Hamidreza Aghajani

• Additive Manufacturing Engineer and PhD candidate in Mechanical and Mechatronics Engineering at the University of Waterloo specializing in metal additive manufacturing and Design for Additive Manufacturing (DfAM). Experienced in Laser Powder Bed Fusion (LPBF) and Electron Beam Powder Bed Fusion (EB-PBF) for high‑performance nickel‑based superalloys and complex components.
• Strong expertise in AM build strategy development, process parameter optimization, defect mitigation, and post‑processing of metal AM components including heat treatment and microstructure engineering. Skilled in CAD modeling, manufacturing process development, and advanced materials characterization (SEM, EBSD, TEM, EDS, X‑ray CT). Proven ability to translate process–microstructure–performance relationships into manufacturable engineering solutions supporting additive manufacturing R&D and production environments.
• Enjoy tackling challenging technical problems and continuously expanding skills through hands-on research and development. Known for being a collaborative team player with strong communication skills, actively contributing to multidisciplinary and multi-institutional projects.

ISI JOURNALS

• H.Aghajani, M. Mosayebi, B. Pourbahari, S. Maleksaeedi, P. Alimehr, R. Esmaeilizadeh, M. Hasanabadi, N. Bassim, E. Toyserkani, “Mechanistic process–microstructure–cracking correlations in laser powder bed fusion of the Ni-based superalloy IN738”, Materials & Design, 2026, vol. 262, (DOI: https://doi.org/10.1016/j.matdes.2026.115504)
• H.Aghajani, E. Toyserkani, “From micro- to macro-cracks and recrystallization in a non-weldable Ni-based superalloy manufactured by electron beam powder bed fusion”, Additive Manufacturing Letters, 2025, vol. 15, (DOI: 10.1016/j.addlet.2025.100323)
• H.Aghajani, M. Bahrami, M. Pouranvari, “Transitioning solidification mode via electroplated Ni coatings in martensitic stainless steel resistance spot welds: new insights into fabricating tough microstructure”, Scientific Reports, 2024, vol. 14, (DOI: 10.1038/s41598-024-53897-1)
• H.Aghajani, M. Bahrami, M. Pouranvari, “Enhancing load-bearing capacity of martensitic stainless steel resistance spot welds: Microstructural vs. geometrical approaches”, Materials Science & Engineering A, 2024, vol. 901, (DOI: 10.1016/j.msea.2024.146508)
• H.Aghajani, A. Ghasemi, Z. Peng, M. Bahrami, M.Pouranvari, “Microstructure engineering of fusion zone in resistance spot welding of martensitic stainless steels: The role of Ni interlayer thickness” Materialia, 2023, vol. 30, (DOI: 10.1016/j.mtla.2023.101811)
• H.Aghajani, M.Pouranvari, “Influence of in-situ thermal processing strategies on the weldability of martensitic stainless steel resistance spot welds: Effect of second pulse current on the weld microstructure and mechanical properties”, Metallurgical and Materials Transactions A, 2019, vol.50, pp. 5191-5209 (DOI: 10.1007/s11661-019-05443-2)
• M.Pouranvari, H.Aghajani and A.Ghasemi, “Enhanced mechanical properties of martensitic stainless steels resistance spot welds enabled by in-situ rapid tempering”, Science & Technology of Welding & Joining, 2020, vol. 25, pp.119-126 (DOI: 10.1080/13621718.2019.1641962)
• H.Aghajani, M.Pouranvari, “A pathway to produce strong and tough martensitic stainless steels resistance spot welds”, Science and Technology of Welding and Joining, 2019, vol.24, pp.185-192 (DOI:10.1080/13621718.2018.1483065)

PROFESSIONAL CONFERENCES PARTICIPATION

• H.Aghajani, E. Toyserkani, “Laser powder bed fusion of IN738: Cracking mechanism and strategies for crack mitigation”, 8th Holistic Innovation in Additive Manufacturing (HI-AM) Conference, Waterloo, ON, Canada, July 23-24, 2025 (Presentation)
• H.Aghajani, M. Mosayebi, B. Pourbahari, S. Maleksaeedi, P. Alimehr, N. Bassim, E. Toyserkani, “Laser powder bed fusion of IN738LC Ni-base superalloy: Crack mechanism and microstructure”, 64th Annual Conference of Metallurgy and Materials (COM & MetSoc), Montreal, QC, Canada, July 7-10, 2025 (Poster)
• H.Aghajani, E. Toyserkani, “Crack susceptibility and grain structure evolution in electron beam powder bed fusion of a non-weldable Ni-base superalloy”, 36thCanadian Materials Science Conference (CMSC), Waterloo, Canada, May 12-15, 2025 (Poster)
• H.Aghajani, E. Sadeghi, P. Karimi, E. Toyserkani, “Non-weldable Ni base superalloys additively manufactured via electron beam powder bed fusion: A survey and a case study”, 6th Holistic Innovation in Additive Manufacturing (HI-AM) Conference, Halifax, NS, Canada, June 27-28, 2023 (Presentation)
• H.Aghajani, M.Pouranvari, “ Microstructure and mechanical properties relationship in single-pulse and double-pulse resistance spot welding of M1400 advanced automotive steels”, Steel Symposium 2020, Kish International Convention Center, Kish, Iran, October 5-7, 2020 (Presentation)