Dr. Ajay Essampally
Senior Metallurgist and Head of Quality Assurance; NADCAP AC7101 Materials Testing Lead, TCR Engineering.
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Ajay Essampally is a metallurgical engineer with deep expertise in corrosion engineering, failure analysis, welding, and advanced material characterisation. He holds a Ph.D. from the Indian Institute of Technology Bombay, specialising in the corrosion and stress corrosion cracking behaviour of super duplex stainless steel welds.
His career spans extensive hands-on R&D work involving mechanical testing, microstructural analysis (SEM, EBSD, XRD), electrochemical testing, and customized test rig fabrication for aggressive environments.
Background and experience
Ajay has played a lead role in consultancy projects for major clients such as SHELL and ELEMENT, where he designed and executed high-temperature deaerated corrosion testing systems. His work reflects strong cross-functional abilities in project execution, test protocol development, research mentoring, and technical documentation.
At IIT Bombay, he served as a Teaching Assistant in the Department of Metallurgical Engineering and Materials Science and mentored several M.Tech and undergraduate students.
He is well-versed in welding technologies like Gas Tungsten Arc Welding (GTAW) and Friction Stir Welding (FSW), with a deep understanding of their metallurgical and electrochemical performance in critical service environments such as marine and desalination. Ajay’s technical software expertise includes SolidWorks, AutoCAD, EChemAnalyst, and Origin.
Ajay has presented his work at numerous national and international conferences and has been the recipient of several Best Paper awards. His contributions to the field are further reflected in his peer-reviewed publications.
At TCR, Ajay leads the accreditation and audit function. He handles the NABL ISO/IEC 17025:2017 assessments, the NADCAP AC7101 Materials Testing accreditation, and the BIS, IBR, PDIL, and RITES audits, and he leads the preparation, the assessment response, and the corrective-action closure for each of them.
Selected Publications:
- Role of microstructure on the varying corrosion behaviour across the UNS S32750 super duplex stainless-steel friction stir weld - Journal of Materials Science, 2025, 60, 1628–1646
- Effect of wide range of heat treatments on the corrosion resistance of additively manufactured 316L stainless steel (316L SS) via PBF-LB/M (powder bed fusion of metals using a laser beam) - Progress in Additive Manufacturing, 2025
- Stress corrosion cracking behaviour of welded UNS S32750 in aggressive chloride environments
In the Insights
Dr. Ajay Essampally is named in 1 published article in the TCR Engineering Insights archive, covering the investigations, accreditations and technical work Ajay has been part of. Each one is dated and on the record.
The rest of the bench
Dr. Ajay Essampally is one of 28 named leaders across TCR Engineering, TCR Advanced and the group functions. Every one of them is on record with their role, their credentials and the work they sign for.