Shalini Singh

Additive Manufacturing (WAAM, LPBF, LDED), Smart Material-Integrated 4D Structures, Material Characterization & Processing, CAD/CAM & Metrology, Industry 4.0 & Digital Manufacturing, Thin Films & Surface Engineering, Structural Optimization & Design for Additive Manufacturing (DFAM)

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My research focuses on advancing metal additive manufacturing by addressing key challenges in process optimization, material properties, and in-situ monitoring. I specialize in integrating smart materials such as NiTi and Cu-based shape memory alloys into additively manufactured structures, enabling the development of high-performance components for aerospace, biomedical, and industrial applications. Key areas of my work include:

Metal Additive Manufacturing – Optimization of WAAM, LPBF, and LDED processes for enhanced mechanical properties, microstructural refinement, and defect mitigation. I have developed process parameter strategies to improve the manufacturability of high-chromium white iron, AlSi10Mg, and tungsten carbide for wear-resistant and high-efficiency applications.

Smart Materials and Thin Films – Fabrication of multifunctional structures using NiTi and CuAlNiMn shape memory alloys, tailored for actuation and sensing applications. My work also includes deposition of functional coatings via magnetron sputtering to enhance surface properties for corrosion and wear resistance.

Characterization & Metallurgy – Extensive experience in microstructural characterization, phase analysis, and mechanical property evaluation using techniques such as SEM,  EBSD,XRM ,XPS,TEM, XRD, microhardness testing, and corrosion analysis. I have worked on in-situ characterization methods to understand phase transformations and mechanical performance in metal AM components.

In-Situ Monitoring and Process Control – Implementation of spectroscopic and thermal imaging techniques for real-time monitoring of AM processes. This includes using machine learning algorithms to correlate process parameters with microstructural evolution and mechanical performance. I have authored 12 peer-reviewed journal articles as the first author and co-authored 7 additional journal papers. I have also actively contributed to the academic community as a reviewer for several reputed journals, including the Journal of Alloys and Compounds, the International Journal of Material Research, the Journal of Process Mechanical Engineering, Materials and Material Letters.