Materials Science, Metals and Alloys, Mechanical Engineering
22
Scopus Publications
270
Scholar Citations
10
Scholar h-index
10
Scholar i10-index
Scopus Publications
Innovative SolidStir extrusion for energy-efficient metal recycling Anurag Gumaste, Ravi Sankar Haridas, Supreeth Gaddam, Kumar Kandasamy, Brandon A. McWilliams, Kyu C. Cho, Rajiv S. Mishra Materials and Design, 2026 • A sustainable solid-state recycling route, SolidStir Extrusion, is demonstrated. • Metallic chips are directly converted into dense, defect-free extrudates. • Refined microstructure in order of ∼5 µm achieved due to dynamic recrystallization. • Enhanced mechanical performance validates effective recycling. • Energy analysis shows a minimum of 19% energy saving over conventional methods. Metal recycling is essential for green manufacturing, yet conventional routes remain energy-intensive and complex. Reducing the carbon footprint of metal manufacturing requires the development of greener and more efficient recycling methods. This work introduces SolidStir® Extrusion (SSE), as an energy-efficient friction-stir-based process, for directly recycling AlSi10Mg waste into fully dense, defect-free rods. Microstructural analysis showed the extrudate is fully dense with fine, equiaxed grains (2.43 μm ± 1.5 μm) and uniformly distributed Si-rich particles, enhancing mechanical performance. The as-extruded material had a yield strength of 140 MPa and 26% ductility. Aging increased yield strength to 239 MPa and ultimate tensile strength to 346 MPa while retaining ductility of 19%. The energy efficiency and sustainability of SSE were assessed through analysis of process dynamics and mechanical work. Energy flow analysis indicated that SSE offers improved energy efficiency compared to conventional extrusion-based recycling approaches. This study demonstrates a solid-state pathway for metal reuse that enables direct conversion of aluminum waste into high-performance products, supporting circular manufacturing objectives.
Additive friction stir deposition of Fe-Cr-Ni transformative alloy Shreya Mukherjee, Anurag Gumaste, Priyanka Agrawal, Aishani Sharma, Abhijeet Dhal, Ravi Sankar Haridas, Rajiv S. Mishra Materials and Design, 2025 A comprehensive microstructure-oriented mechanical property investigation of Fe-Cr-Ni alloy manufactured via additive friction stir deposition (AFSD) was conducted. This study aims to design a comprehensive understanding of the spatial correlation between microstructure and mechanical properties as a function of the build height. Multiple reheating cycles that exist during the layer-by-layer deposition enabled microstructural variation from a single-phase BCC (bottom layer) to a dual-phase microstructure (top layer) consisting of a secondary FCC phase. The enhancement in work-hardening response in the top layer was driven from concurrent transformation-induced plasticity (TRIP) and deformation twinning mechanisms activated within the metastable austenite , yielding an excellent strength-ductility synergy. A mechanistic understanding of strain-hardening behavior was achieved using the dislocation-based Kocks-Mecking model. The primary constituent of the texture, specifically modified brass, resulted from the deformation-induced martensitic transformation. These insights provide a path for designing enhanced mechanical properties by tuning dual phase transformative microstructure.
Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing Amit Kumar Singh, Prithvi D. Awasthi, Ankita Roy, Priyanka Agrawal, Aishani Sharma, Anurag Gumaste, Ravi Sankar Haridas, Rajiv S. Mishra Additive Manufacturing Letters, 2025 • Laser powder bed fusion is enabled for printing hollow strut lattice of Al-Ni-Ti-Zr-Mn alloy. • Thin cross plates are introduced within the strut without causing blockages, enhancing structural strength. • Lattice achieves microstructurally reinforcement by L1 2 precipitates and heterogeneous grain distribution. • The yield strength is 67 MPa in compression with 28% lower density than Ti-6Al-4V. Additive manufacturing has opened a paradigm for the efficient and quick production of lightweight lattice structures showing characteristic high specific strength (strength-to-weight ratios). The current study describes the development of methodology and utilization of high strength Al alloy for building complex lattice using additive manufacturing. Thin plate lattice <1 mm of Al-Ni-Ti-Zr-Mn alloy with wide processing window, achieving an average yield strength of 63.13±3.32 MPa in compression, with 28% lower density than Ti-6Al-4V demonstrates a successful design of Al-Ni-Ti-Zr-Mn alloys using laser beam powder bed fusion (PBF-LB). The mitigation of cracks within thin plate parallel to the loading axis was achieved through the formation of Al-Al₃Ni eutectic channels, exploiting the rapid solidification of this short-freezing-range alloy. In addition to multi-topology structural design, the enhanced strength is attributed to hierarchical microstructure featuring L1₂ phases, bimodal grain distribution, and solid solution strengthening by Mn. This work establishes a printability-performance synergy of Al-Ni-Ti-Zr-Mn alloy for thin plate complex lattice, advancing the use of metamaterials through PBF-LB.
SS316/CCA laminated metal composite fabricated by additive friction stir deposition: Microstructure and mechanical properties Ravi Sankar Haridas, Anurag Gumaste, Eric Kusterer, Devin Davis, Supreeth Gaddam, Brandon McWilliams, Kyu C. Cho, Rajiv S. Mishra Journal of Materials Research and Technology, 2025 Laminated metal composites (LMCs) are a unique class of metallic composites that contain layers of different alloys that are alternately fabricated, and whose distinct interface characteristics enhance their properties. Conventionally, adhesive bonding, roll bonding or deposition methods are used to engineer the LMC for property optimization. For the first time, the present study investigated the potential of the novel solid-state additive friction stir deposition (AFSD) technique to additively manufacture an LMC containing SS316 and Fe 40 Co 20 Mn 20 Cr 15 Si 5 complex concentrated alloy (CS-CCA) exhibiting transformation induced plasticity (TRIP). The stability of SS316/HEA dissimilar interfaces in the LMC ensured displacement continuity and promoted synchronous deformation of both alloys under tension, which enabled mechanical property enhancement. The study revealed the unprecedented ability of CS-CCA layers in the LMC to sustain ∼50% more transverse strain than their monolithic counterparts. Additionally, the LMC exhibited better strength, work hardening, and failure strain compared to the corresponding weaker counterpart in the LMC. Better work hardening and strength achieved in the LMC were correlated with the unique deformation mechanisms such as TRIP and deformation twinning that prevailed in the TRIP-CCA during tensile deformation, as supported by detailed mechanical and microstructural characterization. The current study provides insights into considering AFSD as an alternate route to roll/press bonding for LMC fabrication of high-strength structural alloys.
Bioinspired Aluminum Composite Reinforced with Soft Polymers with Enhanced Strength and Plasticity Arpan Rout, Anurag Gumaste, Praful Pandey, Eliezer Fernando Oliveira, Solomon Demiss, Vaikkara Purushothaman Mahesh, Chintan Bhatt, Kiran Raphael, Ravi Sastri Ayyagari, Pedro A. S. Autreto, Mithun Palit, Femi Olu, Douglas S. Galvao, Amit Arora, Chandra Sekhar Tiwary Advanced Engineering Materials, 2020
Innovative SolidStir extrusion for energy-efficient metal recycling A Gumaste, RS Haridas, S Gaddam, K Kandasamy, BA McWilliams, ... Materials & Design 264, 115818 , 2026 2026 Citations: 1
Microstructural gradients in an Al-Mg-Ti-Zr alloy via tool offset-controlled SolidStir® extrusion A Sharma, SK Jha, A Gumaste, R Jain, RS Mishra Materials Letters, 139668 , 2025 2025 Citations: 1
Novel high specific-strength multi-topology Al-Ni-Ti-Zr-Mn alloy using laser powder bed fusion additive manufacturing AK Singh, PD Awasthi, A Roy, P Agrawal, A Sharma, A Gumaste, ... Additive Manufacturing Letters, 100308 , 2025 2025 Citations: 1
Additive friction stir deposition of Fe-Cr-Ni transformative alloy S Mukherjee, A Gumaste, P Agrawal, A Sharma, A Dhal, RS Haridas, ... Materials & Design 255, 114146 , 2025 2025 Citations: 5
SS316/CCA laminated metal composite fabricated by additive friction stir deposition: Microstructure and mechanical properties RS Haridas, A Gumaste, E Kusterer, D Davis, S Gaddam, B Mcwilliams, ... Journal of Materials Research and Technology 35, 2676-2692 , 2025 2025 Citations: 6
Solid State Upcycling of Aluminum Alloys RS Mishra, RS Haridas, A Gumaste REMADE Circular Economy Tech Summit & Conference , 2025 2025
Enhanced thermal stability in additive friction stir deposited ODS IN9052 Al alloy A Sharma, R Jain, P Agrawal, S Mukherjee, A Gumaste, DF Davis, ... Acta Materialia 279, 120284 , 2024 2024 Citations: 12
Excellent work hardening ability in a novel compositionally complex alloy by hierarchical microstructuring A Dutta, SK Gupta, A Gumaste, RS Haridas, S Suwas, RS Mishra, ... Applied Materials Today 39, 102300 , 2024 2024 Citations: 16
Wires using multi-hole SolidStir Extrusion A Gumaste, J Tiu, D Schwendemann, A Singh, E Alvarado, A Berumen, ... Manufacturing Letters 40, 174-178 , 2024 2024 Citations: 1
SolidStir technology: A novel solid-state integrated manufacturing process for structural fabrication RS Haridas, W Knight, J Tiu, J Summers, D Davis, E Cubit II, A Sekung, ... Manufacturing Letters 40, 154-158 , 2024 2024 Citations: 8
Synergistic enhancement of strength and ductility in novel solid-stir continuous extrusion: influence of heterogeneous microstructure and alloy chemistry A Sharma, A Dhal, A Gumaste, S Gaddam, RS Haridas, BA McWilliams, ... Materials Science and Engineering: A 901, 146534 , 2024 2024 Citations: 5
Strength-conductivity synergy via lean alloy design: A study on novel solid stir extrusion of an Al-2Cu-0.1 Nb-0.15 Zr (∼ wt.%) alloy A Sharma, A Gumaste, P Agrawal, S Thapliyal, S Gupta, RS Haridas, ... Journal of Alloys and Compounds 976, 173082 , 2024 2024 Citations: 9
Novel SolidStir extrusion technology for enhanced conductivity cable manufacturing via in-situ exfoliation of graphite to graphene A Sharma, RS Haridas, P Agrawal, A Gumaste, T Scharf, K Kandasamy, ... Materials & Design 238, 112643 , 2024 2024 Citations: 11
A Novel Approach for Enhanced Mechanical Properties in Solid-State Additive Manufacturing by Additive Friction Stir Deposition Using Thermally Stable Al-Ce-Mg Alloy: Gumaste … A Gumaste, A Dhal, P Agrawal, RS Haridas, VK Vasudevan, D Weiss, ... Jom 75 (10), 4185-4198 , 2023 2023 Citations: 33
SolidStir Additive Manufacturing: A Novel Deformation-Based Additive Manufacturing Using Friction Stir Technology: Haridas, Gumaste, Varshney, Manu, Kandasamy, Kumar, and Mishra RS Haridas, A Gumaste, P Varshney, BR Manu, K Kandasamy, N Kumar, ... JOM 75 (10), 4231-4241 , 2023 2023 Citations: 21
Solid Stir Extrusion: Innovating friction stir technology for continuous extrusion process A Gumaste, RS Haridas, S Gupta, S Gaddam, K Kandasamy, ... Journal of Materials Processing Technology 316, 117952 , 2023 2023 Citations: 34
Favorable property integration in high entropy alloys via dissimilar friction stir welding: A case study using Al0. 3CoCrFeNi and Fe38. 5Co20Mn20Cr15Si5Cu1. 5 HEAs RS Haridas, A Gumaste, P Agrawal, S Yadav, RS Mishra Materials Today Communications 35, 105822 , 2023 2023 Citations: 17
Submerged Bobbin Tool (SBT) Tunneling Technology DA Burford, M Manzo, H Siller, S Gaddam, A Gumaste, J Koonce III, ... TMS Annual Meeting & Exhibition, 249-267 , 2023 2023 Citations: 2
Work hardening in metastable high entropy alloys: a modified five-parameter model RS Haridas, P Agrawal, S Yadav, P Agrawal, A Gumaste, RS Mishra Journal of Materials Research and Technology 18, 3358-3372 , 2022 2022 Citations: 25
A Process for Preparation of a Polymer Reinforced Metal Matrix Composite A Arora, C S Tiwary, A Rout, A Gumaste, VP Mahesh IN Patent 389,338 , 2021 2021
MOST CITED SCHOLAR PUBLICATIONS
Solid Stir Extrusion: Innovating friction stir technology for continuous extrusion process A Gumaste, RS Haridas, S Gupta, S Gaddam, K Kandasamy, ... Journal of Materials Processing Technology 316, 117952 , 2023 2023 Citations: 34
Atomically locked interfaces of metal (Aluminum) and polymer (Polypropylene) using mechanical friction A Rout, P Pandey, EF Oliveira, PA da Silva Autreto, A Gumaste, A Singh, ... Polymer 169, 148-153 , 2019 2019 Citations: 34
A Novel Approach for Enhanced Mechanical Properties in Solid-State Additive Manufacturing by Additive Friction Stir Deposition Using Thermally Stable Al-Ce-Mg Alloy: Gumaste … A Gumaste, A Dhal, P Agrawal, RS Haridas, VK Vasudevan, D Weiss, ... Jom 75 (10), 4185-4198 , 2023 2023 Citations: 33
Work hardening in metastable high entropy alloys: a modified five-parameter model RS Haridas, P Agrawal, S Yadav, P Agrawal, A Gumaste, RS Mishra Journal of Materials Research and Technology 18, 3358-3372 , 2022 2022 Citations: 25
SolidStir Additive Manufacturing: A Novel Deformation-Based Additive Manufacturing Using Friction Stir Technology: Haridas, Gumaste, Varshney, Manu, Kandasamy, Kumar, and Mishra RS Haridas, A Gumaste, P Varshney, BR Manu, K Kandasamy, N Kumar, ... JOM 75 (10), 4231-4241 , 2023 2023 Citations: 21
Favorable property integration in high entropy alloys via dissimilar friction stir welding: A case study using Al0. 3CoCrFeNi and Fe38. 5Co20Mn20Cr15Si5Cu1. 5 HEAs RS Haridas, A Gumaste, P Agrawal, S Yadav, RS Mishra Materials Today Communications 35, 105822 , 2023 2023 Citations: 17
Excellent work hardening ability in a novel compositionally complex alloy by hierarchical microstructuring A Dutta, SK Gupta, A Gumaste, RS Haridas, S Suwas, RS Mishra, ... Applied Materials Today 39, 102300 , 2024 2024 Citations: 16
Corrosion behavior of aluminum surface composites with metallic, ceramic, and hybrid reinforcements using friction stir processing VP Mahesh, A Gumaste, N Meena, J Alphonsa, A Arora Metallurgical and Materials Transactions B 51 (5), 2131-2146 , 2020 2020 Citations: 14
Enhanced thermal stability in additive friction stir deposited ODS IN9052 Al alloy A Sharma, R Jain, P Agrawal, S Mukherjee, A Gumaste, DF Davis, ... Acta Materialia 279, 120284 , 2024 2024 Citations: 12
Novel SolidStir extrusion technology for enhanced conductivity cable manufacturing via in-situ exfoliation of graphite to graphene A Sharma, RS Haridas, P Agrawal, A Gumaste, T Scharf, K Kandasamy, ... Materials & Design 238, 112643 , 2024 2024 Citations: 11
Strength-conductivity synergy via lean alloy design: A study on novel solid stir extrusion of an Al-2Cu-0.1 Nb-0.15 Zr (∼ wt.%) alloy A Sharma, A Gumaste, P Agrawal, S Thapliyal, S Gupta, RS Haridas, ... Journal of Alloys and Compounds 976, 173082 , 2024 2024 Citations: 9
SolidStir technology: A novel solid-state integrated manufacturing process for structural fabrication RS Haridas, W Knight, J Tiu, J Summers, D Davis, E Cubit II, A Sekung, ... Manufacturing Letters 40, 154-158 , 2024 2024 Citations: 8
SS316/CCA laminated metal composite fabricated by additive friction stir deposition: Microstructure and mechanical properties RS Haridas, A Gumaste, E Kusterer, D Davis, S Gaddam, B Mcwilliams, ... Journal of Materials Research and Technology 35, 2676-2692 , 2025 2025 Citations: 6
Joining of Polymer Matrix Composites Through Friction Stir Processes VP Mahesh, S Patel, A Gumaste, A Arora Elsevier. Encyclopedia of Materials: Composites, https://doi.org/10.1016 … , 2021 2021 Citations: 6
Bioinspired aluminum composite reinforced with soft polymers with enhanced strength and plasticity A Rout, A Gumaste, P Pandey, EF Oliveira, S Demiss, VP Mahesh, ... Advanced Engineering Materials 22 (3), 1901116 , 2020 2020 Citations: 6
Additive friction stir deposition of Fe-Cr-Ni transformative alloy S Mukherjee, A Gumaste, P Agrawal, A Sharma, A Dhal, RS Haridas, ... Materials & Design 255, 114146 , 2025 2025 Citations: 5
Synergistic enhancement of strength and ductility in novel solid-stir continuous extrusion: influence of heterogeneous microstructure and alloy chemistry A Sharma, A Dhal, A Gumaste, S Gaddam, RS Haridas, BA McWilliams, ... Materials Science and Engineering: A 901, 146534 , 2024 2024 Citations: 5
Submerged Bobbin Tool (SBT) Tunneling Technology DA Burford, M Manzo, H Siller, S Gaddam, A Gumaste, J Koonce III, ... TMS Annual Meeting & Exhibition, 249-267 , 2023 2023 Citations: 2
Design And Development Of Step Climbing Wheelchair M Khot, A Gumaste, V Jagdale International Journal Of Advances In Production And Mechanical Engineering 2 (5) , 2016 2016 Citations: 2
Innovative SolidStir extrusion for energy-efficient metal recycling A Gumaste, RS Haridas, S Gaddam, K Kandasamy, BA McWilliams, ... Materials & Design 264, 115818 , 2026 2026 Citations: 1
