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Dr Debajyoti Bhaduri

Dr Debajyoti Bhaduri


+44 (0)29 2251 0922
Room W/2.21, Adeiladau'r Frenhines -Adeilad y Gorllewin, 5 The Parade, Heol Casnewydd, Caerdydd, CF24 3AA
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Dr Debajyoti Bhaduri is a Lecturer in High-Value Manufacturing within the Cardiff School of Engineering. His research interest broadly centres on the advanced machining / grinding, laser based micro-manufacturing and metal additive manufacturing (AM), hybrid manufacturing technologies, e.g. ultrasonic assisted machining / grinding, surface engineering via PVD coating, laser texturing, polishing etc.

Dr Bhaduri has been involved in several European projects over the past five years that focussed on development and implementation of hybrid manufacturing process chains incorporating various pre- and post-processing steps of metallic AM parts. During his PhD, he developed a novel hybrid ultrasonic assisted creep feed grinding process for machining of advanced aerospace alloys such as Inconel 718, CMSX-4 and gamma titanium aluminide. His research expertise also encompasses evaluation of surface integrity of machined parts via roughness, microhardness, microstructure and different microscopic and spectroscopic (EDS, WDS, EMPA, SIMS, XPS, OES and XRD) analysis.


  • Lecturer (current post): School of Engineering, Cardiff University, Cardiff, UK
  • Research Fellow (2013-2018): School of Engineering, Department of Mechanical Engineering, University of Birmingham, Birmingham, UK
  • Honorary Senior Research Fellow (2018-present): School of Engineering, Department of Mechanical Engineering, University of Birmingham, Birmingham, UK
  • PhD (2010-2014): School of Mechanical Engineering, University of Birmingham, Birmingham, UK
  • Assistant Professor (2009): National Institute of Technology Rourkela, India
  • Master of Technology (2007-2009): Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, India
  • Bachelor of Engineering (2003-2007): Department of Production Engineering, Jadavpur University, Kolkata, India

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  • Al Sonntag award for the best paper on solid lubricants subject, awarded by the Society of Tribologists and Lubrication Engineers (stle) (2019)
  • Joseph Whitworth Award for the best paper on a manufacturing industries mechanical engineering subject, awarded by the Institution of Mechanical Engineers (2017)
  • Institute Silver Medal, awarded by Indian Institute of Technology Kharagpur, India (2009)
  • B. M. Belgaumkar Memorial prize, awarded by Indian Institute of Technology Kharagpur, India (2009)
  • University Gold Medal, awarded by Jadavpur University, India (2007)

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  • Research Affiliate of the CIRP

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  • Committees: Member of the 5th CIRP Conference on Surface Integrity (CSI) 2020 Scientific Committee

  • Journal reviewer: Applied Surface Science, CIRP Journal of Manufacturing Science and Technology, Materials and Manufacturing Processes, Machining Science and Technology, Measurement, Surface and Coatings Technology, Precision Engineering, Ceramics International, Wear, I. Mech. E.- Part B, International Journal of Advanced Manufacturing Technology, Journal of Cleaner Production, Ultrasonics, Manufacturing Letters.

  • PhD theses reviewer:  
Name of the PhD student Year of review University/Institution
Gaurav Dinkar Sonawane 2020 Dr. Babasaheb Ambedkar Technological University, Lonere, India
Anshuman Das 2019 National Institute of Technology Rourkela, India



















  • Advanced manufacturing technologies
  • Industrial project management

Research Interests:

Dr Debajyoti Bhaduri is currently undertaking research in the following areas:

  • Circular Hubrid Manufacturing (CHM) - The research focuses on the development of a novel circular manufacturing route for the production of sustainable powders for metal additive manufacturing (AM). The process enables synergistic study on the sustainability of AM processes and their environmental impact from the life-cycle perspective. The research strategy aligns with the UK Government's 'Net Zero' target, with the aim to dramatically reduce the carbon footprint of the current AM powder production techniques and to foster recycle of materials to produce high-value AM parts.

  • Development of Hybrid Manufacturing Process Chains - The research involves AM process optimisation for new metallic materials, followed by post-processing of the AM parts via laser-based surace engineering techniques, such as laser polishing and laser surface texturing, to improve the built parts' surface integrity.

  • Surface texturing via mechanical micromilling - This is a complementary surface engineering technique to the laser surface texturing (LST). Comparative surface integrity analyses are undertaken on the parts, textured via mechanical micromilling and LST.

  • Machining of metal-composites stacks - The effects of single-shot milling of metal-compasite (e.g. Al/CFRP) stacks are investigated on the workpeices' surface inegrity and cutting tool wear.

Research publications:



Research Grants:

Title People Sponsor Role Amount Duration
Evaluation of hybrid additive-subtractive metallic parts D Bhaduri University of Birmingham PI £6400 2018-2021

Surface integrity analysis of selective laser melted AlSi10Mg alloy following laser polishing

D Bhaduri

Shri Gopal Rajgarhia International Programme (SGRIP), IIT Kharagpur

PI INR 196,000 2019

Architectural microstructure-modification mechanisms and the microstructure-performance optimization for SLM Aluminum matrix composites

R Setchi, D Bhaduri, M Ryan, P Wang

The Royal Society - International Exchanges 2021

Co-I £12,000 2022-2024


I am interested in supervising PhD students in the areas of:

  • Metal additive manufacturing - process optimisation, circular manufacturing, hybrid manufacturing
  • Laser surface texturing, Laser polishing
  • Laser-based micromachining
  • Conventional machining (turning, milling, grinding)
  • Evaluation of the machinability of materials

Goruchwyliaeth gyfredol

Hao Shen

Research student

Benjamin Mason

Research student


Aland Escudero

Research student


Karan Baramate

Research student

Past projects


Haydee Martinez Zavala - "High Peak, Perishable Energy Recovery – Foundation Phase" (awarded 2022).