Research Overview
Our research spans the complete lifecycle of engineered surfaces—from solid-state deposition to finishing and performance evaluation. Using our in-house developed co-axial laser-assisted cold spray (LACS) system, we carry out advanced coating and additive manufacturing, including repair and remanufacturing of components with hard materials such as stainless steels, tool steels, Stellite alloys, and metal matrix composites. We also enable polymer metallization through controlled particle impact and substrate texturing, depositing metallic coatings on thermoplastics, thermosets, and polymer matrix composites. Post-deposition, we investigate machining, grinding, and polishing across multiple scales to control surface finish and integrity, supported by in-house orthogonal machining experiments with thermal and high-speed diagnostics as well as numerical simulations. Across all stages—deposition, repair, and finishing—we employ advanced characterization techniques such as EBSD, XRD, and residual stress analysis to establish rigorous process–structure–property–performance relationships for high-performance engineering applications.

Solid-state material deposition by in-house developed co-axial laser-assisted cold spray (LACS)

A key achievement of our research program is the development of an in-house co-axial laser-assisted cold spray (LACS) system, one of its kind in an academic environment. This indigenously built platform integrates localized co-axial laser heating with high-velocity particle impact for advanced solid-state material deposition, coating, and additive manufacturing.

The controlled laser assistance enhances particle plasticity at impact, allowing improved bonding, higher deposition efficiency, and processing of harder materials while avoiding bulk melting.

Using this unique setup, we investigate impact physics, bonding mechanisms, microstructural evolution, and phase stability, while establishing process–structure–property relationships for advanced coating, repair, and additive manufacturing applications.

Polymer Metallization via Cold Spray

Polymer metallization using cold spray provides a solvent-free and environmentally benign approach for depositing metallic coatings on polymer substrates without inducing thermal degradation. Our research focuses on understanding particle–polymer interaction mechanisms through single-particle impact studies and advanced simulations. By tailoring substrate surface texturing, we enhance mechanical interlocking and interfacial bonding during deposition.

We deposit metallic coatings such as Sn and Cu on thermoplastic and thermosetting polymers, as well as on polymer matrix composites. The work involves detailed investigation of adhesion development and interfacial characterization, aiming to enable lightweight conductive coatings and multifunctional surfaces for structural and electronic applications.

Surface Finishing

Surface generation in engineering components is governed by chip-formation-based material removal processes operating at different finishing scales. We investigate machining, grinding, and polishing within a unified framework to understand how surface roughness transitions from ~1–2 µm Ra in turning, to sub-micron levels in grinding, and down to micro- to nano-scale finishes in polishing.

Our research integrates in-house developed orthogonal machining experiments with thermal diagnostics and high-speed imaging to capture chip formation and deformation mechanisms in real time. These experimental studies are supported by analytical and numerical simulations to develop predictive understanding. We work on advanced and difficult-to-machine materials such as C–SiC ceramic matrix composites, nickel-based superalloys, and cold-sprayed or other additively deposited materials, systematically investigating their machining behavior and surface integrity evolution

Repair and Remanufacturing via LACS

Laser-assisted cold spray enables solid-state repair and remanufacturing of worn or damaged components while minimizing thermal distortion and undesirable metallurgical transformations. Our work focuses on making this repair technology economically viable for Indian MSMEs by significantly reducing operational cost—particularly by eliminating expensive carrier gases and utilizing compressed air while maintaining acceptable coating quality.

We deposit hard and wear-resistant materials such as stainless steels, tool steels, Stellite alloys, and metal matrix composites for structural restoration and performance enhancement. The research investigates bonding integrity, microstructural evolution, mechanical performance of repaired regions, and the overall sustainability benefits in terms of life extension and resource efficiency compared to component replacement.

Surface Integrity and Microstructural Characterization

Surface integrity governs the mechanical performance, durability, and reliability of engineering components. In our research, surface integrity analysis serves as a unifying framework to evaluate the effects of deposition, machining, finishing, and repair processes.

We employ advanced material characterization techniques including EBSD, XRD, residual stress analysis, and detailed microstructural examination to investigate deformation mechanisms, texture evolution, phase transformations, and subsurface damage. Particular emphasis is placed on correlating process parameters with microstructural modifications and functional performance.

Through this approach, we establish robust process–structure–property relationships for cold spray deposits, repaired components, and machined advanced materials