Dr Rajan T P D

Dr Rajan T P D
Profile

Dr. T. P. D. Rajan is a senior materials scientist at the CSIR–National Institute for Interdisciplinary Science and Technology (NIIST), Thiruvananthapuram, and a distinguished metallurgist specializing in advanced metallic materials and manufacturing technologies. His work focuses particularly on lightweight, strategic, and critical materials. His research interests encompass aluminium alloys, metal matrix composites, functionally graded materials, rare earth metals, surface coating technologies, and product development for the aerospace, automotive, defence, and energy sectors. He has made notable contributions to national initiatives such as Atmanirbhar Bharat and Make in India through the development of indigenous technologies for strategic applications. In addition to his research, he serves as the Head of the Human Resource and Academic Division (HRAD) at the institute. Dr. Rajan earned his Ph.D. in Metallurgical and Materials Engineering from CSIR–NIIST, Thiruvananthapuram, in 2002, and his M.Tech. in Process Metallurgy from the National Institute of Technology Karnataka (NITK), Surathkal, in 1996. He also gained early professional experience as a project trainee at the Vikram Sarabhai Space Centre (ISRO), Thiruvananthapuram, and as an industrial trainee at the Bhilai Steel Plant. He has received numerous prestigious awards in recognition of his contributions to metallurgy and materials science. These include the National Metallurgist Award (2023) from the Ministry of Steel, Government of India, for his outstanding work in developing lightweight aluminium alloys, composites, and functionally graded materials for aerospace, automotive, and defence applications. Other honours include the Award for Excellence in Corrosion Science and Technology from NACE International (2018), the IIM Nalco Gold Medal from the Indian Institute of Metals (2015), the Chandran Menon Memorial Award from the Institute of Indian Foundrymen (2015), the IIF Industry Research Award (2009), the INAE Innovation Award for the best doctoral thesis in engineering (2003), and the Soli- Commissariat Award. He has also been recognized among the world’s top 2% scientists in
Materials Science by Stanford University and Elsevier (2025). As principal investigator of several research and development programmes, Dr. Rajan has led the indigenous development of advanced materials and components for strategic sectors. His contributions include aluminium–silicon carbide metal matrix composite thermal management materials for light combat aircraft and unmanned aerial vehicles, developed in collaboration with the Aeronautical Development Establishment (DRDO). He has also developed lightweight Al–Mg–Sc alloys and associated sheet processing technologies for aircraft, launch vehicles, and naval systems, successfully transferring these
technologies to Indian industry. His work extends to the development of aluminium composite components such as gear housings, piston rings, and functionally graded armour plates for battle tanks in collaboration with the Combat Vehicles Research & Development Establishment (CVRDE). He has contributed to space applications through the development of aluminium alloys and copper-coated epoxy–carbon composites for radio frequency reflector antennas in
collaboration with ISRO, and to nuclear applications through boron carbide–reinforced aluminium composites for neutron shielding in association with the Bhabha Atomic Research Centre.

Dr. Rajan has also established an industry-sponsored Centre of Excellence for Lightweight Material Technologies at CSIR–NIIST, supported by ZF Commercial Vehicle Control Systems India Limited. His international collaborations include work with RWTH Aachen University, Germany, on carbon fibre–reinforced aluminium composites under a project funded by the Indo-German Science and Technology Centre. In partnership with automotive industries, he has developed a range of advanced components, including functionally graded brake rotor discs, hybrid cylinder liners, scroll compressor components, squeeze-cast compressor heads, and manifolds. Additionally, he has developed wear-
resistant, self-lubricating, and anti-corrosive smart coatings for aluminium alloy structures and components. He has published about 170 technical papers (journals/proceedings), 15 Book Chapter and filed 3 patents. Guided 15 Ph.Ds., 45 M.Tech./ M.Sc. theses and currently guiding 5 Ph.D. students. He is life member of various professional bodies and currently Chairman of The Indian Institute of Metals, Trivandrum Chapter, Vice-Chairman of The Institute of Indian Foundrymen, Kerala Chapter and former Chairman of the Materials Research Society of India, Trivandrum Chapter.

Major R&D Activities

R&D Programmes

1. Development of Aluminium- Silicon Carbide Composite Thermal Management Component for Flight Control Computers of Light Combat Aircraft and Unmanned Aerial Vehicles
Al-SiC Composite thermal management components are currently imported and used by DRDO in Flight Control Computers of Light Combat Aircraft and other fighter aircrafts. In the present programme, CSIR-NIIST in collaboration with ADE-DRDO has indigenously developed Al-SiC composite thermal management component by liquid metal
squeeze infiltration technique matching the thermal properties of the imported thermal management component. About 25 Nos. of Al-SiC thermal management components have been developed and supplied to DRDO. The present indigenous development will contribute towards import substitution and the national mission of Atmanirbhar Bharat in strategic sector of our country. The Al-SiC Composite thermal management component developed by CSIR NIIST is handed over to ADE-DRDO by Dr. N. Kalaiselvi, Director General, CSIR and Secretary, DSIR on March 13, 2023 at CSIR-NIIST, Trivandrum. The components were received by Shri Vasanth Sastry, Sc 'G', Technology Director (Aero Structures Project), Shri V Srinivasa Rao, Sc 'G', Group Director (Aero Structures) and Shri Vivek Bharti, Sc 'D', ADE in the presence of Dr. C. Anatharamakrishnan, Director, CSIR-NIIST, Dr. M. Ravi, Chief Scientist, Head, MSTD and Dr. T.P.D. Rajan, Senior Principal Scientist and Project Leader, CSIR-NIIST..

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Figure: Transfer of Al-SiC Composite thermal management component developed by CSIR NIIST is handed over to ADE-DRDO

 

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Figure: Al-SiC MMC thermal plate component developed and supplied to ADE-DRDO


Aluminum Silicon Carbide (AlSiC) metal matrix composite (MMC) materials have a unique set of properties that are ideally suited for thermal management solutions in aerospace, automotive and portable devices over traditional thermal management materials due to lightweight, low coefficient of thermal expansion (6 - 10 x10 -6 K -1 ) and better thermal dissipation (Al-SiC thermal conductivity 150 – 180 W/mK). The Al-SiC composite thermal management component developed at CSIR-NIIST has lightweight (density: 2.9 g/cc), high thermal conductivity (176 W/mK), low coefficient of thermal expansion (9.73 х10 -6 /°C) and high stiffness (120 GPa). Squeeze casting and Liquid metal squeeze infiltration techniques are the advanced near net fabrication techniques established as a national facility at CSIR NIIST for fabrication of aluminium alloy and composite components.

 

 

2. Development of lightweight and high-strength Al-Mg-Sc alloys and Rolled Sheets for
aerospace structures
Al-Mg-Sc alloy has potential applications in aerospace, defence, and naval systems due to its low density, exceptional weldability, excellent damage tolerance, good corrosion resistance, creep-formability, thermal stability, and ease of recycling. Al-Mg-Sc lightweight alloy sheets are recommended for use as fuselage skin of aircraft with high strength (YS: 330 MPa, UTS: 400 MPa; Elongation, El: 12%) along with excellent damage tolerance and corrosion resistance. Al-Mg-Sc alloy sheet has the potential to replace the conventionally used AA2024 alloy (Al-Cu alloy) without significant change in the structural design. The improvement of properties in Sc-added aluminium alloys are attributed to Al 3 Sc precipitates and its interaction with dislocations. Addition of Sc and Zr to Al-Mg alloys can form coherent L1 2 structure Al 3 (Sc,Zr) particles, which can refine the grain and enhance the precipitation- strengthening effect of Al-Mg alloys. Small addition of Sc and Zr can enhance the mechanical strength of Al-Mg-Sc alloy as much as 50% by producing 5-20 nm sized coherent nanoscale precipitates. The addition of Sc as an alloying element imparts an excellent combination of strength, ductility and enhanced crack growth resistance.

    CSIR-NIIST, Thiruvananthapuram has developed the Al-Mg-Sc alloy through gravity casting followed by rolled sheet by combination of hot and cold rolling. Al-Mg-Sc alloy rolled sheets of thickness from 0.7 to 3 mm and length of 1000 mm and width of 150 mm has been successfully developed. The indigenously developed Al-Mg-Sc alloy rolled sheet exhibited high mechanical properties. The technology was transferred to M/S Star Alucast, Mumbai for the commercialisation and production of Al-Mg-Sc alloy and rolled sheets of larger dimensions.

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Fig. (a) Al-Mg-Sc alloy plate (b) Microstructure of rolled Al-Mg-Sc alloy sheet (c) Theindigenously developed Al-Mg-Sc alloy rolled sheet.

 

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The Transfer of Technology (ToT) Agreement signed with M/S Star Alucast (REMAL),Mumbai for the manufacture of Al-Mg-Sc alloy and rolled sheets for aerospace and defence sectors.

 

 

3. Established Industry sponsored “Centre of Excellence for Lightweight Material
Technologies”

A Centre of Excellence for Lightweight Material Technologies is established for the development of advanced lightweight material technologies and components for automotive applications sponsored by ZF Commercial Vehicle Control Systems (ZF CVCS), Chennai. The centre of excellence was virtually launched on April 26, 2021. The proposed CoE will be an interdisciplinary technology incubation centre with focus on development of structural and functional components in vehicle brake control systems for ZF CVCS applications using light alloys based on aluminium, advanced composites and coatings using state of art facilities for material processing, characterisation and component development. The centre will also implement product specific projects in collaboration with WABCO based on requirements and separate MoUs. The identified areas of research are Light Aluminum alloys and composites, Thermal management and frictional materials and Multi-material structures. Various automotive components like squeeze cast Aluminium alloy manifold and compressor cover, Al-graphene composite compressor heads and Al alloy crankcase were developed.

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Figure: Automotive components of squeeze cast Aluminium alloy manifold and compressor cover, Al-graphene composite compressor heads and Al alloy crankcase

4. Development of light weight functionally graded metal-ceramic composite armour
materials for defence applications
Aluminum-Silicon carbide functionally graded aluminum composite plates were fabricated by squeeze infiltration technique using 42 µm average particle size and the plate is supplied to CVRDE for evaluation. The dimensions of the plates are 120 x 120 x20 mm. Figure shows five numbers of the Al-SiC FGMMC prototype armour plates fabricated and
supplied to CVRDE, Chennai. Figure shows 2024 Aluminium-SiC infiltrated composite fabricated using 50%SiC preform. The composite with 50%SiC volume fraction shows the maximum hardness of 206 BHN in the heat treated condition. CSIR-NIIST, Thiruvananthapuram has developed functionally graded armour plates using liquid metal
squeeze infiltration technique with targeted characteristics of hardness 206 BHN in the ceramic-rich region, density: 2.96 g/cc, compressive strength 610 MPa.

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Figure: Transfer of Al-SiC Composite thermal management component developed by CSIR NIIST is handed over to ADE-DRDO

 

 

5. Development of Al-SiC Functionally Graded Composite Brake Rotor Discs for
Automotive Applications.(Industrial Collaborator and User: Mahindra and Mahindra,
Nasik)
Al-SiC functionally graded prototype brake rotor discs containing 20% SiC particle have been processed by vertical centrifugal casting and supplied to M&M. The discs are suitable for application in four wheelers like passenger cars and multi utility vehicles replacing the heavier cast iron counterpart. The characterization of Al-20%SiC functionally
graded composite disc has shown enhanced structural and mechanical properties towards the outer periphery of the casting. The presence of higher concentration of silicon carbide particles towards the outer periphery provided higher hardness, tensile and compressive properties compared to the inner periphery having particle depleted region. The improved properties in the braking area of the disc enhance its braking efficiency. The road test of the discs has been successfully carried out by fitting it to the ‘Scorpio’ multi utility vehicle. Structural integrity of the disc is very good during testing.

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Figure: Al-SiC Brake Rotor Discs fabricated by Vertical Centrifugal Casting

 

 

6. Development of Al-SiC-Graphite Hybrid Functionally Graded Composite Cylinder liners
for Automotive Applications.(Industrial Collaborator and User: TVS Motors, Hosur)


Al-SiC-Graphite hybrid Composites are developed for providing better abrasive and adhesive wear resistance. The hybridization of Al-SiC (p) mono composite with soft reinforcements such as graphite particulates or fibres increases the adhesive wear resistance of the composites and also keep the coefficient of friction very low. Further, the mild to severe wear transition load value has been shifted to very high value for Al-SiC (p) -Gr (p) HMMC compared to Al(356) alloy and Al(356)-SiC (p) mono composites. The present invention relates to the fabrication of functionally graded hybrid metal matrix composites by centrifugal casting, based on cast aluminum as matrix material and silicon carbide, alumina,
graphite and primary silicon as reinforcements, wherein both the hybrid particles, denser and lighter reinforcements with respect to matrix alloy are distributed at the inner periphery of the hollow cylindrical casting. In general, during centrifugal casting the lighter reinforcements move towards the inner periphery and denser reinforcements move
towards the outer periphery of the casting compared to the matrix alloy density. However, in the present invention, both the denser and lighter reinforcements are distributed with a gradient near the inner periphery by controlling the material and solidification parameters such as melt viscosity, composite pouring temperature, mould temperature, heat extraction
rate and mould spinning speed. A patent is filed for the above invention. Figure 4 a shows the vertical centrifugally cast cylinders showing the machined top surface of Al(356)-10SiC-5Graphite functionally graded hybrid MMC and machined Cast Al(356)-10SiC-5 Graphite FGMMC Cylinder liner along with Al(356)-15SiC FGMMC gears. The hybrid composites show the presence of graphite and silicon carbide particles in the inner periphery of the casting. Figure show the microstructures of vertical centrifugally cast

Al(356)-10%SiC-5%Graphite hybrid functionally graded composite cylinder. The Cast Al(356)- 10SiC-5 Graphite FGMMC Cylinder liner has been supplied to TVS Motors, Hosur and the evaluation has shown better wear resistance and low coefficient of friction compared to cast iron cylinder liners.

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Figure: (a) Machined top surface of Vertical Centrifugally Cast Al(356)-10SiC-5 Graphite FGMMC Cylinder and (b) Machined Cast Al(356)-10SiC-5 Graphite FGMMC Cylinder liner along with Al(356)-15SiC FGMMC gears

 

 

 

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Figure: Optical microstructures from outer to inner periphery Al(356)-SiC-Graphite functionally graded aluminium composite fabricated using centrifugal casting

 

 

 

7. Processing of in-situ primary silicon reinforced functionally graded aluminium
composite cylinders for Automotive Applications (Industrial Collaborator and User:
WABCO TVS, Chennai)
The in-situ formed primary silicon reinforced functionally graded aluminium composite hollow cylinder fabricated using 390 Al alloy has shown the presence of primary silicon particles towards the inner periphery. The region from 0-6 mm from outer periphery shows the presence of eutectic microstructures and the region at 6.5 mm shows the gradient interface layer of transition from eutectic to hypereutectic microstructure. The region from 7-13 mm from outer periphery shows the hypereutectic microstructure. The centrifugal force and faster cooling rate has modified the primary silicon particles from acicular to equiaxed form. These hollow cylinder liners fabricated by the in-situ FGM provides better hardness, wear resistance and durability compared to those fabricated by a homogenous structured alloy. WAPCO-TVS, Chennai is collaborating with NIIST on making cylinder liners for air compressor applications for automotive industry.

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Figure: Photograph of in-situ reinforced functionally graded aluminium matrix composite hollow cylinder fabricated using 390 Al alloy.

 

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Figure 7: Optical microstructures from outer to inner periphery of functionally graded aluminium composite fabricated using Al 390 alloy by horizontal mode of dual centrifugal casting machine

 

 

 

8. Processing of Boron Carbide Reinforced Aluminium Matrix Composites for Nuclear
Applications. (Collaborator: BARC, Mumbai)


Boron carbide is one of the potential neutron absorption materials used in nuclear applications. Boron has a naturally occurring isotope, B 10 , which is an efficient absorber of neutrons and has a neutron capture cross section of approximately 4000 barns (1 barn=10 -24 cm 2 ). For structural nuclear shielding applications such as nuclear waste containers or shielding elements for nuclear installations, the material would also be manufacturable into a desired shape, should posses high strength and toughness, and not be prone to brittle fracture. One solution is going for boron carbide reinforced metal matrix composites (MMC), which are uniquely suited as a structural neutron shielding material, where tailorable properties of neutron absorption as well as enhanced mechanical properties such as high strength, stiffness and hardness can be obtained. Boron carbide reinforced aluminium matrix composites have been successfully fabricated using stir casting method. The microstuctural evaluation shows uniform distribution of particles in the matrixes such as commercial pure Al, 356 cast and 6061 wrought aluminium alloys. The addition of boron carbide has increased the hardness in both as cast and heat treated condition.

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Figure: Al(356) – B 4 C MMC produced by liquid metal stir casting technique

 

 

9. Design and Fabrication of a Dual Centrifugal Casting Machine for Making Functionally
Graded Materials


Conventional centrifugal casting machines contain only single mode of operation, i.e.either horizontal or vertical axis of mould rotation. A dual centrifugal casting machine has been designed and fabricated at NIIST incorporating both horizontal and vertical modes of operations in a single unit. Horizontal centrifugal casting is suitable for manufacturing
tubular products such as sleeves, rings and pipes, whereas vertical one is beneficial in making shorter components such as gears, turbine discs with blades, rotor disc, fittings, rings, bushes and flanges. Functionally graded 390Al alloy and Al(356)-SiC-Graphite hybrid composite have been fabricated using horizontal mode of the dual centrifugal casting
machine fabricated in the laboratory. Both these systems are useful for making cylinder sleeves for automotive applications.

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Figure: Dual Centrifugal casting machine

 

 

 

10. Development of in-situ intermetallic Functionally Graded Al-Al 3 Ni Composites
Al- Al 3 Ni insitu functional graded composite processed from Al-20%Ni alloy melt has shown a well graded microstructure compared to that of Al-10%Ni, Al-30%Ni and Al-40%Ni alloy systems studied. The gradation inmicrostructural features is also reflected in hardnessvalues. The Al- Al 3 Ni insitu FGM formed from Al-20%/Ni alloy melt shows high volume fraction of Al 3 Ni primary crystals near the outer periphery and a depleted region near the
inner periphery. The region near outer periphery is a hypereutectic microstructure and that near the inner periphery is hypoeutectic.

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Figure: Optical micrographs of Al-Al 3 Ni insitu functionally graded composite formed from Al-20%Ni alloy melt.

 

 

 

11. Squeeze Casting and Characterization of Al 2124 Alloy and 2124-10%SiCp Metal Matrix
Composite Process
Aluminium 2124 alloy and its composite with 10% SiC particles of average particle size of 23µm were squeeze cast at different pressures (Figure 9). The effect of squeeze pressure during solidification was evaluated with respect to microstructural characteristics using optical microscopy and image analysis and mechanical properties by tensile testing. The microstructural refinement, elimination of casting defects such as shrinkage and gas porosities and improved distribution of SiC particles in the case of the composite were resulted when pressure is applied during solidification. A pressure level of 100MPa was found to be sufficient to get the microstructural refinement and very low porosity level in both the alloy and the composite. The improved mechanical properties observed in the squeeze cast alloy and the composite could be attributed to the refinement of microstructure within the material.
T

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Figure 11: Macro photograph of 2124 -10SiCp composite squeeze cast at different pressures

12. Fabrication and characterisation of Al–7Si–0.35Mg/fly ash metal matrix composites
processed by different stir casting routes
 

The effect of three different stir casting routes on the structure and properties of fine fly ash particles (13 µm average particle size) reinforced Al–7Si–0.35Mg alloy composite is evaluated. Among liquid metal stir casting, compocasting (semi solid processing), modified compocasting and modified compocasting followed by squeeze casting routes evaluated, the latter has resulted in a well-dispersed and relatively agglomerate and porosity free fly ash particle dispersed composites. Interfacial reactions between the fly ash particle and the matrix leading to the formation of MgAl 2 O 4 spinel and iron intermetallics are more in liquid metal stir cast composites than in compocast composites. The compression strength of Al–fly ash composite processed by modified compocasting cum squeeze casting
is enhanced compared to the matrix alloy.

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Figure: Optical photomicrographs of Al(356)–15% fly ash composite processed by modified compocasting followed by squeeze casting.

13. Development First Gear Housing and Piston ring using Aluminum Matrix Composites for
battle tank applications (Collaborator& User: CVRDE, DRDO, Chennai)
 

Silicon carbide reinforced aluminium matrix composite clutch housing and piston ring were fabricated using stir casting followed by sand casting. The components are machined by CNC machining to the accurate dimension with required surface finish. The microstructural characterisation has shown uniform distribution of the particles throughout the casting. The castings have qualified the radiographic testing as per the specification of the user. Figure 13 shows the machined and radiography tested castings.The prototype component developed had been successfully test for one lakh cycles and qualified for use in the battle tanks.

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Figure: (a) First gear housing and (b) piston ring fabricated by silicon carbide reinforced aluminium matrix composites

14. Modified Compocasting for making Microsilica Reinforced Aluminum Matrix
Composite (Industrial Collaborator and User: 3M India Ltd., Bangalore)
Aluminium alloy reinforced with microsilica composites were produced by the liquid metal stir casting and compocasting followed by squeeze casting route. The work is carried out in collaboration with 3M India Ltd, Bangalore using the microsilica produced by them aiming to produce wear resistance metallic composites. Microstructure of liquid metal stir
cast Al MMC shows agglomeration of particles leading to the formation of high porosity level in the developed material. Adopting new route of compocasting cum squeeze casting process capitulate the agglomeration sites with uniform distribution and dispersion of the dispersoids in the matrix metal which enhances the mechanical, tribological and corrosion properties of the composites. Superior wear-resistance properties were exhibited by the composite compared to alloy.

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Figure: Microstructures of (a) surface treated A356-micro silica composite synthesized by liquid metal stir casting and (b) modified compocasting and squeeze casting.

15. Bidirectional Carbon Fiber Fabric Reinforced 6061 Aluminum Composites by Squeeze
Infiltration Technique (Collaborator: GTRE, Bangalore)
Bidirectional (BD) satin weave polyacrylonitrile (PAN) based carbon fiber (C f ) fabric preform was successfully infiltrated with Al6061 alloy by direct squeeze infiltration process for aeroengine applications (GTRE, Bangalore). The infiltrated composite shows uniform distribution of carbon fibers in the matrix with the elimination of porosities, fiber damage and control indeleterious interfacial reactions. C f /Al6061 composite exhibits superior wear resistance compared to unreinforced alloy due to the formation of self-lubricant tribo-film on and enhanced hardness and compressive strength.

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Figure: Micrographs of (a) BD C f fabric/ Al6061 Infiltrated composite (b) cross section of the infiltrated composite

 

16. IIM & EMSI National Award Winning Cast Metal Matrix and Functionally graded
Composite Optical and SEM Micrographs.

(a) ‘IIM Metallography Award – 2006’(in Color Category) for the optical photomicrograph in the NMD-ATM-2006 held at Jamshedpur during 14-16 November, 2006. The photo entitled ‘Intermetallic Orchid’ features the formation of Al 3 Ni intermetallic phase in the Al matrix in the form of Orchid. The Al- Al 3 Ni insitu functionally graded composite was
formed by centrifugal casting from Al-20%Ni alloy.

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Figure: ‘Intermetallic Orchid’

(b) ‘IIM Metallography Award – 2005’ for Best Optical Micrograph Award (I prize) in Black and White Category conducted by Indian Institute of Metals at National level during the NMD-ATM-2005, Nov. 14-16, 2006 held at IIT, Chennai. The micrograph titled “Silicon Star” shows star like growth of primary Si crystals in an Al-18%Si alloy solidified under a cooling rate of 3 Ks -1 and nucleation of α-aluminum as a halo around the primary silicon.

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Figure: ‘Silicon Star’

(c) ‘IIM National Metallography Award – 2005’ for Best Optical Micrograph Award (II prize) in Colour Category conducted by Indian Institute of Metals at National level during the NMD-ATM-2005, Nov. 14-16, 2006 held at IIT, Chennai. The micrograph titled “Intermetallic Fossil” shows an Al 3 Ni intermetallic phase in the form of a fossil in an Al- Al 3 Ni intermetallic Functionally Graded Material formed from Al-20%Ni alloy by
centrifugal casting.

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Figure: “Intermetallic Fossil”

(d) ‘EMSI-Leo Micrograph Award – 2002’ at National levelfor the best SEM microstructure of Al(356)-Flyash composite at 25 th Annual Conference of Electron Microscopic Society of India (EMSI) held at IIT, Mumbhai, Feb 19-22, 2002.SEM photomicrograph of Aluminium (356)-15% fly ash composite processed by modified semisolid stir casting followed by squeeze casting showing the solidification of infiltrated matrix alloy into a hollow space of broken cenospherical particle containing fine solid fly ash particle. The broken hollow sphere is in the form of ‘crescent moon’ (Figure 15).

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Figure: ‘Crescent Moon’.

 

 

 

Research Interest

R&D Areas of Interest

 

  •  Lightweight Metallic Materials,
  •  Aluminium alloys
  •  Metal Matrix Composites (MMC)
  •  Functionally Graded Materials (FGM)
  •  Rare Earth Metals, Strategic and Critical Materials
  •  Surface Coating Technologies
  •  Product Development for the Aerospace, Automotive, Defence and Energy Sectors.
Academic Qualification
  •  Ph.D. (Engg.), CSIR-National Institute for Interdisciplinary Science and Technology,
    Trivandrum, Metallurgical and Materials Engineering (2002)
  •  M.Tech., National Institute of Technology, Surathkal, Mangalore, Metallurgical
    Engineering (1996)

 

Professional Experience

 

    •  Senior Research Fellow - (Sept. 1996 - Mar. 2000)
    •  Research Associate – (Apr. 2000 - Jan 2003)
    •  Principal Investigator – (Jan. 2003 – April 2005)
    •  Scientist – (April 2005 – April 2009)
    •  Senior Scientist – (April 2009-April 2013)
    •  Principal Scientist (April 2013-April 2018)
    •  Senior Principal Scientist (April 2018-April 2023)
    •  Chief Scientist / Scientist G (since April 2023)
Patents & Publications

Selected Publications

    •  Reinforcement coatings and interfaces in aluminium metal matrix composites T.P.D. Rajan, R.M. Pillai and B.C. Pai, Journal of Material Science, Vol. 33 (1998) p3491-3503.
    •  Studies on fibre treatments and fabrication of short ceramic fibre reinforced aluminum matrix composites T.P.D. Rajan, R.M. Pillai and B.C. Pai,Journal of Material Science Letters, Vol. 18 (1999) p1683-1686.
    •  Assessment of grain refinement and modification of Al-Si alloys by computer-aided cooling curve analysis (CA-CCA) S.A. Kori, T.P.D. Rajan, B.S. Murthy and M. Chakraborthy.,Indian Foundry Journal, Vol. 46, No.8 (2000) p. 35-40.
    •  Interfacial Reactions in Aluminmosilicate short fibre reinforced composites T.P.D. Rajan, R.M. Pillai and B.C. Pai,Metallurgical and Materials Transactions-A, 2002, Vol 33A, p. 2755-2761.
    •  Solidification Processing of Functionally Graded Metal- Ceramic Composites T.P.D. Rajan, R.M. Pillai and B.C. Pai, Indian Foundry Journal, 2003, 49(9), 19-30.
    •  Aluminium matrix composite castings for Automotive Applications B.C. Pai, T.P.D. Rajan and R.M. Pillai Aluminum in India, 2004, Vol.4(1), 33-42.
    •  Composites in automobiles B.C. Pai, T.P.D. Rajan and R.M. Pillai Minerals & Metals Review,32(2006), October, pp 23-24, 27-28.
    •  Solidification Characteristics of discontinuous aluminum matrix composites T.P.D. Rajan, K. Narayan Prabhu, R.M. Pillai and B.C. Pai, Composites Science and Technology67 (2007) 70–78(Listed as Top 25 Hottest research article during Oct-Dec, 2007 by Science Direct)
    •  Effects of Individual and Combined Additions of Be, Mn, Ca and Sr on the Solidification Behaviour, Structure and Mechanical Properties of Al-7Si-0.3Mg-0.8Fe Alloy S.S. Sreeja kumari, R.M. Pillai , T.P.D. Rajan and B.C. Pai Materials Science & Engineering A 460–461 (2007) 561–573
    •  Solidification of hybrid aluminium alloy matrix composites B.C. Pai, T.P.D. Rajan and R.M. Pillai Trans. Indian Inst. Met.,60(2) (2007) 355-360
    •  Fabrication and Characterization of Al-7Si-0.35 Mg / Fly Ash Metal Matrix Composites Processed by Different Stir Casting Routes T.P.D. Rajan, R.M.Pillai , B.C. Pai, K.G. Satyanarayana and P.K. Rohatgi Composites Science and Technology,67 (2007) 3369-3377
    •  Centrifugal Casting: A Potential Technique for making Functionally Graded Materials and Engineering Components T.P.D. Rajan, R.M. Pillai and B.C. Pai Indian Foundry Journal, 53(6) (2007) 79-87
    •  Functionally Graded Al-Al 3 Ni in-situ Intermetallic Composites: Fabrication and Microstructural Characterization T.P.D. Rajan, R.M. Pillai and B.C. Pai Journal of Alloys and Compounds,453 (2008) L4–7
    •  Studies on Squeeze Casting of Al 2124 Alloy and 2124-10%SiCp Metal Matrix Composite K. Sukumaran, K.K. Ravikumar, S.G.K. Pillai, T.P.D. Rajan, M. Ravi, R.M. Pillai and B.C. Pai Materials Science & Engineering A,Vol. 490 (1-2), (2008) Pages 235-241
    •  Centrifugal Casting of Functionally Graded Aluminium Matrix Composite Components T.P.D. Rajan, R.M. Pillai and B.C. Pai International Journal of Cast Metals Research,Vol. 21(1-4), (2008), 214-218
    •  Elaboration et caractérisation d'alliages d'aluminium et de composites à gradient de structure obtenus par centrifugation (Processing and Characterization of Functionally Graded Aluminum Alloys and Composites by Centrifugal Casting) T.P.D. Rajan, R.M. Pillai and B.C. Pai Hommes et Fonderie(in French), Vol. 390, 2008, pp.20-30.
    •  Formation of solidification microstructures in centrifugal cast functionally graded aluminum matrix composites T.P.D. Rajan and B.C. Pai Trans. Indian Inst. Met.,2009, vol. 62(4-5), pp. 383-389
    •  Processing and Properties of Ultrafine grained and Nanostructured Aluminum matrix compositesT.P.D. Rajan, R.M. Pillai and B.C. Pai Aluminum in India, 2009, Vol. 9, No. 2, pp. 8-15.
    •  Fabrication of Functionally Graded Aluminium Metal MatrixComposites And its Mechanical Behavior Using Artificial NeuralNetwork K.Vinoth Babu, T.P.D. Rajan , R.M.Pillai , B.C.Pai International Journal of Advanced Engineering Applications (IJAEA), (2009)Volume 2, Issue 2, pp.21-25
    •  Development In Manufacturing Processes of Functionally Graded Materials T.P.D. Rajan and B.C. Pai International Journal of Advanced Engineering Applications (IJAEA), (2009)Volume 2, Issue 2, pp.64-74
    •  Characterization of Centrifugal Cast Functionally Graded Aluminum-Silicon Carbide MetalMatrix Composites T.P.D. Rajan, R.M. Pillai and B.C. Pai Materials Characterization, 61 (2010) 923 – 928
    •  Processing of Surface Treated Boron Carbide Reinforced Aluminium Matrix Composites by Liquid Metal Stir Casting Technique V.P. Mahesh, Praseeda S. Nair, T.P.D. Rajan, B.C. Pai and R.C. Hubli Journal of Composite Materials 45 (23) , (2011) pp. 2371-2378
    •  Studies on the Influence of Surface Pre-treatments on Electroless Copper Coating of Boron Carbide Particles J.P. Deepa, V.G. Resmi, T.P.D. Rajan, C. Pavithran and B.C. PaiApplied Surface Science, 257 (2011) 7466–7474
    •  Studies on the effect of processing parameters on electroless coating of copper on boron carbide particles J.P.Deepa, Resmi, V.G., Rajan, T.P.D.,Pavithran, C., Pai, B.C. Transactions of the Indian Institute of Metals 64 (1-2) , (2011) pp. 47-51
    •  Novel approach on characterization of inter-laminar failure in glass fiber reinforced composite Nagarajan, V.A., Sundaram, S., Thyagarajan, K., Selwinrajadurai, J., Rajan, T.P.D. Advanced Composite Materials 20 (6) , (2011) pp. 585-609
    •  Drilling Studies on silicon carbide reinforced functionally graded aluminum matrix composites. K. Vinoth Babu, J.T. Winowlin Jappes and T.P.D. Rajan Journal of Emerging Technology in Mechanical Science and Engineering, Vol. 2 (2011) 54- 60.
    •  Processing of functionally graded aluminium matrix composites by centrifugal casting technique Rajan, T.P.D.,Pai, B.C. Materials Science Forum 690 , (2011) pp. 157-161
    •  Fabrication and optimization of drilling parameters in heat treated sic reinforced functionally graded Al composites using taguchi method Vinoth Babu, K., Winowlin Jappes, J.T., Rajan, T.P.D. Materials Science Forum 710 , (2012) pp. 353-358
    •  Refined delamination characterization for composite laminates using digital means Nagarajan, V.A., Sundaram, S., Thyagarajan, K., Selwin Rajadurai, J., Rajan, T.P.D. Journal of Composite Materials 46 (13) , (2012) pp. 1535-1547
    •  Synthesis of porous SiC preform and squeeze infiltration processing of Aluminium-SiC Metal ceramic composites Sree Manu, K.M., Resmi, V.G., Brahmakumar, M., Anand, N., Rajan, T.P.D.,Pavithran, C., Pai, B.C., Manisekar, K. Materials Science Forum 710 , (2012) pp. 371-376
    •  Fabrication and Characterization of Short Carbon Fiber Reinforced AZ91 Mg Alloy Composites K.A. Ajukumar, K.K. Ajith Kumar, K.K. Ravikumar, T.P.D. Rajan, U.T.S. Pillai Pillai, B.C. Pai Materials Science Forum Vol. 710 (2012) 347-352
    •  Refined delamination factor failure characterization of composite wind turbine blade V.A. Nagarajan, S. Sundaram, K. Thyagarajan, J.S. Rajadurai, T.P.D. Rajan International Journal of Damage Mechanics 21 (8) , 2012 pp. 1227-1244
    •  Developments in Solidification Processing of Functionally Graded Aluminium Alloys and Composites by Centrifugal Casting Technique T.P.D. Rajan, E. Jayakumar, B.C. Pai Transactions of the Indian Institute of Metals, 65(6) 2012, pp. 531-537
    •  Effect of Mg on Solidification Microstructures of Homogenous and Functionally Graded A390 Aluminum Alloys E. Jayakumar, T.P.D. Rajan, B.C. Pai Transactions of the Indian Institute of Metals, 65(6) 2012, pp. 677-681
    •  Squeeze Infiltration Processing of Functionally Graded Aluminum-SiC Metal Ceramic Composites Sree Manu, K.M., Resmi, V.G., Brahmakumar, M., Narayanasamy, P., T.P.D.Rajan, Pavithran, C., Pai, B.C. Transactions of the Indian Institute of Metals, 65(6) 2012, pp. 747-751
    •  Influence of Autocatalytic Coating Bath Parameters on the Formation of Copper over Surface Treated Boron Carbide Particles J.P. Deepa, T.P.D. Rajan, C. Pavithran, B.C.Pai Surface and Coatings Technology,214 (2013) 77–85 DOI: 10.1016/j.surfcoat.2012.11.005
    •  Measuring Delamination Severity of Glass Fiber-Reinforced Epoxy Composites During Drilling Process Nagarajan, V.A., Sundaram, S., Thyagarajan, K., Selwin Rajadurai, J., T.P.D.Rajan, Experimental Techniques,2013, 37 (2) , pp. 66-73 Sliding Wear Behavior of Stir Cast AZ91/ SiCpComposites S. Prasanth, V. Abhilash, K.K. Ajith Kumar, T.P.D. Rajan, U.T.S. Pillai and B.C. Pai Journal of Solid Mechanics and Materials Engineering, 2013 (7) 169-175
    •  Effect of Centrifugal Force and Addition of Modifier on Morphology and Distribution of Eutectic/Primary Silicon in Hypereutectic Aluminum-Silicon Alloy A390 V.P. Mahesh, K. Narayan Prabhu and T.P.D. Rajan Indian Foundry Journal, 2013, Vol. 59(7), pp. 31-35
    •  Studies on Electroless Nickel Boride Coating on Boron Carbide Particles J.P. Deepa, T.P.D. Rajan, C. Pavithran, B.C.PaiSurface Engineering, 2014, 30(10), 702-708
    •  Physical, Mechanical, and Tribological Attributes of Stir-Cast AZ91/SiCp Composite K. K. Ajith Kumar, Abhilash Viswanath, T. P. D. Rajan, U. T. S. Pillai, B. C. Pai Acta Metallurgica Sinica (English Letters),2014, 27(2), 295-305
    •  Developments in Processing of Functionally Gradient Metals and Metal–Ceramic Composites: A Review T. P. D. Rajan, B. C. Pai Acta Metallurgica Sinica (English Letters),2014, Vol. 27, No. 5, 825-838(invited article)
    •  New Directions in Development and Applications of Cast Metal Matrix Composites T.P.D. Rajan and B.C. PaiIndian Foundry Journal,2014, 60 (11), 22-30 (invited article)
    •  Hafnium silicate: a new microwave dielectric ceramic with low thermal expansivity J. Varghese, T. Joseph, K.P. Surendran, T.P.D. Rajan, M.T. Sebastian Dalton Transactions, 2015, 44 (11), 5146-5152
    •  Development of Al 319-Micro silica Metallic Composite by SqueezeInfiltration Technique K. M. Sree Manu, P. S. Rahul, L. Ajay Raag, T.P.D.Rajan, M. Brahmakumar, B.C.Pai Materials Science Forum Vols. 830-831 (2015) pp 489-492
    •  Ultrasonic-Assisted Electroless Coating of Ni-B Alloy and Compositeson Aluminum Alloy Substrates Jerin K. Pancrecious, J. P. Deepa, R. Ramya, T.P.D. Rajan, E. Bhoje Gowd and B.C. Pai Materials Science Forum Vols. 830-831 (2015) pp 687-690
    •  Structure and Properties of Electroless Cu and Ni-B coated B4C particle dispersed Aluminum Composites by Powder Metallurgy Technique J.P. Deepa, S. Abhilash, T.P.D. Rajan, C. Pavithran, B.C. Pai Materials Science Forum Vols. 830-831 (2015) pp 480-484
    •  Centrifugal Casting and Characterisation of Primary Silicon and Mg 2 SiDispersed Aluminium Functionally Graded Materials P. Midhun Krishnan, S. Hari, E. Jayakumar, T.P.D. Rajanand K. Narayan Prabhu Materials Science Forum Vols. 830-831 (2015) pp 11-14
    •  Characteristics of Functionally Graded BimetallicAluminium Alloys by Sequential Casting Technique Akhil S. Karun, Hari Sanil, T.P.D. Rajan , U.T.S. Pillai and B.C. Pai Materials Science Forum Vols. 830-831 (2015) pp 383-386
    •  Processing of Porous Ceramics using Aluminium Derived Binders andSacrificial Porogen Leaching Method V.G. Resmi, K.M Sree Manu, J.P. Deepa, V. Lakshmi, T.P.D. Rajan,C. Pavithran and B.C.Pai Materials Science Forum Vols. 830-831 (2015) pp 448-451
    •  Processing and Characterization of Functionally Graded in-situAluminum Composite A.G. Arsha, E. Jayakumar, T.P.D. Rajan and B.C. Pai Materials Science Forum Vols. 830-831 (2015) pp 485-488
    • Processing and Characterization of Hypoeutectic Functionally GradedAluminum – SiC Metal Matrix Composites E. Jayakumar, Jibin C Jacob , T. P. D. Rajan , M. A. Joseph and B.C. Pai Materials Science Forum Vols. 830-831 (2015) pp 456-459
    •  Micropatterning of Polystyrene-Alumina Nanocomposite Film by Nonsolvent Induced Phase Separation Lakshmi V., Annu Raju, T.P.D. Rajan, C. Pavithran, B.C. Pai Materials Science Forum Vols. 830-831 (2015) pp 569-572
    •  Processing of Porous SiC by Aluminium Derived Binders and Sacrificial Porogen Leaching Method V.G. Resmi, J.P. Deepa, V. Lakshmi, T.P.D. Rajan, C. Pavithran and B.C.Pai International Journal of Applied Ceramic Technology, 2015, 12 [5] 967–975
    •  Optimization of Drilling Processon Al-SiC Composite usingGrey Relation Analysis K.R. Vinothbabu,M. Uthayakumar, J.T. Winowlin Jappes,T.P.D. Rajan International Journal of Manufacturing, Materials, and Mechanical Engineering, 2015, 5(4), 18-32 (DOI: 10.4018/IJMMME.2015100102)
    •  Structure and Properties of Modified Compocast Microsilica Reinforced Aluminum Matrix Composite K.M. Sree Manu, K. Sreeraj , T.P.D. Rajan, R. M. Shereema, B.C. Pai, B. Arun Materials and Design, 2015, 88, 294–301 (DOI: 10.1016/j.matdes.2015.08.110)
    •  Concentration dependent pore morphological tuning of kaolin clay foams using sodium dodecyl sulphate as foaming agent V Lakshmi, VG Resmi, Annu Raju, JP Deepa, TPD Rajan, C Pavithran, BC Pai Ceramics International, 2015, 41, 14263–14269 (Doi:10.1016/j.ceramint.2015.07.056)
    •  Processing of silica bonded porous SiC preform for metallic composites VG Resmi, KMS Manu, V Lakshmi, M Brahmakumar, TPD Rajan, C Pavithran, BC Pai Journal of Porous Materials, 2015, 22 (6), 1445-1454 (DOI 10.1007/s10934-015-0025-7)
    •  Design and Fabrication of Functionally Graded In-situ Aluminum Composites for Automotive Pistons A.G. Arsha, E. Jayakumar, T. P. D. Rajan, V. Antony, B.C. Pai Materials and Design, 2015, 88, 1201–1209 (DOI:10.1016/j.matdes.2015.09.099)
    •  Bulk Processing of ZnO Nanostructures via Microwave Assisted Oxidation of Mechanically Seeded Zn Dust for Functional Paints and Coatings Santhosh Balanand, Mathews Jeen Maria, T.P.D. Rajan, A. Peer Mohamed, S. Ananthakumar Chemical Engineering Journal, 284 (2016) 657–667
    •  Dry Sliding Wear Studies on SiC Reinforced Functionally Graded Aluminium Matrix Composites K.R. Vinothbabu, J.T. Winowlin Jappes,T.P.D. Rajan,M. Uthayakumar Journal of Materials, Design and Applications , 2016 vol. 230 no. 1 182-189, DOI: 10.1177/1464420714556665
    •  Amino-functionalized Breath-Figure cavities in Polystyrene-Alumina hybrid Films : Effect of particle concentration and dispersion Lakshmi V., Annu Raju, Resmi V.G., Jerin K. Pancrecious, Rajan T.P.D., and Pavithran C. Physical Chemistry Chemical Physics, 2016, 18, 7367
    •  Adduct modified nano-clay mineral dispersed polystyrenenanocomposites as advanced corrosion resistance coatings foraluminum alloys Annu Raju, V. Lakshmi , R.K. Vishnu Prataap , V.G. Resmi , T.P.D. Rajan, C. Pavithran,V.S. Prasad, S.Mohan Applied Clay Science 126 (2016) 81–88
    •  Processing of Functionally Graded Aluminium Alloy and Composite Engineering Components by Centrifugal and Squeeze Casting Techniques T. P. D. Rajan, E. Jayakumar, K.M. Sree Manu, Akhil S Karun and B. C. Pai Indian foundry Journal, 2016, 62 (4), 21-25
    •  Enhancement in Tribological Behaviour of Functionally Graded SiC Reinforced Aluminium Composites by Centrifugal Casting Akhil S. Karun, T.P.D. Rajan, U.T.S. Pillai, B.C. Pai, V.R. Rajeev, A. Farook Journal of Composite Materials, 2016; 50(16) pp. 2255-2269 (DOI: 10.1177/0021998315602946)
    •  Processing and Characterization of Functionally Graded Aluminum (A319) - SiCp MetallicComposites by Centrifugal Casting Technique E. Jayakumar, Jibin C Jacob , T. P. D. Rajan, M. A. Joseph, B.C. Pai Metallurgical and Materials Transactions A, 2016, 47(8), 4306-4315 (DOI: 10.1007/s11661-016-3558-8)
    •  Liquid Metal Infiltration Processing of Metallic Composites - A Critical Review K.M. Sree Manu, L. Ajay Raag, T.P.D. Rajan, Manoj Gupta, B.C. Pai Metallurgical and Materials Transactions B, 2016, 47 (5), 2799-2819
    •  Structure and Properties of Squeeze Infiltrated Zirconia Grade-Aluminosilicate Short Fiber Reinforced Aluminum Composites K.M. Sree Manu, T.P.D. Rajan, B.C. Pai Journal of Alloys and Compounds, 2016, 688, 489-499 (DOI: 10.1016/j.jallcom.2016.07.135)
    •  Functionally Graded Bimetallic Aluminum Alloy Design and Fabrication by Sequential Casting Technique Akhil S. Karun, S. Hari, Ebhota Williams S., T.P.D. Rajan, U.T.S. Pillai, B.C. Pai Metallurgical and Materials Transactions A, 2017, 48: 279-293 Doi:10.1007/s11661-016-3824-9
    •  Effect of Alumina Nanoparticle on Strengthening of Al-Si alloy through Dendrite Refinement, Interfacial Bonding and Dislocation Bowing K.M. Sree Manu, S. Arun Kumar, T.P.D. Rajan, M. Riyas Mohammed, B.C. Pai Journal of Alloys and Compounds, 712 (2017) 394-405
    •  Developments in Smart Anticorrosive Coatings with Multifunctional Characteristics Sarah B. Ulaetoa, Ramya Rajan, Jerin K. Pancreciousa, T.P.D. Rajan, B.C. Pai Progress in Organic Coatings, 111 (2017) 294–314
    •  Microstructural Aspects of Particle-Assisted BreathFigures in Polystyrene-Alumina Hybrid Free Standing Film Lakshmi V., Ramya R, Annu Raju, T.P.D.Rajan and Pavithran C. Journal of Physical Chemistry C, 2017, 121 (28), pp 15154–15159 DOI: 10.1021/acs.jpcc.7b02941
    •  Role of Centrifugal Casting on Electrochemical Corrosion Behavior of A356-SiCp Composite in 3.5 wt.% NaCl Maimunnisa S., Poorwa G., Rajan T. P. D., Raja V. S. Journal of Materials Engineering and Performance, 2018, 27:4210–4224, DOI: 10.1007/s11665-018-3508-2
    •  Metallic Composite Coatings by Electroless Technique – A Critical Review Jerin K. Pancrecious, Sarah Bill Ulaeto, R. Ramya, T.P.D. Rajan and B.C. Pai International Materials Review, 2018, 63:8, 488-512, DOI: 10.1080/09506608.2018.1506692
    •  Nanoceria induced grain refinement in electroless Ni-B-CeO 2 composite coating for enhanced wear and corrosion resistance of Aluminum alloy Jerin K. Pancrecious, Sarah Bill Ulaeto, R. Ramya, T.P.D. Rajan and B.C. Pai Surface and Coatings Technology, 2018, Volume 356, Pages 29-37
    •  Selectively Reinforced Aluminum Metallic Hybrid Composites by Liquid Metal Squeeze Infiltration Process K. M. Sree Manu, Vaisakh Manoj,A. G. Arsha, R. L. Vishnu, V. G. Resmi, T. P. D. Rajan, B. C. Pai Transactions of the Indian Institute of Metals, 2018, 71 (11), 2827-2832
    •  Studies on Tribological Characteristics of Centrifugally Cast SiCp-Reinforced Functionally Graded A319 Aluminium Matrix Composites E Jayakumar, AP Praveen, TPD Rajan, BC Pai Transactions of the Indian Institute of Metals, 2018, 71 (11), 2741-2748
    •  Characterization and heat treatment of Al6061 with and without TiB 2 S. Senthil Murugan, T. P. D. Rajan Journal of Metallurgy and Materials Science 60.2 (2018): 73-78
    •  A Study on the Machining of Al–SiC Functionally Graded Metal Matrix Composite Using Die–Sinking EDM M. Uthayakumar, Vinoth Babu K., S. Thirumalai Kumaran, S. Suresh Kumar, J. T. Winowlin Jappes, T. P. D. Rajan Particulate Science and Technology, 2019, 37 (1), 103-109 Doi: 10.1080/02726351.2017.1346020
    • Smart nanocontainer-based anticorrosive bio-coatings: Evaluation of quercetin for corrosion protection of aluminium alloys Sarah B Ulaeto, Anju V Nair, Jerin K Pancrecious, Akhil S Karun, Gincy Marina Mathew, T.P.D. Rajan, BC Pai Progress in Organic Coatings, 2019, 136, 105276
    •  Reciprocating Wear Analysis of Magnesium-Modified Hyper-eutectic Functionally Graded Aluminium Composites E Jayakumar, Tony Varghese, T.P.D. Rajan, BC Paitran Transactions of the Indian Institute of Metals, 2019, 72 (6) 1643-1649
    •  Self-lubricating Bidirectional Carbon Fiber Reinforced Smart Aluminum Composites by Squeeze Infiltration Process K.M. Sree Manu, L. Ajay Raag, T.P.D. Rajan, B.C. Pai, Vijay Petley, Shweta Namdeo Verma Journal of Materials Science and Technology, 2019, 35 (11) 2559-2569
    •  Processing of functionally graded aluminum composite brake disc and machining parameters optimization K Vinoth Babu, S Marichamy, P Ganesan, D Madan, M Uthayakumar, T.P.D. Rajan Materials Today: Proceedings, 2020, Vol. 21, pp. 563-567
    •  Biogenic Ag Nanoparticles of Neem Extract; its Structural Evaluation and Antimicrobial Effects against Pseudomonas nitroreducens and Aspergillus unguis - NII 08123 Sarah B Ulaeto, Gincy Marina Mathew, Jerin K Pancrecious, Akhil S Karun, Jyothi Nair, T.P.D. Rajan, BC Pai, Kaustabh Maiti ACS Biomaterials Science & Engineering, 2020, 6, 1, 235-245
    •  Solid particle erosion studies on SiC reinforced functionally graded aluminium matrix composites S Prathap Singh, T Prabhuram, K Vinoth Babu, D Elilraja, M Uthayakumar, T.P.D. RajanIOP Conf. Series: Materials Science and Engineering 764 (2020) 012005
    •  Foundry Processing Techniques for Functionally Graded Engineering Components T.P.D. Rajan, Akhil S. Karun, M.G. Akhil, A.G. Arsha Indian Foundry Journal, 2020, Vol. 66(5), 16-19
    •  Solidification processing of cast metal matrix composites over the last 50 years and opportunities for the future Pradeep K. Rohatgi, Ajay Kumar P, Nagaraj M. Chelliah, T.P.D. Rajan JOM, 2020, 72, 2912–2926
    •  Investigations on the Melt Flow Behavior & Microstructure of A390 Alloy during vertical centrifugal casting Process - CFD Simulation and Experiments Akhil S. Karun, Aneesh Kumar J., Jeyalakshmi T.S., Sai Gopal Krishna B, Vignesh Suraj K.S., Karthik V. Sankar, T.P.D Rajan, S. Savithri Transactions of the Indian Institute of Metals, 2020, 73, 2321–2331
    •  Cast Metal Matrix Composites Over Last 50 Years and Future Opportunities in India Ajay Kumar P, Pradeep Rohatgi, David Weiss, T.P.D. Rajan, B C Pai, D P Mondal and S Das Indian Foundry Journal, 2020, Vol. 66(10), 17-27
    •  Squeeze Infiltration Processing and Structural Characteristics of Lightweight Aluminum- Carbon Metal Matrix Composites M.G. Akhil, A.G. Arsha, Vishak Manoj, R.L. Vishnu, T.P.D. Rajan, and B.C. Pai Transactions of the Indian National Academy of Engineering, 2021, 6, pages41–48 https://doi.org/10.1007/s41403-020-00172-0
    •  Aluminium Metal Matrix Composite Processing by Liquid Metal Infiltration Techniques T.P.D. Rajan, M.G. Akhil, A.G. Arsha, K.M. Sree Manu, Visakh Manoj, H. Sundara Murthy and B.C. Pai Aluminum in India, 2021, Vol 20(4), 7-13
    •  Characterization of Graphite-Reinforced LM30-Aluminium Matrix Composite Processed through Gravity and Vertical Centrifugal Casting Processes S Senthil Murugan, T.P.D. Rajan Journal of The Institution of Engineers (India): Series D, 2020
    •  Particle Assisted Breath Figure Pattern on Polystyrene Alumina Nanocompposite Film: Effect of particle Size Lakshmi V, Annu Raju, T.P.D. Rajan, Teresian International Journal of Chemical Sciences, 2021, Vol II (4), pp. 19-27.
    •  Study on Al/TiB2 functionally graded metal matrix composites,Nidhi Sindhu, Rajendra Kumar Goyal, Thankachan T Pullan, TPD Rajan, Sreekumar Vadakke Madam,Materials Today: Proceedings, 2021, Vol 44, pp. 2945-2951
    •  Anticorrosive Enamels: Evaluation of Nanocomposite Additives on Enamel Efficiency on Cold Rolled Steel Sarah B Ulaeto, Gincy Marina Mathew, Jerin K Pancrecious, Akhil S Karun, T.P.D. Rajan, BC Pai Journal of Materials Engineering and Performance, 2021, vol. 30, pp. 4103–4116
    •  Ni-Al polyvanadate layered double hydroxide with nanoceria decoration for enhanced corrosion protection of aluminium alloy, Jerin K. Pancrecious, S.V. Vineetha, Ulaeto Sarah Bill, E. Bhoje Gowd, T.P.D. Rajan, Applied Clay Science, 2021, 106199 [IF: 5.907]
    •  Role of layered double hydroxide in enhancing wear and corrosion performance of self- lubricating hydrophobic Ni-B composite coatings on aluminium alloy, Jerin K. Pancrecious, P.S. Gopika, P. Suja, Sarah Bill Ulaeto, E. Bhoje Gowd and T.P.D. Rajan, Colloids and Surfaces A: Physicochemical and Engineering Aspects, Volume 634, 5 February 2022, 128017
    •  Smart anticorrosive and antimicrobial multifunctional epoxy coating using bergenin and malabaricone C bio-nanocomposite dispersoids on mild steel and aluminium-6061 alloy P.R. Rajimol, Sarah Bill Ulaeto, Anoop Puthiyamadam, S. Neethu, T.P.D. Rajan, K.V. Radhakrishnan, Rajeev K.Sukumaran Progress in Organic Coatings, 2022, 169, 106924
    •  Squeeze infiltration processing and characterization of Silicon Reinforced Composites, A G Arsha, Visakh Manoj, M G Akhil, R Anbukkarasi, P R Rajimol, T P D Rajan, Materials Today Communications, 2022, 103870.
    •  Design and fabrication of nano textured superhydrophobic and anti-corrosive silane- grafted ZnO/bio-based polyurethane bilayer coating Ben John, P.R.Rajimol, T.P.D.Rajan, Sushanta Kumar Sahoo, Surface and Coatings Technology, Volume 451, 15 December 2022, 129036
    •  Azadirachta indica (Neem) self-healing efficacy assessment in epoxy primer coatings: A bio- responsive strategy for counteracting corrosion Sarah B Ulaeto, Gincy Marina Mathew, Jerin K Pancrecious, Akhil S Karun, T.P.D. Rajan, BC Pai Colloids and Surfaces A: Physicochemical and Engineering Aspects, Vol. 658, 5 February 2023, 130684
    •  Graphitic Carbon Nitride (g-C3N4) Based Heterogenous Single Atom Catalysts: Synthesis, Characterisation and Catalytic Applications P SUJA, J John, TPD Rajan, AM Gopinathan, T Yamaguchi, SC Pillai, ... Journal of Materials Chemistry A, 2023, 11 (16), 8599-8646
    •  Functionally Graded Al-SiC Composites by Squeeze Infiltration Technique AG Arsha, MG Akhil, V Manoj, PR Rajimol, R Anbukkarasi, TPD Rajan, S. Dhanalakshmi International Journal of Metalcasting, 2023, Vol. 17, Iss. 4, 2981-2991,https://doi.org/10.1007/s40962-022-00954-y
    •  Development of an oxyresveratrol incorporated bio-based smart nanocomposite coating with anti-corrosive, self-healing, and anti-microbial properties PR Rajimol, Sarah Bill Ulaeto, Anoop Puthiyamadam, Sushanta Kumar Sahoo, TPD Rajan, KV Radhakrishnan, Rajeev K Sukumaran Green Chemistry, 2023, 25 (18), 7189-7215
    •  Squeeze infiltration processing of lightweight smart aluminum graphite functionally graded composite for enhanced wear resistance MG Akhil, V Manoj, P Suja, TPD Rajan Journal of Manufacturing Processes, 2023, 104, 177-188
    •  Fluorescent Carbon Dots from Bamboo Stem Waste: Synthesis, Characterization, and InkjetPrinting. Bavya V, Adarsh Sivan Pillai, Kuzhichalil Peethambharan Surendran, Rajan T.P.D., Suresh K.I. Chemistry Select, 2024, 9(4).
    •  A GPU based accelerated solver for simulation of heat transfer during metal casting process R Jayakumar, TPD Rajan, S Savithri Modelling and Simulation in Materials Science and Engineering, 2024, 32 (5), 055013
    •  Copper metallization of carbon fiber-reinforced epoxy polymer composites by surface activation and electrodeposition Bashida Basheer, Madhusoodhanan Geethakumari Akhil, T.P.D. Rajan, Pankaj Agarwal, Venkataramani Vijay Saikrishna, Surface and Coatings Technology, 2024, 487, 131016
    •  Aluminium alloys and composites for electrochemical energy systems M Manikkoth, SK Kannan, JM Gladis, TPD Rajan Progress in Materials Science, 2024, 101322 [IF:40]
    •  Solidification processing of reduced graphene oxide dispersed aluminum composites by squeeze casting AG Arsha, Omid Ghaderi, TPD Rajan, PK Rohatgi International Journal of Metalcasting, 2025,19 (2), 664-673
    •  Development of A356-TiB2 in-situ nanocomposite brake disc via intensive high shear mixing and vertical centrifugal casting techniques V.M. Sreekumar, Sunil Manani, Nidhi Sindhu, Rajendra Kumar Goyal, Rajan T.P.D. International Journal of Metalcasting 19 (4), 2313-2331
    •  Synthesis of graphene reinforced aluminum nanocomposites with enhanced mechanical and tribological properties by solidification processing Arsha Antony Geetha, Aswathy Sobhana Nair, Omid Ghaderi, Jayasanker Kalidoo, T.P.D. Rajan, Pradeep K. Rohatgi Diamond & Related Materials 152 (2025) 111942
    •  Design of Fluorescence Enhancing Sensor for Mercury Detection via Bamboo Cellulose- Derived Carbon Dots Vallil Bavya, Thazhavilai Ponnu Devaraj Rajan, and Kattimuttathu Ittara Suresh Langmuir 2025, 41, 2, 1333-1343
    •  Atomically Dispersed Cu on Graphitic Carbon Nitride Nanosheets as Catalysts for the Synthesis of Disubstituted Triazoles Suja P, Rahul P, Vidha Bhasin, Dibyendu Bhattacharya, Jin Won Seo, Sreeprasanth Pulinthanathu Sree, T. P. D Rajan, Jubi John, and Unnikrishnan Nair Saraswathy Hareesh, ACS Applied Nano Materials 2025, 8, 2, 1214-1224
    •  Self-Assembled Designer Polymersomes of In Situ Hybrid Nanocomposites from Copolymers of Polystyrene and Poly (Acrylic Acid) with Functionalized-Kaolinite for pH- Induced Delivery. P. Anju, V.S. Prasad, T.P.D. Rajan Chemistry Select, 2025, 10, e202405679, doi.org/10.1002/slct.202405679
    •  Sustainable Development of Rare Earth-Added Aluminum Alloys by Direct Metallothermic Reduction of Rare Earth Oxides, K Sivakumar, J Robert, A Srinivasan, SS Sreejakumari, TPD Rajan, Journal of Sustainable Metallurgy, 2025, 11 (3), 2912-2921 (IF: 3.2)
    •  Towards Sustainable Al–Air Batteries: Electrolyte Engineering Using Water-in-Salt Chemistry for Improved Performance M Manikkoth, MG Akhil, V Manoj, TPD Rajan Journal of Energy Storage, 2026, 143, 119544
    • Multifunctional Epoxy Nanocomposite Coatings with Anticorrosive, Antimicrobial, and Self- Healing Characteristics Derived from Floral Biomass Rajimol P. R., Samuel A. S., Sarah Bill Ulaeto, Rajan T. P. D. Discover Electrochemistry, 2026, (in press)
    • Carbon Dot/Cerium Oxide Hybrid Nanomaterial for Enhanced Corrosion Protection of Mild Steel Substrates under Acidic Conditions V Bavya, TPD Rajan, KI SureshSurfaces and Interfaces, 2026, 109015
Achievements & Awards
    •  National Metallurgist Award conferred by Ministry of Steel, Govt. of India (for the year2023) towards contribution in development of lightweight metallic materials,manufacturing technologies and products.
    •  Award for Excellence in Corrosion Science and Technology conferred by NACE International, Mumbai (2018) towards the contribution in the corrosion studies ofmetallic composites, functionally graded materials and development of smartanticorrosive coatings.
    •  IIM Nalco Gold Medal conferred by The Indian Institute of Metals (IIM) (2015) towards the contribution in the development of metal matrix composites and functionally graded materials for engineering applications.
    •  Chandran Menon Memorial Award for Applied Research and Innovative Technology conferred by The Institute of Indian Foundrymen (IIF), Kolkata (2015)
    •  World Top 2% Scientist, listed by Stanford University and Elsevier's 2025 in the area ofMaterials Science.
    •  IIF Industry Research Award at national level conferred by The Institute of Indian Foundryman, Calcutta (2009) towards the contribution in development of cast metal matrix composites and functionally graded materials for engineering applications.
    •  INAE Innovation Award conferred by Indian National Academy of Engineering, New Delhi for the Best Doctoral thesis in Engineering at all India level for the year 2003
    •  Soli-Commissariat Award conferred by Institute of Indian Foundryman, Calcutta for the Studies on Casting/Mould interfacial heat transfer during solidification of aluminium matrix composites, awarded during 6 th Asian Foundry Congress and 47 th Indian Foundry Congress, Science city, Calcutta, Jan. 26, 1999.
    •  Editor, Transactions of Indian Institute of Metals, Springer Nature Publications (2018-)
    •  IGSTC Visiting Scientist, RWTH Aachen University, Germany (2019-22)
    •  UKIERI Honorary Visiting Researcher - visiting and delivering lectures at the Universities of Bradford, Oxford, Leeds and Brunel, United Kingdom (Jan. 2014)
    •  Young Scientist Fellowship, Dept. of Science and Technology, New Delhi, (2002)
    •  IIM National Metallography Awards from Indian Institute of Metals (IIM) for the years 2005, 2006 and 2019 for the best optical microstructures
    •  EMSI SEM Micrograph Awards at National level conferred by Electron Microscopy Society of India (EMSI) for the years 2002, 2004 and 2006.
    •  Various Best paper awards in national and international conferences.
Professional recognition

Professional Activities


Membership in Professional societies

    •  Life Member, The Indian Institute of Metals (IIM).
    •  Life Member, Materials Research Society of India (MRSI).
    •  Life Member, The Society for Polymer Science, India (SPSI)
    •  Life Member, Academy of Microscope Science and Technology (AMST)
    •  Life Member, Kerala Academy of Sciences (KAS)
    •  Life member, Indian Society for Advancement of Materials and Processing Engineering (ISAMPE)
    •  Member, The Institute of Indian of Foundrymen (IIF)
  • Professional and related activities
    •  Chairman, The Indian Institute of Metals, Trivandrum Chapter (2024-26)
    •  Chairman, Materials Research Society of India, Trivandrum Chapter (2019-21)
    •  Chairman, Academic Program Committee, CSIR-NIIST (2019-23)
    •  Head, Human Resource and Academic Division, CSIR-NIIST, (2025-)
    •  Principal Investigator, Centre of Excellence on Lightweight Material Technologies,CSIR-NIIST (2021-26)
    •  Vice-Chairman, The Indian Institute of Metals, Trivandrum Chapter (2021-24)
    •  Vice-Chairman, The Institute of Indian Foundrymen, Kerala Chapter (2015-25)
    •  Hon. Secretary, The Indian Institute of Metals, Trivandrum Chapter (2014-16)
    •  Secretary, Materials Research Society of India, Trivandrum Chapter (2013-16)
    •  Editor, Met News, Quarterly bulletin of Indian Institute of Metals, Trivandrum Chapter
    • Professor, Academic of Scientific and Innovative Research (AcSIR), New Delhi (Since 2018)
    •  Recognized Research Guide of AcSIR-New Delhi, CUSAT-Kochi and University of Kerala-Trivandrum.
    •  Journal Reviewer in various International Journals such as Composite Science and Technology, Journal of Materials Science, Journal of Alloys and Compounds, Journal of Nanoscience and Nanotechnology, Journal of Composite Materials etc.
    •  Ph.D. thesis examiner of IIT-Chennai, NIT-Trichi, Nagpur & Jaipur, Anna University- Chennai, MS and MG University, KTU, CUSAT, etc.
    •  Convener of AMMT-2023, ICAMPS-2015, Co-convener of LMCMP-2017, ICAFM-2014, HTMHS-2013 & ICAMPS-2012, and Organizing committee member of various national and international conferences like IIM NMD-ATM 2004, ICAMC-2007, ICAFM-2009, ICMST-2010, IIM NMD-ATM 2019 etc.
Team
Smitha Dr. Rajimol P.R
CSIR-Research Associate
Email: rajipr19@gmail.com
Smitha Mr. Muhammad M
UGC-SRF & PhD Scholar
Email: muhammadmch@gmail.com
Smitha Mr. Visakh Manoj
UGC-SRF & PhD Scholar
Email: visakhmanoj009@gmail.com
Smitha Mr. Izahaq S Khan
Project Associate & PhD Scholar
Guides: Dr. T.P.D. Rajan & Dr. A. Srinivasan
Email: izahaq.s.khan2727@gmail.com
Smitha Ms. Bavya V
KSCSTE Fellow & PhD Scholar
Guides: Dr. K.I. Suresh & Dr. T.P.D. Rajan
Email: bavyasreedharan@gmail.com
Smitha Mr. Sibi S.P.
Senior Project Associate & PhD Scholar
Guides: Dr. Parijat Pallab Jana & Dr. T.P.D. Rajan
Email: sibisppadippura@gmail.com
Smitha Dr. Revathy Sreekumar
Project Associate
Email: revathyias26@gmail.com
Smitha Mr. Shan Kumar S
Project Associate
Email: 49shan@gmail.com
Smitha Mr. K. Sivakumar
Project Associate
Email: ksivakumar6384@gmail.com
Smitha Mr. Athul G Anil
Project Associate
Email: athulganil@gamil.com
Smitha Mr. Sourav K Krishnan
Project Associate
Email: souravkkrishnan2000@gmail.com
   
Smitha Mr. Delvin Daniel Saju
Smitha Mr. Karthik S
Project Assistant
Email: karthikveeraputhran@gmail.com
Smitha Mr. Rithuraj k Santhosh
Project Assistant
Email: rithurajks007@gmail.com
Smitha Mr. Ananthu M.S.
Project Assistant
Smitha Mr. Adarsh M.S.
Project Associate
Email: adarshaswini@gmail.com
Smitha Mr. Shibu Prabhakaran
Project Assistant
Email: shibuprabhakaran01@gmail.com
   
Alumni
  Dr. Deepa J.P.
  Dr. Resmi V.G
  Dr. Annu Raju
  Dr. V. Lakshmi
  Dr. Jobin Varghese
  Dr. K. Sree Manu
  Dr. Jayakumar
  Dr. Akhil S Karun
  Dr. Asha Susan Chacko
  Dr. Jerin Pancreciuos
  Dr. Sarah Bill Ulaeto
  Dr. Rajimol P.R.
  Dr. Arsha A.G
  Dr. Anju P
  Dr. Suja P
   
   

TWAS Sandwich PhD Scholars / M.S. (Research)

 

  Dr. Willam Ebhota
  Mr. Thomas Aghogho
  Dr. Mahesh V.P.
Ph.D., M. Tech/M.Sc. Students
  Dr. Willam Ebhota
  Mr. Thomas Aghogho
  Dr. Mahesh V.P.