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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

• M. Asherloo, Z. Wu, M.H. Delpazir, E. Ghebreiesus, S. Fryzlewicz, R. Jiang, B. Gould, M. Heim, D. Nelson, M. Marucci, M. Paliwal, A.D. Rollett, A. Mostafaei, “Laser-beam powder bed fusion of cost-effective non-spherical hydride-dehydride Ti-6Al-4V alloy”, Additive Manufacturing, 56 (2022) 102875.
• V. Salarvand, H. Sohrabpoor, M.A. Mohammadi, M. Nazari, R. Raghavendra, A. Mostafaei, D. Brabazon, Microstructure and corrosion evaluation of as built and heat-treated 316L stainless steel manufactured by laser powder bed fusion, Journal of Materials Research and Technology, 18 (2022) 4104-4113.
• A. Mostafaei, C. Zhao, Y. He, S.R. Ghiaasiaan, B. Shi, S. Shao, N. Shamsaei, Z. Wu, N. Khouraytem, T. Sun, J. Pauza, J.V. Gordon, B. Webler, N.D. Parab, M. Asherloo, Q. Guo, L. Chen, A.D. Rollett, “Defects and anomalies in powder bed fusion metal additive manufacturing”, Current Opinion in Solid State and Materials Science, 26 (2022) 100974.
• Z. Wu, M. Asherloo, R. Jiang, M.H. Delpazir, A. Sivakumar, M. Paliwal, J. Capone, B. Gould, A.D. Rollett, A. Mostafaei, “Study of Printability and Porosity Formation in Laser Powder Bed Fusion Built Hydride-Dehydride (HDH) Ti-6Al-4V”, Additive Manufacturing, 47 (2021) 102323.
• C. Zheng, A. Mostafaei, P. Rodriguez de Vecchis, I. Nettleship, M. Chmielus, “Microstructure evolution for isothermal sintering of binder jet 3D printed alloy 625 above and below the solidus temperature”, Additive Manufacturing, 47 (2021) 102276.
• E. Stevens, K. Kimes, D. Salazar, A. Mostafaei, R. Rodriguez, A. Acierno, P. Lázpita, V. Chernenko, M. Chmielus, “Mastering a 1.2 K hysteresis for martensitic para-ferromagnetic partial transformation in Ni-Mn(Cu)-Ga magnetocaloric material via binder jet 3D printing”, Additive Manufacturing, 37 (2020) 101560.
• A. Mostafaei, P. Rodriguez De Vecchis, K.A. Kimes, D. Elhassid, M. Chmielus, “Effect of print processing parameters on microstructure and - 2 - resulting properties of sinter-HIP binder-jet 3D-printed WC-Co composites”, Additive Manufacturing, 46 (2021) 102128.
• A. Mostafaei, A.M. Elliott, J.E. Barnes, F. Li, W. Tan, C.L. Cramer, P. Nandwana, M. Chmielus, “Binder jet 3D printing – process parameters, materials, properties, modeling and challenges”, Progress in Materials Science, 119 (2021) 100707.
• Heidarzadeh, S. Mironov, R. Kaibyshev, G. Cam, A. Simar, A. Gerlich, F. Khodabakhshi, A. Mostafaei, D.P. Field, J.D. Robson, A. Deschamps, P.J. Withers, “Friction stir welding/processing of metals and alloys: A comprehensive review on microstructural evolution”, Progress in Materials Science, 117 (2020) 100752.
• R. Jiang, A. Mostafaei, Z. Wu, A. Choi, P-W. Guan, M. Chmielus, A.D. Rollett, “Effect of heat treatment on microstructural evolution and hardness heterogeneity in laser powder bed fusion of Inconel 718”, Additive Manufacturing, 35 (2020) 101282

Books

Book chapters:

• A.M. Elliott , C.L. Cramer, P. Nandwana, M. Chmielus, A. Mostafaei, “Binder Jet – Metals”, Encyclopedia of Materials: Metals and Alloys, Elsevier, pp. 120-133, 2022.
• Mostafaei, A. Heidarzadeh, D. Brabazon, “Production of Metal Matrix Composites Via Additive Manufacturing”, Encyclopedia of Materials: Composites, Elsevier, pp. 605-614, 2021.
• Mostafaei, J.V. Gordon, A.D. Rollett, “Additive Manufacturing of Cobalt Alloys”, ASM Handbook, Vol. 24, Additive Manufacturing Processes, 2020.
• Z. Wu, S.R. Yarasi, A. Mostafaei, A.D. Rollett, Powder Characterization for Metal Additive Manufacturing, ASM Handbook, Vol. 24, Additive Manufacturing Processes, 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,

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