Vahid Fallah, PhD

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Assistant Professor

Room 305A Nicol Hall
Phone: (613) 533-6000 ext 77790
FAX: (613) 533-6489

Email: vahid.fallah@queensu.ca 

Biography and Research Interests

  • PhD – Mechanical Engineering-Materials Processing (2011, University of Waterloo, Waterloo, ON, Canada)
  • MSc – Materials Identification and Selection (2005, Sharif University of Technology, Tehran, Iran)
  • BSc – Industrial Metallurgy (2002, Sharif University of Technology, Tehran, Iran)

Dr. Vahid Fallah has over 13 years of experience in academic research and industrial R&D in the fields of Additive Manufacturing (AM), Solidification and Casting, Precipitation Hardening (of aerospace & automotive aluminum alloys) and Computational Materials Science. Dr. Fallah earned his PhD in 2011 with a focus on laser additive manufacturing of advanced metals and metal matrix composites. From 2011 to 2015, he served as a postdoctoral fellow and research associate at McMaster University and University of Waterloo, and collaborated with Novelis Inc. on development of automotive aluminum alloys. Prior to joining Queen’s University in January 2018, as a senior scientist and technical project leader at Alcereco Inc., Dr. Fallah led several Industrial R&D projects. Among these are the successful development of superior continuously-cast Al alloys and thermomechanical processing routes for automotive and aerospace industries, as well as a proprietary atomization technology for specialty powders for AM applications.

Dr. Fallah’s research group welcomes applicants with strong background/interest in Materials Characterization and Analysis (Microstructure and Mechanical Properties), Solidification and Phase Transformation in Metals, Mechanical/Electrical Design & Control, Finite Element Analysis and Numerical Simulation of Transport & Metallurgical Phenomena. 

Areas of Research

  • Laser Additive Manufacturing of Metals
  • Thermomechanical Processing of Aluminum Alloys
  • Thermal FEM Analysis of Metallurgical Processes
  • Solidification and Phase Transformation Phenomena in Metals (Analysis, Characterization and Simulation)

Research Projects

  • Selective Laser Melting (SLM)-Process Design and Optimization: We are rigorously working on devising processing criteria for improved as-built properties in SLM-produced components. My research team performs advanced microstructural and mechanical characterization on test coupons as well as on real-size components produced by our research partners. 
  • SLM Machine Design: A novel SLM system with innovative features is being designed and will be built by my research team. Our system will be equipped with unique laser/laser optics design and assemblies as well as a high performance printing enclosure for effective processing of reactive metals such as Al, Ti and Zr alloys. 
  • Specialty Metal Powders for AM applications: We are actively working with our industrial partners for developing, characterization and SLM-testing of AM metal powders with superior characteristics. In particular, these powders are custom-manufactured with controlled size distribution, exceptional sphericity, oxide-free internal microstructure and uniform chemical composition. 
  • Thermal FEM Modelling of SLM process: A multi-scale FEM model of the SLM process is being developed by my research team in order to predict the temporal development of temperature, melt-pool morphology and residual stresses throughout the build process.  
  • Advanced Aluminum Alloys for Transportation Industry: Together with our industrial partners, we are developing alloy compositions and processing routes for Al alloys in order to achieve superior mechanical performance in sheet products. Our focus is on Sc-containing 3000 (Al-Mn), 5000 (Al-Mg) and 6000 (Al-Mg-Si) series alloys with applications in aerospace and automotive sectors.
  • Simulation of Solidification and Precipitation Phenomena: Our team uses Phase-Field and Phase-Field Crystal simulation methods to investigate the mechanisms of phase transformation phenomena and microstructural development in relation to the processing conditions in a variety of metallurgical processes (e.g., SLM, Casting & Age-Hardening Treatments).

Publications

Google Scholar Link

Courses

MECH 213 Manufacturing Methods