Dr. U. Kamachi Kamachi MUDALI
Present Designation:
Vice Chancellor, Homi Bhabha National Institute (HBNI), DAE MumbaiAreas of Interest:
Localised Corrosion Studies (Pitting, Crevice Corrosion & Intergranular Corrosion) of Stainless Steels and Their Weldments
o Role of nitrogen in enhancing corrosion resistance of steels and stainless steels
o Nature, morphology and composition of passive films of stainless steels
o Corrosion aspects of various materials used for different units of fast breeder reactors
Advanced Materials Development for Highly Corrosive Nitric Acid / Molten Chloride Media
o AISI Type 304L SS, Nitric acid grade (NAG) SS and their welds
o Ti, Ti-5%Ta-2%Nb, Zirconium, Zircaloy-2 and 4 and their welds
o Dissimilar joints between 304L SS and titanium or Zircaloy-4
o AISI Type 316L SS, Inconel 600 & 625, 9Cr-1Mo Steel, PSZ Thermal Barrier Coatings
o Long term immersion and electrochemical corrosion studies in molten LiCl+KCl medium
Establishing Corrosion Loops and Online Corrosion Monitoring
o Nitric acid loops/systems based on stainless steel, titanium and zircaloy for various concentrations
o Corrosion testing and monitoring through electrochemical polarization, impedance, noise and corrosion potential measurements
o Online corrosion monitoring probes for electrochemical noise and corrosion potential measurement
Nanostructured Coatings and Surface Modification
o Mixed oxide (Ruo2/TiO2/PtO2) coated titanium anodes for electrochemical processes
o Long life noble metal based (Pt, Ir, Pd) intermetallic coated titanium anodes
o Diffusion alloyed platinum electroplated and Nano-Pt deposited titanium anodes
o DOCTOR coating on Titanium for corrosion protection
Coatings, Surface Modification and Surface Characterisation
o Defect free chromium plating technology for components made of steels and stainless steels
o Laser surface modification, Nitrogen Ion Implantation, Plasma sprayed thermal barrier coatings
o Anodic passivation technology for corrosion protection of stainless steels and titanium
o Nanostructured superhydrophobic & self-healing coatings, and inorganic nanofilter membranes
o Surface analysis by XPS, AES, Laser Raman and scanning probe microscopy (STM/AFM)
Biomaterials and Coatings for Orthopedic Implant Devices
o Advanced Nitrogen alloyed and Ti-modified stainless steels
o Titanium and advanced alloys & their surface modification using laser and ion beams
o Titanium dioxide nanotube based surface modification
o Biodegradable materials and coatings development
Research & Development towards Spent Nuclear Fuel Reprocessing
o Metal fuel development, characterisation and pyro reprocessing
o Dissolution of spent nuclear fuels and actinide partitioning including process modeling
o Radiation and corrosion resistant nonmetallic materials and coatings
o Solvent wash, Solvent and Diluent degradation, and Denitridation aspects
o Equipment development (Centrifugal Extractors, Dissolvers, Evaporators etc.)
Since September 2017:
• Responsible for the smooth and efficient operation of Heavy Water plants and other plants (for diversification activities) located at Kota, Manuguru, Thal, Hazira, Baroda, Tuticorin and Talcher.
• Leading the diversification activities of the HWB including, production of organic Solvents, Sodium, Oxygen-18, and enriched Boron & B4C, in addition to the production of deuterated compounds for societal and industrial applications.
• Current interests includes Helium and Hydrogen production, Rare materials from Indian phosphate rock, and other special materials (Gallium, Cobalt, Magnesium, etc.) of relevance to Indian Nuclear power and fuel cycle activities & allied industries.
Specialisation:
Advanced Materials; Coating Technology; Corrosion Engineering; Heavy Water and Specialty Materials..
Major Professional Contributions:
• The most outstanding contribution in the 1980s was introducing nitrogen as an alloy element to austenite stainless steel and their weldments, and understanding the microstructural changes and improvement in corrosion behaviour.
• The PhD thesis explained the beneficial effects of nitrogen alloyed 304LN and 316LN SS alloys for fast breeder reactor applications. A time-temperature-sensitization-pitting diagram for type 304L SS and 316L SS with nitrogen addition was established which provided time-temperature combinations leading to sensitization as well as pitting attack.
• Studies on the role of nitrogen in enhancing corrosion resistance of 304L SS alloys in nitric acid solutions resulted in the application of nitric acid grade 304LN SS alloys for FRFCF plant, and 4000 tons of the indigenous 304LN SS alloys were produced for this purpose with Indian steel manufacturer.
• For the first time Mixed Oxide Coated Titanium Anodes (MOCTA) and its variants MOCTAG developed were used upto highly corrosive boiling concentrated nitric acid based electrochemical processes employed in FBR reprocessing.
• Based on R&D studies titanium vessel with dissimilar joints was fabricated and used in the CORAL plant since 2003 for the reprocessing of FBTR mixed carbide fuel.
• An innovative and unique coating technique ‘double oxide coating on titanium for reconditioning (DOCTOR)’ was evolved which brought down the corrosion rate from 20 mils per year to less than 5 mils per year with the formation of pure nano grained (~200 nm) TiO2 on the surface of titanium.
• Proposed and evaluated Ti-5%Ta-2%Nb alloy through systematic R&D for the high corrosion resistance of future FBR dissolvers.
• Based on extensive laboratory and long term corrosion investigations using Zircaloy Corrosion System (15,000 h) and Mock Up dissolver system (operating now 3000 h) Zircaloy has been proposed for future FBR dissolvers.
• Established a 400 litres capacity ‘dynamic nitric acid loop’ made of 304L SS simulating the reprocessing plant inactive operating conditions. Based on long term corrosion rate data of 10000 h operation, corrosion processes degrading the performance were modeled using an Artificial Neural Network model to predict the remnant life of 304L SS components.
• Established a ‘Pyrochemical Materials and Coating Facility’ for assessing long term corrosion in molten LiCl+KCl salt and molten uranium environments towards pyrochemical reprocessing of metallic nuclear fuels.
• Type 316L, Inconel 600, 625 and 690, 9Cr-1Mo steel, electroformed Ni and Ni-W have been evaluated for corrosion at 873 K towards vessels for salt preparation, electrorefining and cathode processing.
• Yttria Stabilised Zirconia Coating technology was established after setting up “Plasma and HVOF Coating Facility” for corrosion protection upto 2000 h in molten LiCl+KCl medium.
• Yttria based coatings with SiC interlayer was established over high density graphite crucibles for uranium and its alloy melting upto 1500◦C with more than 25 thermal cycles and longer life.
• Developed ‘Superhydrophobic’ surface modification on titanium, stainless steels and Cr-Mo steels; ‘Self-healing’ protective coatings on Cr-Mo steels; ‘polymeric PEEK based coatings’ on steels and aluminium; ‘hydroxyapatite bioceramic coatings’ on 316L SS and titanium alloys; for enhanced corrosion and biofouling resistances.
• Successful collaboration with many national and international academic and R&D institutions for pursuing R&D collaboration projects, and also supporting projects of students and research scholars. Eighteen collaboration projects and projects of 162 B.E/B.Teh/M.E/M.Tech/M.Phil/Ph.D students from various institutions were achieved.
Made outstanding contributions to many important projects of high relevance and has put in remarkable efforts for implementing such R&D projects of immense value to the department. The hallmarks of work are: high level of originality, focus and innovation, and direct application, for field and industry.
Consultancy Areas:
Corrosion Control and Prevention, Corrosion Testing and Monitoring, Corrosion Failure Analysis, Advanced Materials, Coating Technologies, Surface Analysis and Characterization, Reprocessing Materials, Equipments, and Process.
Sector Associated With:
R&D
Sectors Interested to Offer Service:
Educational / Academic institutions, Industry (Private), Industry (PSUs), R&D Organizations, Government (including funding agencies)
Professional Experience
Associate Director, Corrosion Science and Technology Group (since March 2011) & Materials, Process and Equipment Development Group (since September 2015). Head, Reprocessing Research and Development Division (July 2009-Aug. 2015). Convener, IGCAR Patents & Technology Transfer Cell (since January 2009). Head, Corrosion Science and Technology Division (November 2010 to March 2011). Head, Corrosion Science & Technology Section – Reprocessing Plant Materials (July’04- March’11).
Keywords
Metallurgy, Materials Science, Corrosion Science and Engineering, Coating Technologies, Surface Engineering, Surface Analysis, Electrochemical Science and Technology, Chemical Process and Equipment Development, Radiation Resistant Materials, Nanostructured Materials and Coatings, Corrosion Testing and Analysis, Corrosion Monitoring
Education
Ph.D (Metallurgy-Corrosion)M.Tech. (Corrosion), IIT BombayM.Sc. (Materials Science)
Awards and Recognitions
Best Scientist Award 1997 from the Tamilnadu State Council for Science and Technology, Madras, for outstanding contributions in metallurgy and corrosion aspects of materials used in nuclear industry.
MASCOT National Award 2000 from the Electrochemical Society of India, Bangalore, for outstanding contributions in applied corrosion science and technology.
ONGC Corrosion Awareness Award 2003 from National Association of Corrosion Engineers (India Section), Mumbai, for excellence in corrosion science and technology.
INS Medal 2004 from Indian Nuclear Society, Mumbai for excellent contributions in corrosion science and technology of materials used in nuclear industry.
Homi Bhabha Science and Technology Award for 2004 from the Department of Atomic Energy, Government of India, for outstanding contributions in corrosion science and technology.
Metallurgist of the Year 2005 from the India Institute of Metals, Kolkata and instituted by Ministry of Steel and Mines, Government of India, for meritorious achievements and significant contributions towards the development of corrosion resistant materials for strategic applications in nuclear industry.
Distinguished Alumni Award for 2005 from P.S.G. College of Technology, Coimbatore.
15th NIGIS Meritorious Contribution Award from National Association of Corrosion Engineers (India Section), Mumbai, 2009, for outstanding contributions in corrosion science and technology & awareness.
DAE Group Achievement Award as Leader for establishing a Dynamic Nitric Acid Loop for Long Term Corrosion Studies, 2011.
DAE Group Achievement Award as Member for Establishing an Engineering Scale Facility for Pyroprocessing, 2011.
Vocational Excellence Award from the Rotary Club of Chennai Port City, Chennai for excellent contributions in nuclear materials, 2012
DAE Group Achievement Award as Member for Development of Oxide Dispersion strengthened 9Cr Ferritic- Martensitic Steel Cladding Tubes, 2012.
Outstanding Achievement Award from ASM International Chennai Chapter, 2012.
VASVIK Award 2014 in the field of Material & Metallurgical Sciences & Technology from VASVIK Foundation, Mumbai.
DAE Group Achievement Award as Member for Design, Development and Manufacture of Titanium Dissolver for Fast Reactor Fuel Reprocessing, 2014.
DAE Group Achievement Award as Member for Performance testing of Primary Ramp & Primary Tilting Mechanism of the Inclined Fuel Transfer Machine of PFBR, 2014.
G.D. Birla Gold Medal 2014 for outstanding Research work in the field of Materials Sciences and Technologies from Indian Institute of Metals, Kolkata.
AICTE-INAE Distinguished Visiting Professorship by INAE, New Delhi for the year 2015-17.
Distinguished Faculty Award from Homi Bhabha National Institute, Mumbai in August 2015.
Meritorious Award for excellent contributions to corrosion science and technology from National Corrosion Council of India, Karaikudi, 2016.
DAE Group Achievement Award as Member for Development of Nitrogen Enhanced 316LN Austenitic Steel for Primary Components of Sodium Cooled Fast Reactors, 2016.
Distinguished Achievement Award from ASM International, Chennai Chapter, 2016.
Frank Newman Speller Award from National Association of Corrosion Engineers (NACE) International, USA, 2019.
Distinguished Alumnus Award from IIT Bombay, 2019.
Honorary Member Award, UDCT Alumni Association, ICT Mumbai, 2019.
Honorary Member Award, The Indian Institute of Metals, 2020.
Honour Lecture
First Prof. S.M. Mayanna Endowment Lecture by the Electrochemical Society of India, IISc., Bangalore, July 2004.
19th Prof. T.L. Rama Char Memorial Lecture by the Electrochemical Society of India, IISc., Bangalore, July 2008.
G.D. Birla Gold Medal Lecture by The Indian Institute of Metals, Kolkata, November 2014.
Ninth Dr. Placid Rodriguez Memorial Lecture Award by IIM Kalpakkam & Chennai Chapters at SRI Convention Centre, Anupuram, October 05, 2017.
Dr. Baldev Raj Memorial Lecture, National Design and Research Forum of The Institution of Engineers (India), Bengaluru, May 2018.
Fourth Dr.Abdul Kalam Memorial Materials Science Lecture Series, DMSRDE (DRDO), Kanpur, October 2018.
Inventa Prof. CK Murty Memorial Award Lecture of Indian Institute of Chemical Engineers, December 2018.
Prof. G R Damodaran Endowment Lecture, PSG Institutions, Coimbatore, February 2019.
Prof. Brahm Prakash Memorial Lecture by IIM Trivandrum Chapter, July 2019.
Diamond Jubilee Commemoration Lecture by IIM Bangalore Chapter, August 2019.
Vikram Sarabhai Memorial Lecture by ITM University, Baroda, October 2019.
OP Jindal Memorial Lecture, Jindal Steel Works Ltd., Vijayanagar, December 2019.
National Science Day Lecture, Indian Women Scientists Association, IWSA Kalpakkam, Jan 2020.
Tenth Prof. TR Anantharaman Memorial Lecture, IIT BHU & IIM Varanasi, July 2020.
Teachers Day Special Lecture, IIM Bhubaneswar & IMMT, Bhubaneswar, Sept. 2020.
Second Dr. Baldev Raj Memorial Lecture, NIT Raipur & IIM Bhilai Chapter, Sept. 2020.
38th Foundation Day Lecture, IEOT, Panvel, November 2020
Fellow of Academic Professional Bodies:
International
2013 Fellow of National Association of Corrosion Engineers (NACE), USA.
2013 Fellow of American Society of Materials International (ASM), USA.
2013 Academician (Fellow) of Asia Pacific Academy of Materials, China.
National
2006 Fellow of the Indian Institute of Metals (IIM), Kolkata.
2008 Fellow of the Indian National Academy of Engineering (INAE), New Delhi, India.
2008 Fellow of Electrochemical Society of India (ECSI), Bangalore.
2009 Fellow of Institution of Engineers (India), Kolkata.
2010 Fellow of Tamilnadu Academy of Sciences, Chennai.
2013 Honorary Fellow of Electrochemical Society of India.
2018 Fellow of National Academy of Sciences (NASI), Allahabad.
2018 Fellow of Indian Institute of Chemical Engineers, Kolkata
2019 Honorary Member, UDCT Alumni Association, ICT Mumbai
2020 Honorary Member, The Indian Institute of Metals, Kolkata
2020 Fellow, The Indian Chemical Society, 2020
Best Paper / Poster / Presentation Awards
Indian Institute of Welding (1986), Indian Institute of Metals (1991, 1997, 2000, 2009), NACE India Chapter (1997, 2005, 2007), Materials Research Society of India (2000), Society for Advancement of Electrochemical Science & Technology (2001,2007), National Corrosion Council of India (2002), IIM Kalpakkam Chapter (2008, 2009, 2010, 2011), International Nano 2010 (2010), NSEST 2011, International ICAM 2011 (2011), ECNTSE 2012, IWCEM 2012, ICONEST 2014 & 2017, CORSYM 2015 & 2017, NCCI 2016, CORCON 2015, 2016 & 2017.
12. Recognitions and Honours :
Fellowships
• Max-Planck Institute Fellowship, MPI, Dusseldorf, Germany, 1994
• Science and Technology Agency Fellowship, NIMS, Tsukuba, Japan, 1998
• Gordon Energy Centre Fellowship, Tel Aviv University, 2003 to deliver an intensive course on “Advanced Materials and Manufacturing Processes for Power Plant Components” from May 28 to June 04, 2003 at Tel Aviv University, Israel.
• Poitiers Regional Fellowship, France to work at LCD, ENSMA, Futuroscope, France, Sept.- Oct. 2008.
• Max-Planck Institute Fellowship, MPI, Dusseldorf, Germany, 2012.
Editorial Responsibilities
Member, Editorial Board, INAE Journal, 2013-2014
Member, Editorial Board, Journal of Frontiers in Materials, 2014 onwards
Key Reader, Metallurgical Transactions A, 2011-2017
Associate Editor, Journal of Electrochemical Society of India, Bangalore, 2009 -2018
Member Secretary, IIM-Universities Press Book Series, from 2009-2015.
Co-Editor in Chief, IIM-Springer Book Series, from 2016 onwards.
Member, Editorial Board, International Journal of Corrosion Reviews, 2003 onwards
Member, Editorial Board, Surface Engineering Journal, 2004 onwards
Member, Editorial Board, Materials and Manufacturing Processes Journal, 2004-2014
Member, Editorial Board, Journal of Materials Science and Technology, Bulgarian Academy of Sciences, Sofia, Bulgaria from 2007 onwards
Member, Editorial Advisory Board, Transactions of the Indian Institute of Metals, 2010-2016.
Member, Editorial Board, The Open Corrosion Journal, Bentham Sci. Publishers from 2008 – 2017.
Reviewer for reputed journals in Corrosion, Chemistry, Metallurgy & Materials Science
Books / Proceedings Edited / Published
1. Co-Editor, Special Issue on “Biomaterials Corrosion” in International Journal of Corrosion Reviews, M/s Freund Publishers, London and Tel Aviv, Vol. 21, 2003
2. Invited to contribute Guest Editorial in Surface Engineering Journal, Issue No.5, 2003
3. Co-Editor, Issue on ‘High Nitrogen Steels’, Transactions of the Indian Institute of Metals, 2002
4. Co-Editor, “High Nitrogen Steels and Stainless Steels”, Narosa, ASM & Alpha Publishers, 2004
5. Invited Article on “Anodic and Cathodic protection” in ‘Vol.4 : Corrosion and Oxide Films’ of Encyclopedia of Electrochemistry, eds. A.J. Bard and M. Stratmann, VCH Publishers, Germany, 2003
6. Co-Editor, “Corrosion Science and Technology”, Narosa, ASM & Alpha Publishers, 2008.
7. Co-Editor, “Corrosion Prevention & Control”, Narosa Publishers, New Delhi, 2009.
8. Co-Editor, Special Issue on “Corrosion Science and Technology in India” International Journal of Corrosion Reviews, M/s Freund Publishers, London and Tel Aviv, 2009.
9. Co-Editor, Proceedings of 23rd International Conference on “Surface Modification Technologies XXIII”, eds., T.S. Sudarshan, U. Kamachi Mudali and Baldev Raj, Valardocs Publishers, India, August 2010.
10. Co-Editor, Proceedings of Second International Conference on Asian Nuclear Perspectives (ANUP 2010), Energy Procedia of Elsevier Publishing Co., Oxford, UK, Baldev Raj, P.R. Vasudeva Rao, K.V.G. Kutty and U. Kamachi Mudali (2011).
11. Co-Editor, Strategies of Corrosion prevention, Proceedings of International Corrosion Prevention Symposium for Research Scholars, Published by NIGIS South Zone student section, Kalpakkam, Chennai , U. Kamachi Mudali, Pradeep Kumar Samantaroy, Rani P. George, N. Rajendran, and Baldev Raj (2013)
12. Co-Editor, Proceedings of the 11th International Conference on High Nitrogen Steels and Interstitial Alloys, VRK Printing House, Chennai, U. Kamachi Mudali, M.G. Pujar, Baldev Raj (2013)
13. Co-Editor, Proceedings of the International Conference on Heat Treatment and Surface Engineering, VRK Printing House, Chennai, U. Kamachi Mudali, Baldev Raj (2013)
14. Co-Editor, Series of technical books on Corrosion Prevention, CII-Corrosion Management Committee, Chandigarh, 2015.
15. S. Ningshen and U. Kamachi Mudali, ‘Nature & Forms of Corrosion’, FAQs Series Booklets Confederation of Indian Industry, Booklet No: 11, (2015), New Delhi, India
16. Co-Editor, Science based Technologies for Sustainable and Adequate Energy for India, A Monograph of Indian National Science Academy INSA, New Delhi, Baldev Raj, I. Manna and U. Kamachi Mudali (Sept. 2015).
17. Co-Editor, “Sensor Science and Technology”, M/s Narosa Publishing House, New Delhi, Baldev Raj and U. Kamachi Mudali, (2016).
18. Co-editor, Corrosion: Fundamental and Practical Aspects and Mitigation Strategies, Proc. of Int. Corr. Prevention Symp. For Research Scholars (CORSYM 2015), U. Kamachi Mudali, T.M. Sridhar, M. Kamaraj, K.R. Rasmi, C. Shanmugam and R.P. George, Sricreeper Publications, Chennai (2017).
19. Corrosion: Fundamental and Practical Aspects for Prevention, Control and Mitigation Strategies, Proc. of Int. Corr. Prevention Symp. For Research Scholars (CORSYM 2018), Radhakrishna G. Pillai, Deepak K. Kamde, Nancy David, N. Rajendran, U. Kamachi Mudali, Sricreeper Publications, Chennai (2018).
20. Co-Editor, Corrosion and Nondestructive Monitoring, John-Wiley Pub. Co., USA, R.K. Singh Raman, Baldev Raj, U. Kamachi Mudali and Prabhakar Singh, (in progress).
INAE Section Affiliated
VIII: Mining, Metallurgical and Materials Engineering
Year of Election to Fellowship
2009
Year of Birth
1960
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