Kumar Ujjwal

Kumar Ujjwal

Assistant Professor
ujjwal.kumar@mahindrauniversity.edu.in

Dr. Kumar Ujjwal is a researcher in Manufacturing Technology with expertise in metal additive manufacturing, particularly wire arc additive manufacturing (WAAM). His research lies at the intersection of manufacturing processes, materials science, and structural performance, with a focus on establishing robust process-structure-property relationships. Through this integrated approach, his work aims to make metal additive manufacturing more reliable, scalable, and suitable for industrial applications.

Education

  • Ph.D. in Mechanical Engineering (Manufacturing), IIT (ISM) Dhanbad, India (Part of doctoral research carried out at Monash University, Australia, under the Sandwich PhD Fellowship)
  • M.Tech. in Computer Integrated Manufacturing, NIT Agartala, India.
  • B.Tech. in Mechanical Engineering, Vellore Institute of Technology, Chennai, India.

Experience

  • Jan 2026 – Present: Assistant Professor, Mahindra University, Hyderabad, India.
  • July 2022 – Jan 2023: Visiting Research Scholar, Monash University, Melbourne, Australia (Experimental research on corrosion and stress corrosion cracking of wire arc additive manufactured aluminium alloys)

List of Publications in International Journals

  • Ujjwal, K., Chauhan, C., Raman, R.S. and Das, A.K., 2025. Mitigation of porosity and surface defects in wire arc additive manufactured aluminium alloy through heat input and inert gas flow control. Journal of Materials Engineering and Performance, https://doi.org/10.1007/s11665-025-11550-6
  • Ujjwal, K., Al-Saadi, S., Das, A.K. and Raman, R.S., 2024. Corrosion and stress corrosion cracking characteristics of 4043 aluminium alloy fabricated through directed energy deposition process. Journal of Alloys and Compounds, 976, p.173154. https://doi.org/10.1016/j.jallcom.2023.173154
  • Ujjwal, K., Raman, R.S. and Das, A.K., 2024. Role of arc weaving strategies in the fabrication of thick-walled 4043 aluminium alloy components through directed energy deposition process. CIRP Journal of Manufacturing Science and Technology, 52, pp.12-25. https://doi.org/10.1016/j.cirpj.2024.05.016
  • Ujjwal, K., Singh, R., Anand, M., Raman, R.S. and Das, A.K., 2024. Novel electric arc-based surface smoothening for wire arc additively manufactured components. Materials Letters, p.136829. https://doi.org/10.1016/j.matlet.2024.136829
  • Ujjwal, K., Anand Kumar, K., Anand, M., Singh Raman, R.K. and Das, A.K., 2023. Effect of current waveforms during directed energy deposition of 4043 aluminum alloy on microstructure, hardness, and wear of alloy. Materials, 16(20), p.6716. https://doi.org/10.3390/ma16206716

List of International Conferences

  • Ujjwal, K., Anand, M., Bishwakarma, H. and Das, A.K., 2023. Effect of clamping position on the residual stress in wire arc additive manufacturing. International Journal of Materials Research, 114(10-11), pp.872-878. https://doi.org/10.1515/ijmr-2022-0249
  • Anand, M., Bishwakarma, H., Kumar, N., Ujjwal, K. and Das, A.K., 2022. Fabrication of multilayer thin wall by WAAM technique and investigation of its microstructure and mechanical properties. Materials Today: Proceedings, 56, pp.927-930. https://doi.org/10.1016/j.matpr.2022.02.542
  • Chauhan, C., Ujjwal, K., Anand, M., and Das, A.K., 2025. Porosity control in 4043 aluminium alloy fabricated through wire arc additive manufacturing process, pp.257-264 https://doi.org/10.1007/978-981-96-1647-3_21

Book Chapter

  • Ujjwal, K., Kumar, R., Tyagi, R. and Das, A.K., 2024. Investigation on Tribology of Additively Manufactured Metal Part. In Tribological Aspects of Additive Manufacturing(pp. 11-38). CRC Press. https://doi.org/10.1201/9781003400523-2

List of Published Patents

  • Process of electric arc-based smoothening of wire arc additive manufactured (WAAM) components. Inventors Name: Kumar Ujjwal, Mukul Anand, Robin Singh, Alok Kumar Das. (Application No: 202431002351; Date of filing: 12/01/2024; Patent Status: Published)
  • A laser-based process for topography correction of Wire-Arc Additive Manufactured components. Inventors Name: Mukul Anand, Kumar Ujjwal, Alok Kumar Das (Application No: 202431067209; Date of filing: 05/09/2024; Patent Status: Published)

Research interests

  • Metal additive manufacturing (wire arc additive manufacturing, WAAM)
  • Welding and joining of materials
  • Laser processing of materials
  • Stress corrosion cracking of additively manufactured materials
  • Simulation and modelling of additive manufacturing processes