Sunil Yadav

Contact

• workRoom B19 Centre for Additive Manufacturing
  Jubilee Campus
  Wollaton Road
  Nottingham
  NG8 1BB
  UK
• Sunil.Yadav@nottingham.ac.uk

Expertise Summary

Over the past seven years, I have gained hands-on experience and contributed to research in metal additive manufacturing, enhancing my credentials as follows:

• Processing and troubleshooting: Specializing in Laser Directed Energy Deposition (LDED) and Laser Powder Bed Fusion (LPBF) based metal AM.
• Material Expertise: Worked with various materials, including Cu, SS304L, SS316L, tool steel (D2), Ni-based super alloys (IN625, IN718, and Hastelloy-X), magnetic materials (Fe and Co-based), and high entropy alloys (Ni, Cr, and Co).
• Characterization Techniques: Proficient in metallography characterization, microstructural analysis, mechanical testing, magnetic property characterization, and corrosion behavior assessment.
• Software Skills: Experienced in Design for Additive Manufacturing (DfAM), SolidWorks, Cura, and Mastercam. self develop code on matlab for data driven-phase fielding modeling.
• Numerical Modeling: Proficient in numerical modeling using tools like MATLAB, COMSOL and ANSYS- fluent (thermal and fluid flow modeling).

Research Summary

Additive Manufacturing of Multi-Metallic Structures

Selected Publications

• S. YADAV, C.P. PAUL, A.K. RAI, R. SINGH and S.K. DIXIT, 2023. Elucidating laser directed energy deposition based additive manufacturing of copper-stainless steel functionally graded material: Processing and material behavior Journal of Manufacturing Processes. 92, 107-123
• YADAV, S, RAI, AK, KAUSAL, SS and PAUL, CP, 2025. A novel coupled model for microstructural evolution prediction during laser additive manufacturing: data driven and physics driven modelling Progress in Additive Manufacturing. 1-10
• S. YADAV, C.P. PAUL, S.S. KAUSAL, A.N. JINOOP, A.K. RAI and S.K. DIXIT, 2024. Identifying optimum process strategy to build geometrically stable cylindrical wall structures using laser directed energy deposition based additive manufacturing Vacuum. 222, 113073
• S. YADAV, C.P. PAUL, A.N. JINOOP, A.K. RAI and K.S. BINDRA, 2020. Laser Directed Energy Deposition based Additive Manufacturing of Copper: Process Development and Material Characterizations Journal of Manufacturing Processes. 58, 984-997

• View all publications

Past Research

Laser based multi-material additive manufacturing of copper-stainless steel and data driven phase field modeling (PhD thesis work)

• YADAV, S, RAI, AK, KAUSAL, SS and PAUL, CP, 2025. A novel coupled model for microstructural evolution prediction during laser additive manufacturing: data driven and physics driven modelling Progress in Additive Manufacturing. 1-10
• ARACKAL NARAYANAN, JINOOP, PAUL, CHRIST PRAKASH, KUMAR, J GANESH, YADAV, SUNIL and HUGHES, DAVID, 2025. Elucidating sequential laser remelting in tailoring microstructure and mechanical performance of laser-directed energy deposited Hastelloy-X The International Journal of Advanced Manufacturing Technology. 1-13
• YADAV, SUNIL, PAUL, C. P., RAI, A. K., JINOOP, A. N. and DIXIT, S. K., 2024. Effect of Interlayer Composition on the Properties of Laser-Directed-Energy-Deposition-Based Additively Manufactured Copper-Stainless Steel Wall Structures Sustainability. 16(2),
• S. YADAV, C.P. PAUL, S.S. KAUSAL, A.N. JINOOP, A.K. RAI and S.K. DIXIT, 2024. Identifying optimum process strategy to build geometrically stable cylindrical wall structures using laser directed energy deposition based additive manufacturing Vacuum. 222, 113073
• SUNIL YADAV, CHRIST PRAKASH PAUL, ARUN KUMAR RAI, ARACKAL NARAYANAN JINOOP, SAURABH SRIDHAR KAUSAL and SUDHIR KUMAR DIXIT, 2024. Assessing crack susceptibility in blended copper-stainless steel compositions during laser directed energy deposition-based additive manufacturing Science and Technology of Welding and Joining. 29(2), 134-142
• S. YADAV, C.P. PAUL, A.K. RAI, R. SINGH and S.K. DIXIT, 2023. Elucidating laser directed energy deposition based additive manufacturing of copper-stainless steel functionally graded material: Processing and material behavior Journal of Manufacturing Processes. 92, 107-123
• POONAM S. DESHMUKH, SUNIL YADAV, G. DAN SATHIARAJ and C.P. PAUL, 2023. Nano to macro-mechanical properties of laser directed energy deposited CoCrNi medium entropy alloy Materials Today Communications. 35, 106351
• YADAV, S, DILEEP, K, JINOOP, AN, PAUL, CP, RAI, AK, SINGH, R and BINDRA, KS, 2023. Laser directed energy deposition of high-carbon high-chromium D2 tool steel structures: processing, heat treatment and material behavior Journal of Materials Engineering and Performance. 32(11), 4881-4891
• S. YADAV, C.P. PAUL, A.N. JINOOP, A.K. RAI and K.S. BINDRA, 2020. Laser Directed Energy Deposition based Additive Manufacturing of Copper: Process Development and Material Characterizations Journal of Manufacturing Processes. 58, 984-997
• YADAV, S, JINOOP, AN, SINHA, N, PAUL, CP and BINDRA, KS, 2020. Parametric investigation and characterization of laser directed energy deposited copper-nickel graded layers The International Journal of Advanced Manufacturing Technology. 108, 3779-3791