Jerold Samuel is currently working as Associate Professor in the Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Coimbatore, Tamilnadu, India. He has completed Bachelor of Engineering in Mechanical Engineering from Anna University, Chennai in the year 2008. He obtained Master of Engineering in Manufacturing Engineering from Anna University of Technology, Coimbatore in 2010. He has completed Ph.D in the area of metal matrix composites from Anna University, Chennai in 2018. He has published many technical papers in SCI and Scopus indexed journals. He has authored and Edited books published by reputed Publishers. He has received best faculty, best research grants and best research paper awards for his outstanding contribution in teaching and research. Furthermore, he has presented many technical seminars, key note lectures to the faculty members and researchers of engineering institutions. Currently 7 scholars are pursuing part time Ph.
EDUCATION
Jerold Samuel is currently working as Associate Professor in the Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Coimbatore, Tamilnadu, India. He has completed Bachelor of Engineering in Mechanical Engineering from Anna University, Chennai in the year 2008. He obtained Master of Engineering in Manufacturing Engineering from Anna University of Technology, Coimbatore in 2010. He has completed Ph.D in the area of metal matrix composites from Anna University, Chennai in 2018.
RESEARCH, TEACHING, or OTHER INTERESTS
Mechanical Engineering, Mechanics of Materials, Automotive Engineering, Industrial and Manufacturing Engineering
59
Scopus Publications
1953
Scholar Citations
25
Scholar h-index
34
Scholar i10-index
Scopus Publications
Enhancement of mechanical properties in LM13 aluminum alloy using hybrid ZrB2 and B4C reinforcements via stir casting Aravindkumar N, Samson Jerold Samuel Chelladurai Particulate Science and Technology, 2026 In the present study, the mechanical behavior of LM13 aluminum alloy-based hybrid composites reinforced with zirconium diboride and boron carbide particles synthesized by the stir casting process was investigated. The objective was to tailor the mechanical properties of the alloy by changing the total amount of reinforcement up to 10 wt.%. Five different compositions were produced, including unreinforced LM13 and the hybrids with a gradually increasing level of the reinforcements, which were afterwards tested by hardness, tensile, and impact testing, as well as microstructural characterization. With ceramic reinforcements, strength and hardness increased significantly. Hardness increased from 72 Hv to 97 Hv, ultimate tensile strength 19.2%, and yield strength 24.3%. Due to homogeneous reinforcement distribution and excellent interfacial bonding, as revealed by microstructural analysis, enhanced grain refinement, load transfer, and Orowan strengthening resulted in improved properties. On the other hand, a decline in the ductility and impact resistance was noticed: elongation dropped from 5.7% to 4.0%, and impact strength decreased by 29.9% in a typical strength-toughness tradeoff of composites. The uniform distribution of reinforcements and low porosity with a maximum value of 5.55% percentage identified in the microstructural evaluations corroborated the reliability of the stir casting process.
Study on the mechanical behaviour of LM24 alloy reinforced with ZrB2 and fly ash hybrid composites using stir casting technique S. Sivananthan, Samson Jerold Samuel Chelladurai Canadian Metallurgical Quarterly, 2026 The objective of the present investigation is to develop zirconium diboride (ZrB2) and fly ash-reinforced LM24 aluminium alloy-based hybrid composites through the stir casting process. The study was conducted with different weight percentages of ZrB2 (2.5, 5, and 7.5 wt%) with the fixed fly ash content of 2.5 wt%. The microscope analysis showed a fine dispersion of fly ash as well as ZrB2 particles in the aluminium matrix. It was assessed that the incorporation of reinforcements led to an enhancement of hardness up to the maximum value of 127 BHN for the hybrid composite containing a total of 10 wt% reinforcements, which is 38% higher than that of the unreinforced LM24 alloy. The ultimate tensile strength also increased, and it was found to be enhanced by upto 12.2% more than the matrix alloy. Nevertheless, these improvements were obtained at a rather significant decrease in ductility of the composites, with the LM24 alloy remaining ductile as a counterpart. Furthermore, lower impact strength was observed for the hybrid composites; a fractographic study revealed that the failure was due to brittle fracture. The hybrid composite with 10 wt% reinforcement exhibited the lowest impact energy absorption of 1.6 J, which is 36% lower than the LM24 alloy.
Optimization of wire electrical discharge machining process parameters of LM24 al alloy - TiB2 - fly ash reinforced hybrid composites Samson Jerold Samuel Chelladurai, K. Jagadeeswaran, S. Sivananthan, S. M. Vinu Kumar, B. Harshavardhan, A. Anand, B. Suresha Discover Materials, 2025 To optimize the Wire Electrical Discharge Machining (WEDM) process for machining a hybrid composite (7.5wt% TiB 2 and 2.5wt% fly ash), Response Surface Methodology (RSM) and desirability function were applied for multi-objective optimization of WEDM parameters, aiming to maximize Material Removal Rate (MRR) and minimize Surface Roughness (Ra). The results were validated through confirmation tests. The stir-cast hybrid composite’s increased hardness and strength were attributed to its fine, round, and evenly distributed microstructures. SEM and EDS studies confirmed the even distribution and strong bonding of fly ash and TiB 2 within the LM24 alloy matrix. Pulse duration was identified as the most significant factor. The study successfully optimized the two conflicting goals, MRR and Ra, simultaneously. The best set of parameters identified by the desirability function was: pulse duration (P) = 110.36 µs, inter-pulse time (I) = 40.0001 µs, cutting speed (C) = 1.19995 mm/min, and servo control voltage (S) = 54.9995 volts. This combination yielded a desirability score of 0.942, indicating a good compromise between material removal rate and surface quality. Confirmation tests showed minimal associated errors in MRR (2.57%) and Ra (0.31%). SEM analysis of the machined surface revealed uniformly distributed discharge craters, further confirming the success of the optimization method. This study also compared the Desirability function and Grey Relational Analysis (GRA) for optimizing WEDM of the hybrid composite. The comparison revealed distinct optimal parameter sets from each method, reflecting an inherent trade-off: the Desirability Function favored a higher MRR, while GRA prioritized a lower Ra. These insights are crucial for guiding parameter selection based on application-specific needs, whether for maximizing productivity or achieving superior surface quality.
Unlocking the potential of WEDM for LM26 hybrid composites: multi-objective optimization using RSM and desirability approach Vijayan S N, Samson Jerold Samuel Chelladurai, Saiyathibrahim A Physica Scripta, 2025 Aluminium-based hybrid composites have tremendous potential on account of their enhanced structural and functional characteristics in technological applications, including aerospace, automotive, defence, and thermally sensitive sectors. However, the addition of hard ceramic reinforcements makes these materials tougher, requiring sophisticated machining processes for cutting. This study explores the machinability of LM26 alloy-based hybrid composites strengthened with 10 wt% ZrB2 and 5 wt% CCSF during wire electrical discharge machining. The microstructure analysis revealed that the CCSF and ZrB2 particles were distributed uniformly in the LM26 hybrid composite along with the low porosity level. XRD analysis revealed the nonappearance of intermetallic compounds and confirmed the presence of elements such as Al, Si, Fe, Zr, and Cu phases, which enhanced the matrix bonding, increased resistance to crack formation, and enabled efficient load transfer. This study focuses on improving the surface finishing and material removal rate by analyzing a consequence of machining parameters by using response surface methodology with a central composite design. The outcome of the characterization substantiates the evenly dispersed reinforcing particles in the matrix and improved mechanical characteristics. The developed RSM model demonstrates the highest accuracy, with R2 values of 0.9756 for MRR and 0.9674 for Ra. Parameter settings of 8.81 μs (Toff), 12.9386 μs (Ton), and 4.70873 Amp (I) are identified as the best in the present study, generating an MRR of 0.627 g min−1 and Ra of 16.1197 μm with 0.915 composite desirability. These findings suggest the suitability of these composites for high-temperature automotive applications such as pistons, piston rings, and internal combustion engine parts.
Evaluation of mechanical and wear properties of LM24/fly ash/titanium diboride hybrid metal matrix composites using stir casting Jagadeeswaran K., Samson Jerold Samuel Chelladurai Particulate Science and Technology, 2025 This study focuses on the development of novel hybrid composites based on the LM24 alloy, utilizing liquid metallurgy stir casting to incorporate dual reinforcements (titanium diboride (TiB2) and fly ash (FA)). The weight percentage of TiB2 was maintained at levels of 2.5%, 5%, and 7.5%, keeping the FA at 2.5% during the course of fabrication. The introduction of 7.5 wt% TiB2 and 2.5 wt% FA displayed a very notable 43.18% increase in hardness and a 21.53% increase in tensile strength of the hybrid composite compared to the LM24 alloy. Furthermore, hybrid composites with a total reinforcement of 10 wt% exhibited superior wear resistance across the entire range of applied loads. Tensile fractography revealed ductile fracture mode for the LM24 alloy, while hybrid composites displayed a mixed-mode fracture. High-load-induced abrasive wear with little plastic deformation was seen on worn surfaces of hybrid composites, whereas adhesive wear was the dominant type of wear in the LM24 alloy. The results show that hybrid composites have better mechanical and tribological properties because the reinforcement particles are well distributed and the load is transmitted optimally. However, it is noted that increased reinforcement levels lead to a reduction in ductility, resulting in decreased impact resistance for the hybrid composites.
Electrochemical performance enhancement of yttrium-modified Mg–Zn–Ca alloy with plasma electrolytic oxidation coating N. Rakesh, S. Marimuthu, S. Manivannan, Samson Jerold Samuel Chelladurai Canadian Metallurgical Quarterly, 2025 The elevated chemical reactivity of magnesium alloys considerably restricts their utilisation in biological and structural domains, especially in corrosive environments. Plasma Electrolytic Oxidation (PEO) is commonly used to augment corrosion resistance, but additional improvements are needed for long-term durability. This study explores the effect of yttrium (0.5 wt-%) addition on the microstructural and electrochemical behaviour of PEO-coated Mg–3Zn–0.5Ca alloy. Microstructural study demonstrated that the incorporation of yttrium resulted in grain refinement and a more homogeneous distribution of intermetallic phases. X-ray diffraction confirmed the formation of MgO in both coatings, with the Y-modified alloy additionally exhibiting stable Y2O3 phases. Potentiodynamic polarisation measurements showed a substantial nine-fold reduction in corrosion current density – from 1.34 × 10−9 A cm–2 for the unmodified alloy to 1.45 × 10−10 A cm–2 for the Y-modified alloy – alongside a significantly reduced corrosion rate (0.000127 vs. 0.001176 mpy).
Synergistic Effect of B4C and TiB2 Reinforcements on the Microstructure, Mechanical and Wear Properties of AA336 Aluminium Hybrid Composites AJ Rakesh, SJS Chelladurai, A Saiyathibrahim, SN Vijayan International Journal of Metalcasting, 1-29 , 2026 2026
Microstructure, Mechanical, Wear and Corrosion Properties of Heat-Treated Mg-3Zn-0.5 Ca-0.5 Y Alloy for Biomedical Applications N Rakesh, S Marimuthu, SJS Chelladurai International Journal of Metalcasting, 1-24 , 2026 2026
Enhancement of mechanical properties in LM13 aluminum alloy using hybrid ZrB2 and B4C reinforcements via stir casting SJS Chelladurai Particulate Science and Technology 44 (1), 156-175 , 2026 2026
Study on the mechanical behaviour of LM24 alloy reinforced with ZrB 2 and fly ash hybrid composites using stir casting technique S Sivananthan, SJS Chelladurai Canadian Metallurgical Quarterly 65 (1), 218-236 , 2026 2026 Citations: 4
Optimization of wire electrical discharge machining process parameters of LM24 al alloy - TiB 2 - fly ash reinforced hybrid composites SJS Chelladurai, K Jagadeeswaran, S Sivananthan, SM Vinu Kumar, ... Discover Materials 5 (1), 202 , 2025 2025 Citations: 2
Electrochemical performance enhancement of yttrium-modified Mg–Zn–Ca alloy with plasma electrolytic oxidation coating N Rakesh, S Marimuthu, S Manivannan, SJS Chelladurai Canadian Metallurgical Quarterly, 1-19 , 2025 2025
Investigating the effect and optimization of WEDM parameters on LM26 aluminium alloy hybrid composites: an response surface methodology based desirability approach V SN, SJS Chelladurai, S A Silicon 17 (13), 3125-3155 , 2025 2025 Citations: 9
Unlocking the potential of WEDM for LM26 hybrid composites: multi-objective optimization using RSM and desirability approach V SN, SJS Chelladurai, S A Physica Scripta 100 (5), 055019 , 2025 2025 Citations: 8
Evaluation of mechanical and wear properties of LM24/fly ash/titanium diboride hybrid metal matrix composites using stir casting K Jagadeeswaran, SJS Chelladurai Part Sci Technol 43, 338-56 , 2025 2025 Citations: 3
Analysing Mechanical Behaviour of LM26/ZrB2 Composite Using Finite Element Modelling (FEM) VS Nagammal, SJS Chelladurai, SA Pari, JAK Sundarabai, M Mani, ... Manufacturing Strategies and Systems, 31-43 , 2025 2025 Citations: 1
Optimization of wire electrical discharge machining process parameters of LM24 al alloy-TiB SJS Chelladurai, K Jagadeeswaran, S Sivananthan, SMV Kumar, ... 2025
Investigation on Mechanical Behavior of LM26 Aluminum Alloy—ZrB 2 and Copper-Coated Short Steel Fiber-Reinforced Composites Using Stir Casting Process SN Vijayan, SJS Chelladurai, A Saiyathibrahim International Journal of Metalcasting 19 (1), 213-226 , 2025 2025 Citations: 28
MACHINABILITY STUDIES OF LM24 ALUMINUM ALLOY–ZrB 2 –FLY ASH REINFORCED HYBRID COMPOSITES USING RESPONSE SURFACE METHODOLOGY S Sivananthan, SJS Chelladurai Surface Review and Letters, 2550075 , 2024 2024
Static analysis of aluminum alloy ingot/zirconium diboride composites for automotive applications SN Vijayan, SJS Chelladurai, A Saiyathibrahim, AJ Infant Jegan Rakesh, ... SAE International Journal of Materials and Manufacturing 18 (1), 93-108 , 2024 2024 Citations: 11
Prediction of received signal strength using the fuzzy Logic controller for localisation of Sensors in Mobile robots. SS Kumaran, SJS Chelladurai, KBB Narayanan, TA Selvan Int. J. Robotics Autom. 39 (4), 302-311 , 2024 2024
Opportunities for the Internet of Things in Automotives RB Manoram, A Sathishkumar, T Devaarjun, SJS Chelladurai, TA Selvan Internet of Things, 85-99 , 2023 2023 Citations: 1
Recent developments in nanofibers research M Khan, SJS Chelladurai 2023 Citations: 20
Research Article Study on the Behavior of Self-Cleaning Impregnated Photocatalyst (Tio2) with Cement Mortar C Palanisamy, G Parvathikumar, S Gnanasekaran, SJS Chelladurai, ... 2023
Research Article Effect of Defocusing Distance on Microstructural, Hardness, and Tribological Behavior of Ni-Cr-Si-BC Powder Deposit on 316LN Austenitic Stainless Steel … S Gnanasekaran, G Padmanaban, SJS Chelladurai, S Tibebu 2023
Study on the Behavior of Self‐Cleaning Impregnated Photocatalyst (Tio 2 ) with Cement Mortar C Palanisamy, G Parvathikumar, S Gnanasekaran, SJS Chelladurai, ... Advances in Materials Science and Engineering 2023 (1), 3571526 , 2023 2023 Citations: 7
MOST CITED SCHOLAR PUBLICATIONS
Optimization of process parameters using response surface methodology: A review SJS Chelladurai, K Murugan, AP Ray, M Upadhyaya, V Narasimharaj, ... Materials Today: Proceedings 37, 1301-1304 , 2021 2021.0 Citations: 465
Investigation on mechanical properties of aluminium 7075-boron carbide-coconut shell fly ash reinforced hybrid metal matrix composites B Subramaniam, B Natarajan, B Kaliyaperumal, SJS Chelladurai China Foundry 15 (6), 449-456 , 2018 2018.0 Citations: 148
Effect of SiC particles reinforcement on mechanical properties of aluminium 6061 alloy processed using stir casting route S Sivananthan, K Ravi, CSJ Samuel Materials Today: Proceedings 21, 968-970 , 2020 2020.0 Citations: 102
A review on mechanical properties and wear behaviour of aluminium based metal matrix composites SG Samson Jerold Samuel Chelladurai, S. SenthilKumar, Narasimharaj Venugopal ... Materials Today Proceedings , 2020 2020.0 Citations: 76
Investigation of mechanical properties and dry sliding wear behaviour of squeeze cast LM6 aluminium alloy reinforced with copper coated short steel fibers SJS Chelladurai, R Arthanari, N Nithyanandam, K Rajendran, ... Transactions of the Indian Institute of Metals 71 (4), 813-822 , 2018 2018.0 Citations: 72
Dry sliding wear characterization of squeeze cast LM13/FeCu composite using response surface methodology SJS Chelladurai, R Arthanari, AN Thangaraj, H Sekar China Foundry 14 (6), 525-533 , 2017 2017.0 Citations: 65
Investigation on microstructure and tensile behaviour of stir cast LM13 aluminium alloy reinforced with copper coated short steel fibers using response surface methodology SJS Chelladurai, R Arthanari, R Selvarajan, R Kanagaraj, P Angappan Transactions of the Indian Institute of Metals 71 (9), 2221-2230 , 2018 2018.0 Citations: 64
Effect of copper coating and reinforcement orientation on mechanical properties of LM6 aluminium alloy composites reinforced with steel mesh by squeeze casting SJS Chelladurai, R Arthanari, K Krishnamoorthy, KS Selvaraj, P Govindan Transactions of the Indian Institute of Metals 71 (5), 1041-1048 , 2018 2018.0 Citations: 62
Effect of stir cast process parameters on wear behaviour of copper coated short steel fibers reinforced LM13 aluminium alloy composites RA Samson Jerold Samuel Chelladurai Materials Research Express , 2018 2018.0 Citations: 62
A study on microstructural effect and mechanical behaviour of Al6061–5%SiC–TiB 2 particulates reinforced hybrid metal matrix composites JJM Hillary, R Ramamoorthi, JDJ Joseph, CSJ Samuel Journal of Composite Materials 54 (17), 2327-2337 , 2020 2020.0 Citations: 52
Investigation on mechanical and wear properties of zinc-coated steel wires reinforced LM6 aluminium alloy composites by squeeze casting SJS Chelladurai, R Arthanari Surface Review and Letters 26 (01), 1850125 , 2019 2019.0 Citations: 51
Optimisation of Dry Sliding Wear Parameters of Squeeze Cast AA336 Aluminium Alloy: Copper-Coated Steel Wire-Reinforced Composites by Response Surface Methodology SRCP Samson Jerold Samuel Chelladurai, Ramesh Arthanari, Rohith Selvarajan ... International Journal of Metalcasting, 1-13 , 2018 2018.0 Citations: 46
Preparation and evaluation of mechanical properties of 6061Al-Al2O3 metal matrix composites by stir casting process S Sivananthan, VR Reddy, CSJ Samuel Materials Today: Proceedings 21, 713-716 , 2020 2020.0 Citations: 41
Wear behaviour of aluminium 7075—boron carbide- coconut shell fly ash reinforced hybrid metal matrix composites BKSJSC Balasubramani Subramaniam, Balaji Natarajan Materials Research Express 6 (10) , 2019 2019.0 Citations: 41
Investigation on mechanical properties and wear behaviour of squeeze cast LM13 aluminium alloy reinforced with copper coated steel wires SJS Chelladurai, R Arthanari, R Selvarajan, S Athanarsamy, S Arumugam, ... Zeitschrift für Physikalische Chemie 232 (12), 1787-1806 , 2018 2018.0 Citations: 39
Investigation on mechanical properties and tribological behaviour of stir cast LM13 aluminium alloy based particulate hybrid composites SJ Samuel C Materialwissenschaft und Werkstofftechnik 50 (7), 864-874 , 0 Citations: 38
Prediction of hardness of stir cast LM13 aluminum alloy‐copper coated short steel fiber reinforced composites using response surface methodology SJS Chelladurai, R Arthanari Materialwissenschaft und Werkstofftechnik 51 (2), 221-229 , 2020 2020.0 Citations: 37
INVESTIGATION OF THE MECHANICAL PROPERTIES OF A SQUEEZE-CAST LM6 ALUMINIUM ALLOY REINFORCED WITH A ZINC-COATED STEEL-WIRE MESH PG Samson Jerold Samuel Chelladurai, Ramesh Arthanari, Kirubaharan ... Materiali in tehnologije 52 (2), 125-131 , 2018 2018.0 Citations: 37
Recent developments in stimuli responsive smart materials and applications: An overview T Ramakrishnan, SS Kumar, SJS Chelladurai, S Gnanasekaran, ... Journal of Nanomaterials 2022 (1), 4031059 , 2022 2022.0 Citations: 31
Effect of laser power on microstructure and tensile properties of pulsed Nd: YAG laser beam welded AISI 301 austenitic stainless steel joints S Gnanasekaran, SS Kumar, N Venugopal, M Upadhyaya, TC Manjunath, ... Materials Today: Proceedings 37, 934-939 , 2021 2021.0 Citations: 31