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Pavan Ajjarapu

Postdoctoral Research Associate

Pavan Ajjarapu is a postdoctoral research associate in the Metals and Composites Processing Group  of the Materials Science and Technology Division at Oak Ridge National Laboratory. He received his Ph.D. in Mechanical Engineering from the University of Louisville, M.S. in Materials Science and Engineering from the University of Cincinnati, and his B. Tech degree in Metallurgy and Materials Engineering from Visvesvaraya National Institute of Technology. His research focuses primarily on understanding and leveraging structure-property-processing correlations in large-scale metal parts fabricated via additive manufacturing and powder metallurgy.

  • Two time recipient of NSF student grant - Additive Manufacturing with Powder Metallurgy Conference (2022, 2023)
  • Two time recipient of Metal Injection Molding Association Graduate Student Conference grant (2021, 2022)
  • Winner of Soy Innovation Challenge - Kentucky Soybean Board (2022)
  • Southeast Regional winner - DoE Office of Technology Transitions' EnergyTech University Prize Competition (2023)
  • Ph.D. in Mechanical Engineering, University of Louisville, KY, USA
  • M.S. in Materials Science and Engineering, University of Cincinnati, OH, USA
  • B. Tech in Metallurgy and Materials Engineering, Visvesvaraya National Institute of Technology, MH, India

Optical Microscopy (OM), Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), Electron Backscatter Diffraction (EBSD), Differential Scanning Calorimetry (DSC), Thermogravimetric Analysis (TGA), Microhardness Testing, Helium Gas Pycnometry, Mechanical Testing (Tensile, Compression & 3-point bend testing)

Mapping 3D printed part density and filament flow characteristics in the material extrusion (MEX) process for filled and unfilled polymers
KPK Ajjarapu, R Mishra, R Malhotra, KH Kate
Virtual and Physical Prototyping 19 (1), e2331206

Development of Aluminum Feedstock for Additive Manufacturing
S Zhang, KPK Ajjarapu, A Blanchard, J Jones, S Atre, K Kate, F Ndiaye
Marshall Jamboree & Poster Expo

Advancements in 3D printing and hot isostatic pressing of copper: bridging the gap between green and sintered states for enhanced mechanical and electrical properties
KPK Ajjarapu, C Barber, J Taylor, T Pelletiers, D Jackson, C Beamer, S. Atre, K. Kate
Progress in Additive Manufacturing, 1-8

Synergistic strategies in sinter-based material extrusion (MEX) 3D printing of copper: process development, product design, predictive maps and models.
KPK Ajjarapu
University of Louisville

Mixed Matrix Thermoset Casting with Thermoplastic Fused Filament Fabrication 3D Printing
S Khanjar, P Tyagi, KPK Ajjarapu, K Kate
Physiology 38 (S1), 5733152

Characterization of industry grade soybean wax for potential applications in natural fiber reinforced composite (NFRC) filaments
AN Surendran, KPK Ajjarapu, AA Arumugham, K Kate, J Satyavolu
Industrial Crops and Products 186, 115163

Barocaloric Properties of Thermoplastic Elastomers
B Bhatia, N Weerasekera, KPK Ajjarapu, K Sudan, G Sumanasekera, K. Kunal
Frontiers in Energy Research, 573

Addressing Powder Morphology and Filament Properties for Extending PIM Feedstocks to Fabricate Green and Sintered Alumina Parts via Ceramic Fused Filament Fabrication (CF3 )
KPK Ajjarapu, K Sudan, P Singh, KH Kate
MPIF Additive Manufacturing with Powder Metallurgy Conference Proceedings

Sintering Behavior of Ni/TiC Cermet Scaffolds Fabricated via Particle-Based Ink Extrusion 3D Printing
KPK Ajjarapu
University of Cincinnati

Generative Design and Topology Optimization Based 3D Printing via Metal Fused Filament Fabrication (MF3)
S Khanjar, KPK Ajjarapu, C Barber, M Barr, M Zanon, SV Atre, KH Kate