Dr. Rashid Ali

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Dr. Rashid Ali

Associate Professor (HEC Approved PhD Supervisor)


Ph.D in Mechanical & Industrial Engineering with specialization in Materials Science & Technology, Roma Tre, Italy, 2015

Master of Science (MS) in Mechanical and Automobile Engineering, Myongji University, Yongin, South Korea, 2009

Bachelor of Engineering (B.E.) in Metallurgy and Materials Engineering, Dawood University, Karachi, 2005

Research Interests:

Residual stress optimization in Ti-TiN Multilayer PVD-Coatings used for Mechanical Application, Residual stress analysis, Multilayer hard coatings, Modeling and Characterization of Thin films for optoelectronics, thermoelectric and energy storage applications, Materials Failure Analysis


Dr.Rashid Ali main area of research is residual stress analysis in engineering materials for their influence on the static and fatigue performance of materials. During his Ph.D studies, he design and develop residual stress-optimized Ti-TiN multilayer PVD hard-coatings on compliant substrate (stainless steel) to increase the overall thickness of coating without deteriorating coating adhesion to the substrate. For an accurate measurement of practical adhesion of brittle coatings to the compliant substrate, he demonstrates the use of analytical modelling for the description of the failure modes under scratch adhesion testing. Moreover, the finite element (FEM) and experimental description of failures produced due to residual stresses and coating delamination related failures in materials were conducted. The work forms the basis to engineered stress-optimized multilayer coatings through FEM design for the use of multilayer coating in wide range of industrial applications. Further, he practically investigate the various failures in engineering components such as failure in melting crucible and performed design study to mitigate those failures; investigate the failure in roller bearing and failure in thermal barrier coating of turbine blades etc. 

  1. R. Ali*, M. Hanif, S. A. B. Shah, S. Z. Abbas, M. R. A. Karim, M. Arshad and S. H. A. Ahmad “Effect of Chromium Doping on Structural and Optoelectronic Properties of Nanostructured Indium Tin Oxide Thin Films. Journal of Applied Physics-Materials Science and Processing, 2022. https://doi.org/10.1007/s00339-022-05639-1
  2. R. Ali, W. Y. Kim, M. Zafar, T. Manzoor, M. U. Rashid, S. Z. Abbas, and B. A. Zai, Analysis for elimination of solidification shrinkage defects in casting process of aluminum alloy, Journal of Mechanical Science and Technology, 2022. https://doi.org/10.1007/s12206-022-0416-z.
  3. R. Ali*, T. Shehbaz, D. d. Felicis, M. Sebastiani, E. Bemporad, “Investigations of Fatigue Failure in e-Type Fastening Clip used in Railway Tracks” Journal of Rail and Rapid Transit, 2020. https://doi.org/10.1177/0954409720967802.
  4. Z. Abbas, R. Ali, F. A. Khalid, K. A. Khan and M. A. Rehman, “Effect of Au additions on the structure and properties of (Fe0.5 Co0.5)71Nb4Si5B20 bulk metallic glass” Journal of Materials Science and Technology, 2019. https://doi.org/10.1080/02670836.2019.1565082
  5. Ali, M. Renzelli, M. I. Khan, M. Sebastiani and E. Bemporad, “Effects of Residual Stress Distribution on Interfacial Adhesion of Magnetron Sputtered AlN and AlN/Al Nanostructured Coatings on a (100) Silicon Substrate” Nanomaterials, 2018. 8(11): p. 896. https://doi.org/10.3390/nano8110896
  6. Karimov, Z. Ahmad, R. Ali, A. Noor, M. Akmal, M. A. Najeeb and R. A. Shakoor, “Fabrication and characterization of the organic rectifying junctions by electrolysis” Applied Physics A-Materials Science and Processing 123, (8), 546, 2017. https://doi.org/10.1007/s00339-017-1160-6.
  7. K. S. Karimov, J.-U. Nabi, R. Ali, N. Fatima, A. Khan, M. M. Rehman and M. M. Bashir, “Resistive and impedimetric properties of elastic composite based on graphene and CNT under uniaxial compressive displacement” Advanced Composite Materials, 2020. https://doi.org/10.1080/09243046.2020.1731104
  8. Ali, M. Sebastiani and E. Bemporad, “Influence of Ti-TiN Multi-layer PVD-coatings design on residual stress and adhesion” Journal of Materials and Design, No. 75, pp. 47-56, 2015. https://doi.org/10.1016/j.matdes.2015.03.007
  9. R. A. Sindhu, M. K. Park, S. J. Lee and K. D. Lee, “Effects of residual stresses on the static and fatigue strength of laser-welded lap joints with different welding speeds” International Journal of Automotive Technology, Volume 11, Number 6, pp. 857-863, 2010. https://doi.org/10.1007/s12239-010-0102-5
  10. M. K. Park, R. A. Sindhu*, S. J. Lee, B. A. Zai and H. Mehboob “A Residual Stress Evaluation in Laser Welded Lap Joint with Hole Drilling Method” International Journal of Precision Engineering and Manufacturing, Vol. 10 / No. 5, pp. 89-95, 2009. https://doi.org/10.1007/s12541-009-0099-8
  11. Z. Iqbal, N. Amjad, R. Ali, M. W. Khan, S. Siddique, S. Aftab, S. M. Wabaidur “Elucidating binder-free magnetron sputtered molybdenum-tungstendisulfide thin films for battery-supercapacitor devices, Journal of Alloys and Compounds, 942 (2023) 168929, 2023.
  12. M. Z. Iqbal, N. Amjad, S. Siddique, R. Ali, U. Aziz, S. Aftab and M. Alzaid, Exploring the synergy of binder free MoWS2@ Ag as electrode materials for hybrid supercapacitors, Journal of Energy Storage, vol. 56, p. 105925, 2022. https://doi.org/10.1016/j.est.2022.105925;
  13. M. Z. Iqbal, J. Khan, S. Alam, R. Ali, M. J. Iqbal, A. M. Afzal and S. Aftab, “Enhanced electrochemical performance of cobalt phosphate via magnetron sputtered copper interfacial layer for potential supercapattery applications”, International Journal of Energy Research, Vol. 45, Issue13, 2021. https://doi.org/10.1002/er.6974.

Research Projects:

  1. Design and Development of Super Duplex Stainless Steel Cast Components with Computer Aided Engineering (2016, Completed), HEC Start-up-Research Grant.

  2. Design, Development, and Characterization of Stress-Optimized Multilayer PVD Hard-Coatings for Bio-Medical & Engineering Applications, NRPU by HEC, 2018, completed. 

    MS Thesis Titles Supervised:

    1. Production and Characterization of Chromium doped Indium Tin Oxide thin films by Magnetron Co-Sputtering for Optoelectronic and Thermoelectric Applications.
    2. Effect of Residual Stresses on Wear, Corrosion and Adhesion of Titanium/Titanium Nitride Multilayer PVD Hard Coatings

    3. Prediction of Residual Stresses in Transition Metal Nitrides Sputtered Coatings using ANN and Experimental Validation
Industrial Experience:
  • Assistant Engineer of Quality Control (Forging Plant) Omega Forging Limited, a unit of Dawood Yamaha Limited, Karachi, Pakistan, July 2005- July 2006
  • Assistant Engineer (Die-Casting Plant) Pirani Engineering, a Unit of N.J. Auto Industries, Hub Chowki, Lasbela, Pakistan, July 2006- February 2007. 

Professional Memberships:
  • Membership of Pakistan Engineering Council 
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