategies to optimize component performance. The findings aim to deepen the understanding of PBF-LB Ti-6Al-4V components, composite production, and the effects of HIP. The research seeks to demonstrate how these approaches can deliver microstructure and performance comparable to conventionally manufactured parts, ultimately unravelling the intricacies of additively manufactured novel alloys and composites, thereby advancing the field of materials science and additive manufacturing.