Education

Ph.D., Materials Science and Engineering, University of Pittsburgh, Pittsburgh, PA, 2018
M.S., Corrosion and Materials Protection, Sahand University of Technology, Tabriz, Iran, 2011
B.S., Materials Science and Engineering-Industrial Metallurgy, Science and Research Branch at Azad University, Tehran, Iran, 2008

Research Interests

  • Laser powder bed fusion and binder jetting of structural (Ni and stainless steel), shape memory (Ni-Mn-based alloys), light alloys (Al and Ti), biomaterials (Co-Cr and Ti), and composite materials
  • Process parameter optimization, microstructure evolution and post-treatment
  • Data analytics in metal additive manufacturing
  • Micro-computed tomography and synchrotron dynamic x-ray radiography
  • Electrochemical and high-temperature corrosion behavior of additively manufactured parts

Publications

  • Mostafaei, A., Rodriguez De Vecchis, P., Buckenmeyer, M. J., Wasule, S. R., Brown, B. N., & Chmielus, M. Microstructural evolution and resulting properties of binder jet 3D printed Stellite 6. Materials Science & Engineering C, 102 (2019) 276-288.
  • Jiang, R., Mostafaei, A., Pauza, J., Kantzos, C., & Rollett, A. D. Varied heat treatments and properties of laser powder bed printed Inconel 718. Materials Science & Engineering A, 755 (2019) 170-180.
  • Mostafaei, A., Rodriguez De Vecchis, P., Nettleship, I., & Chmielus, M. Effect of powder size distribution on densification and microstructural evolution of binder-jet 3D-printed alloy 625. Materials & Design, 162 (2019) 375-383.
  • Mostafaei, A., Neelapu, S. H. V. R., Kisailus, C., Nath, L. M., Jacobs, T. D. B., & Chmielus, M. Characterizing surface finish and fatigue behavior in binder jet 3D printed alloy 625. Additive Manufacturing, 24 (2018) 200-209.
  • Mostafaei, A., Rodriguez De Vecchis, P., Stevens, E.L., & Chmielus, M. Sintering regimes and resulting microstructure and properties of binder jet 3D printed Ni-Mn-Ga magnetic shape memory alloys. Acta Materialia, 154 (2018) 355-364.
  • Mostafaei, A., Hilla, C., Stevens, E. L., Kimes, K. A., Nandwana, P., Elliott, A. M., & Chmielus, M. Characterization of differently atomized nickel-based alloy 625 powders. Powder Technology, 333 (2018) 180-192.
  • Mostafaei, A., Stevens, E. L., Ference, J. J., Schmidt, D. A., & Chmielus, M. Binder jetting of a complex-shaped metal partial denture framework. Additive Manufacturing, 21 (2018) 63-68.
  • Behnamian, Y., Mostafaei, A., Kohandehghan, A., Shalchi Amirkhiz, B., Li, J., Zeng, Y., Zheng, W., Guzonas, D., Chmielus, M., Chen, W., & Luo, J. L. Characterization of oxide layer and micro-crack initiation in alloy 316L stainless steel after 20000 h exposure to supercritical water at 500 °C. Materials Characterization, 131 (2017) 532-543.
  • Mostafaei, A., Kimes, K. A., Stevens, E. L., Toman, J., Krimer, Y. L., Ullakko, K., & Chmielus, M. Microstructural evolution and magnetic properties of binder jet additive manufactured Ni-Mn-Ga magnetic shape memory alloy foam. Acta Materialia, 131 (2017) 482-490.
  • Mostafaei, A., Toman, J., Stevens, E. L., Hughes, E. T., Krimer, Y. L., & Chmielus, M. Microstructural evolution and mechanical properties of differently heat-treated binder jet printed samples from gas- and water-atomized alloy 625 powders. Acta Materialia, 124 (2017) 280-289.
  • Behnamian, Y., Mostafaei, A., Kohandehghan, A., Shalchi Amirkhiz, B., Li, J., Zahiri, R., Aghaie, E., Zheng, W., Guzonas, D., Chmielus, M., Chen, W., & Luo, J. L. Internal oxidation and crack susceptibility of alloy 310S stainless steel after long term exposure to supercritical water at 500 °C. Journal of Supercritical Fluids, 120 (2017) 161-172.
  • Mostafaei, A., Behnamian, Y., Krimer, Y. L., Stevens, E. L., Luo, J. L., & Chmielus, M. Effect of solutionizing and aging on the microstructure and mechanical properties of powder bed binder jet printed alloy 625 nickel-based superalloy. Materials & Design, 111 (2016) 482-491.
  • Behnamian, Y., Mostafaei, A., Kohandehghan, A., Shalchi Amirkhiz, B., Serate, D., Sun, Y., Liu, S., Aghaie, E., Zeng, Y., Chmielus, M., Zheng, W., Guzonas, D., Chen, W., & Luo, J. L. A comparative study of oxide scales grown on stainless steel and nickel-based superalloys in ultra-high temperature supercritical water at 800 °C. Corrosion Science, 106 (2016) 188-207.

Books

Book Chapters

  • Mostafaei, A., Heidarzadeh, A., & Brabazon, D. Encyclopedia of material composites, Chapter 5: Additive manufacturing of metal matrix composites. Elsevier, 2020.
  • Mostafaei, A., Gordon, J. V., & Rollett, A. D. Additive manufacturing of cobalt alloys. ASM Handbook, Vol. 24A (2020).
  • Wu, Z., Yarasi, S. R., Mostafaei, A., & Rollett, A. D. Powder characterization for metal additive manufacturing. ASM Handbook, Vol. 24A (2020).

Patents

US Patent

Alignment of Magnetic Materials During Powder Deposition or Spreading in Additive Manufacturing, University of Pittsburgh, M. Chmielus, Y. Krimer, A. Mostafaei, E. Stevens, J. Toman, https://patents.google.com/patent/WO2018218199A1/en

Expertise

  • Process parameter optimization for additively manufactured metal and composite materials
  • Post-treatment of 3D-printed parts to improve mechanical properties and corrosion behavior
  • Alloy development for additive manufacturing processes