Hossein Rajaei
Department Of Industrial Engineering University Of Trento Via Sommarive 9, 38123 Trento,
Summary
With a robust background at the University of Trento, I excel in materials characterization and experimental design, showcasing achievements in additive manufacturing and surface engineering. My collaborative spirit and SEM expertise have driven process innovations, significantly enhancing material performance and sustainability in industrial applications.
Overview
11
11
years of professional experience
1
1
Certification
Work History
Postdoctoral research Fellowship
University of Trento
Trento
03.2024 - Current
- Conducted advanced research on additive manufacturing of Inconel alloys, focusing on characterizing conventionally produced and recycled Inconel powder
- Performed porosity analysis using ImageJ to determine pore size distribution and surface proximity
- Investigated mechanical properties and microstructural behavior of L-PBF Inconel 718 samples under tensile and fatigue testing conditions
- Conducted in-depth material characterization and mechanical testing to enhance product quality, contributing to process optimization
- Collaborated with multidisciplinary teams to address challenges in additive manufacturing and sustainable material use
- Developed and implemented novel workflows for comparing virgin and recycled Inconel 718 powders in terms of flowability, particle size distribution, and contamination
- Prepared technical reports, publications, and presentations to communicate research outcomes effectively
Postdoctoral Research Fellowship
University of Trento
Trento
07.2023 - 02.2024
- Conducted comprehensive material characterization and quality assessment of diamond cutting tools and metallic brake pads manufactured through the FAST (Field-Assisted Sintering Technology) process
- Investigated densification behaviors of the processed tools, identifying factors influencing porosity levels and mechanical performance through microstructural and phase analysis
- Utilized advanced techniques, including XRD, SEM, and optical microscopy, to evaluate crystallographic properties, phase distribution, and microstructural evolution in FAST-sintered products
- Applied MAUD software for in-depth phase identification and quantitative texture analysis, ensuring accurate interpretation of XRD results
- Evaluated the performance of FAST-produced diamond-cutting tools in industrial settings by conducting wear testing and assessing cutting efficiency in field trials
- Analyzed thermal stability and mechanical properties of the brake pads to meet rigorous demands for high-speed and high-temperature racing conditions
- Compared FAST-processed samples with conventionally produced counterparts, highlighting improvements in energy efficiency, flexibility, and production quality
- Conducted hardness, bending strength, and toughness testing to determine the reliability and durability of the sintered materials under operational stresses
- Explored the role of binder phases and additives in enhancing the sintering kinetics and bonding strength of the diamond-cutting tools
- Investigated solid solution and intermetallic phase formation in the sintered materials, linking processing conditions to phase transformations and material properties
- Prepared detailed technical reports and presentations for project stakeholders, showcasing the benefits of the developed FAST processing technology
- Actively collaborated with a multidisciplinary team of researchers and industry partners to refine and scale up the FAST process for commercial applications
Graduate Research Assistant
University of Trento
Trento
11.2019 - 07.2023
- Refurbished worn-out brake discs by applying Fe-based and Fe₃Al coatings using the Directed Energy Deposition (DED) process
- Developed and optimized Fe-based coatings to enhance the tribological properties of brake discs, achieving significant reductions in friction coefficient and particulate emissions during braking
- Investigated the process-structure-property relationships by conducting a detailed characterization of the coatings, linking microstructure and phase formation to tribological performance
- Utilized advanced analytical techniques, including SEM, XRD, profilometry, and optical microscopy, to evaluate coating morphology, phase composition, and surface roughness
- Performed wear and friction coefficient testing under simulated operational conditions to quantify the tribological improvements achieved through the coatings
- Addressed key challenges in DED, including thermal stress management, dilution control, and defect mitigation, to ensure high-quality coatings with minimal porosity and cracking
- Collaborated with a multidisciplinary team to refine coating formulations and tailor the process parameters for improved adhesion and performance
- Conducted life cycle assessments of coated brake discs to evaluate their environmental impact, focusing on the reduction of wear particle emissions
- Presented research findings at international conferences and published results in peer-reviewed journals, contributing to the academic and industrial understanding of brake disc refurbishing
- Contributed to a successful funding proposal for an aspect of the Ph.D Project, securing support from VRT Fondazione
Graduate Research Assistant
Materials and Energy Research Center
Karaj
09.2018 - 09.2019
- Focused on the development of Yttria-Stabilized Zirconia (YSZ) materials for TBC using advanced mechanical milling techniques
- Optimized heat treatment conditions to maximize material stability, significantly enhancing performance and cost-effectiveness in the production process
Graduate Research Assistant
Materials and Energy Research Center
Karaj
01.2016 - 08.2018
- Conducted the synthesis and sintering of composites using spark plasma sintering and microwave sintering techniques
- Explored the correlation between the microstructure and mechanical properties of the synthesized composites
Graduate Research Assistant
Materials and Energy Research Center
Karaj
11.2013 - 01.2016
- Synthesized and sintered refractory materials (mullite matrix composites) using both direct reaction and sol-gel processes
- Investigated the mechanical and tribological properties of the sintered samples, establishing a correlation between the characteristics of the starting materials, including particle size and purity, and the properties of the final products
- Developed expertise in the Spark Plasma Sintering (SPS) process, examining material behavior under various sintering conditions to optimize the production of high-performance composites
Education
Ph.D. - Materials, Mechatronics and Systems Engineering
University of Trento
Trento, Italy07.2023
Masters - Materials Science and Engineering
Materials and Energy Research Center (MERC)
Karaj, Iran01.2016
Bachelors - Materials Science and Engineering
University of Shahrekord (SKU)
Shahrekord, Iran09.2013
Skills
- Laboratory techniques
- Experimental design
- Research methodologies
- Thermo-Calc Application Skills
- Materials Characterization Proficiency (MAUD and X'Pert High Score)
- Expertise in Ansys Workbench
- Experienced with ImageJ Software
- Python
- Experienced in mechanical testing (Tensile, Fatigue, Micron Hardness, Toughness)
- Scanning Electron Microscopy (SEM) Expertise
- Tribological Testing Expertise (Pin on Disc and Emissions)
Research Interest
- Materials characterization, Additive manufacturing, DED, Coating, Tribology, Brake disc coating, Surface engineering, Composites, Cermet, Spark plasma sintering (SPS)
Collaborations
- Trentino Sviluppo S.p.A, Italy
- Tecnalia Research and Innovation, Spain
- Dellas S.p.A
- Brembo S.p.A, Italy
- University of Pisa
Conferences
- 2022-05, Dresden, Germany, EuroBrake 2022 conference, Poster Presentation
- 2023-03, Lisbon, Portugal, Tribology International 2023 Conference, Oral Presentation
- 2024-09, Napoli, Italy, AIAS 2024 conference
- 2024-10, Malmo, Sweden, Euro PM 2024 conference
Certification
- ECOPADS winter school, from linear to circular thinking, Trento, Italy, 2019
- Electric and magnetic field-assisted processing of inorganic materials, summer school, Jülich, 2020
- Electron microscopy theory and sample preparation (SEM-TEM), Trento, 2020
- Trends in additive manufacturing for engineering applications, winter school, Czech Republic, 2022
- Surface engineering of metals, Metallurgy summer school, Bertinoro, Italy, 2022
- Friction and wear of materials, Trento, 2022
Affiliations
- 2019, University of Trento DII Engineering Doctoral Fellowship
- 2017, Materials and Energy Research Center MERC Incubator Center Grant
- 2015, IRAN Nanotechnology Innovation Council Grant
- 2021, 8. Impact Innovation 2021, Successful funding proposal for the Ph.D. project
Creative work
- IR Patent 2016: Manufacturing of Mullite-WC Nanocomposite by Spark Plasma Sintering, H. Rajaei, I. Mobasherpour, M. Farvizi, M. Zakeri, International Classification: B82Y 30/00; C04B 35/185; C04B 35/71. IR application No. 90430.
Conference Organizing
- Executive member, the 10 Biennial Congress of the Iranian Ceramic Society and the First International Conference on Advanced Ceramics, Karaj, Iran, May 2015
Publications
- A TCD–based statistical method to assess the impact of surface roughness and pores on the fatigue strength of LPBF Inconel 718 specimens
L. Romanelli, C. Santus, G. Macoretta, M. Barsanti, BD. Monelli, I. Senegaglia, H. Rajaei
International Journal of Fatigue, 108821 (2025) - Comparative Study of FAST and Conventional Sintering of Cutting Tool Material
H. Rajaei, A. Molinari, I. Agote, M.A. Lagos, D. Ferrari, M. Dai Pré
Presented at EPMA Conference, 2025 - Microstructure and Wear Resistance of Fe3Al Coating on Grey Cast Iron Prepared via Direct Energy Deposition
H. Rajaei, S. Amirabdollahian, C. Menapace, G. Straffelini, S. Gialanella
Lubricants 11 (11), 477 (2023) - Effect of WC Addition on the Wear Resistance of Mullite-WC Composites Sintered by Spark Plasma Sintering
H. Rajaei, M. Bahamirian, I. Mobasherpour, M. Zakeri, M. Farvizi
Journal of Advanced Materials and Technologies 12 (1), 57-69 (2023) - Characterization, wear and emission properties of MnS containing laser cladded brake disc
H. Rajaei, C. Menapace, G. Straffelini, S. Gialanella
Wear 504, 204405 (2022) - Microstructural and tribological evaluation of brake disc refurbishing using Fe-based coating via directed energy deposition
H. Rajaei, C. Menapace, S. Amirabdollahian, M. Perini, G. Straffelini
Metals 12 (3), 465 (2022) - Microstructure and mechanical properties of YSZ-alumina composites designed for thermal barrier coatings
A.H. Pakseresht, S.M. Mousavi, M. Saremi, E. Ghasali, H. Rajaei
Materials at High Temperatures 38 (1), 23-30 (2021) - Investigation on the recyclability potential of vehicular brake pads
H. Rajaei, M. Griso, C. Menapace, A. Dorigato, G. Perricone, S. Gialanella
Results in Materials 8, 100161 (2020) - Comparative studies on corrosion and tribological performance of multilayer hard coatings grown on WC-Co hardmetals
M.R. Derakhshandeh, M.J. Eshraghi, A. Jam, H. Rajaei, A. Fazili
International Journal of Refractory Metals and Hard Materials 92, 105339 (2020) - Microwave and spark plasma sintering of carbon nanotube and graphene reinforced aluminum matrix composite
E. Ghasali, P. Sangpour, A. Jam, H. Rajaei, K. Shirvanimoghaddam
Archives of Civil and Mechanical Engineering 18, 1042-1054 (2018) - Preparation of mullite/B4C composites: a comparative study on the effect of heating methods
E.K. Saeidabadi, A. Fazili, H. Rajaei, A. Jam, H. Kazemzadeh, T. Ebadzadeh
Ceramics International 44 (15), 18743-18751 (2018) - Comparison of spark plasma and microwave sintering of mullite-based composite: mullite/Ta2O5 reaction
S.M.R. Derakhshandeh, M.S. Gohari, E.K. Saeidabadi, A. Jam, A. Fazili, H. Rajaei
Ceramics International 44 (11), 13176-13181 (2018) - Effect of spark plasma sintering temperature on microstructure and mechanical properties of mullite-WC composites
H. Rajaei, M. Farvizi, I. Mobasherpour, M. Zakeri
International Journal of Refractory Metals and Hard Materials 70, 197-201 (2018) - Effect of Al and Mo addition on phase formation, mechanical and microstructure properties of spark plasma sintered iron alloy
E. Ghasali, Y. Palizdar, A. Jam, H. Rajaei, T. Ebadzadeh
Materials Today Communications 13, 221-231 (2017) - Evaluation of microstructure and electrochemical behavior of dual-layer NiCrAlY/mullite plasma sprayed coating on high silicon cast iron alloy
A. Jam, S.M.R. Derakhshandeh, H. Rajaei, A.H. Pakseresht
Ceramics International 43 (16), 14146-14155 (2017) - Effect of Composition on Mechanical Properties of Mullite-WC Nano Composites Prepared by Spark Plasma Sintering
H. Rajaei, I. Mobasherpour, M. Farvizi, M. Zakeri
Tribology in Industry 38 (4) (2016) - Microstructure and mechanical properties of spark plasma sintered alumina-based composites reinforced with WC
D. Ghahremani, I. Mobasherpour, M. Razavib, H.E. Shahed, H. Rajaei
Journal of Ceramic Processing Research 17 (11), 1143-1147 (2016) - Effect of mullite synthesis methods on the spark plasma sintering behaviour and mechanical properties
H. Rajaei, I. Mobasherpour, M. Farvizi, M. Zakeri
Micro & Nano Letters 11 (8), 465-468 (2016)
Timeline
Postdoctoral research Fellowship
University of Trento
03.2024 - Current
Postdoctoral Research Fellowship
University of Trento
07.2023 - 02.2024
Graduate Research Assistant
University of Trento
11.2019 - 07.2023
Graduate Research Assistant
Materials and Energy Research Center
09.2018 - 09.2019
Graduate Research Assistant
Materials and Energy Research Center
01.2016 - 08.2018
Graduate Research Assistant
Materials and Energy Research Center
11.2013 - 01.2016
Ph.D. - Materials, Mechatronics and Systems Engineering
University of Trento
Masters - Materials Science and Engineering
Materials and Energy Research Center (MERC)
Bachelors - Materials Science and Engineering
University of Shahrekord (SKU)
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