WAAM Researcher | Experimental Metal Additive Manufacturing | Thermo-Mechanical FEM
Materials & Metallurgical Engineer — Amirkabir University of Technology (Tehran Polytechnic)

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I am a materials and metallurgical engineer specializing in Wire Arc Additive Manufacturing (WAAM), welding metallurgy, thermo-mechanical finite-element modelling, and experimental validation.

My research combines robotic GMA-WAAM experiments, thermocouple measurements, microstructural and mechanical characterization, and numerical simulation in ANSYS APDL and SysWeld. I focus on understanding process–thermal–microstructure–property relationships, residual-stress and distortion development, and the influence of deposition conditions on the performance of additively manufactured steels.

I also develop reproducible Python workflows for data-driven WAAM thermal forecasting, including causal, neural-network, and physics-guided modelling with build-independent validation.

A three-dimensional transient thermo-mechanical finite-element framework for investigating residual stress and distortion in multilayer low-alloy-steel WAAM.

• Thermal and structural analysis in ANSYS APDL
• Temperature-dependent material properties
• Element birth-and-death deposition modelling
• Imported thermal histories for mechanical analysis
• Experimental comparison using WAAM measurements

A curated experimental project examining process–structure–property relationships in ER70S-6 low-alloy steel produced under three robotic GMA-WAAM deposition conditions.

• Optical metallography and grain-size analysis
• Vickers hardness characterization
• Direction-dependent tensile testing
• Charpy impact testing
• SEM fractography of tensile and impact specimens
• Reproducible data organization and validation workflow

An independent scientific-computing project based on four-channel thermocouple measurements from three multilayer WAAM builds.

• Thermal-signal preprocessing and feature engineering
• Causal regression and neural-network forecasting
• Physics-guided residual modelling
• Leave-one-build-out validation
• Leakage-aware and reproducible evaluation

• Investigated the relationship between hydrogen content and strain
• Performed hydrogen measurements
• Developed thermo-elastic-plastic finite-element models of temperature and residual-stress fields

• Compared laser, electron-beam, and electric-arc heat sources
• Examined penetration, porosity, distortion, and residual-stress formation

• Wire Arc Additive Manufacturing
• Welding Metallurgy
• Thermo-Mechanical Finite-Element Modelling
• Residual Stress and Distortion
• Process–Structure–Property Relationships
• Experimental Validation
• Data-Driven and Physics-Guided Process Modelling
• Mechanical Anisotropy and Fractography

• Transient thermal and thermo-mechanical analysis
• Residual-stress and distortion modelling
• Thermal-signal processing and machine learning
• Reproducible analysis with Jupyter and Git/GitHub

• Robotic GMA-WAAM, GMAW, GTAW, and multilayer deposition
• Process-parameter analysis and thermocouple measurements
• Steel and aluminium metallography
• SEM image analysis and fractography
• Tensile, Charpy impact, and hardness testing
• Visual, penetrant, and magnetic-particle inspection

Manuscripts under review

1. Finite-Element Simulation of Residual Stress in Wire Arc Additive Manufacturing of Low-Alloy Steel
   Journal of Materials Engineering and Performance

2. Low-Alloy Steel Fabricated by Wire Arc Additive Manufacturing Using ER70S-6: Microstructure and Mechanical Properties
   Journal of Materials Engineering and Performance

• M.Sc. in Materials and Metallurgical Engineering, Amirkabir University of Technology, 2024
  GPA: 3.8/4.0 • Ranked 1st of 15 • Top 3% in Iran's National M.Sc. Entrance Examination

• B.Sc. in Safety and Inspection Engineering, Petroleum University of Technology, 2020
  Ranked in the top 8% of the cohort

Teaching Assistant at Amirkabir University of Technology:

• Advanced Metallurgy in Welding
• Welding Inspection and Quality Control
• Measurement Errors

I am seeking PhD opportunities and research collaborations in metal additive manufacturing, welding engineering, computational materials processing, thermo-mechanical simulation, and data-driven manufacturing.

Email: A.mori@aut.ac.ir