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Biography

Dr. Chavan is presently working as Scientist-E in the Centre for Engineered Coatings, ARCI, Hyderabad. His research areas of interest include development of cold spray and plasma spray coating/build solutions, structure-property correlations especially in coatings, mechanical behavior of materials at extreme conditions, process diagnostics in thermal spray. He completed engineering in Metallurgy from Mahatma Gandhi Institute of Technology under JNTU Hyderabad with a University Gold Medal in 2006. After that he joined IIT Kanpur for the Masters program in Metallurgy. During this time he got selected as Scientist-B at ARCI where he began his career in the area of surface engineering. He obtained his PhD in Metallurgy under the tutelage of Padmashri Dr G Sundararajan (ex Director ARCI) and Prof. Prita Pant from IIT Bombay. At ARCI, true to the mandate, he has made pioneering contributions towards development of the indigenous Cold spray system. The journey led to notable work on nozzle design and material, widening deposition spectrum and post treatment strategies for cold spray coatings. This has paved way for the successful technology transfer of the indigenous cold spray system to IIT (ISM) Dhanbad and in pipeline to other Indian academic institutes and industries. The Indian and Russian patent for ARCI developed cold spray technology have been granted. Dr Chavan has also made efforts on the particle diagnostics front involving measurement of particle velocity and temperature in-flight and correlation to the achieved microstructure and properties in all thermal sprayed coatings. He is also been working on performance evaluation of coatings especially electrical conductivity/resistivity, bond strength measurements at ARCI. Dr Chavan is lately also involved in several R&D and sponsored programs in Plasma spray related to energy and other niche sectors. He has worked on several application and product developments for civilian and strategic sectors during his career at ARCI in various capacities leading to revenue generation to the tune of INR 1500 lakh.  He has over 28 peer reviewed publications, 4 patents, 10 publications in conference proceedia. He was selected as BRICS young scientists forum held in Russia (2011) and South Africa (2023). As a resource person, Dr Chavan had taught Practical course on Advanced manufacturing (MF455) for M.Tech at Univeristy of Hyderabad since the inception of the course in 2020. He was a course faculty for (i) Faculty development (FDP), ATAL program by AICTE, NIFFT, Ranchi, Dec.2022, Topic: Advanced Remanufacturing Technology. (ii) 5 day workshop conducted on “Surface Engineering: Technology, Research and Applications (SETRA) at ARCI in Aug.2012 (iii) Cold spray Applications during TSS workshop conducted at ARCI in Feb.2015 to contribute towards TR Anantharaman Trust.

Dr Chavan delivered an invited talk on (i) Developments in Cold spray at TechEX-17 conducted at ARCI in Feb.2017 (ii) Cold spray: Fundamentals to Applications at One day Business Oppurtunity workshop conducted at ARCI in Oct.2022, (iii) “Surface Engineering and Beyond” at JNTU College of Engineering, April 2022, (iv) Alumnus Guest lecture at MGIT, Hyderabad on Surface Engineering and Adv. Manufacturing, Nov. 2023

On other front he has been an External Examiner for Masters & PhD thesis from University of Hyderabad, VJTI, Mumbai respectively, Regular External Examiner at MGIT, Hyderabad for lab practicals, External Judge at MVSR Engg. college(s) as part of SAE, Hyderabad Chapter, External expert member on BoS (Board of Studies), Metallurgy and Materials Technology, National Inst. of Technology-AP. He has Thesis Supervision – 3 PhD (collaboration-ongoing), M.Tech (4 completed),B.Tech (12 completed, 1-ongoing), Graduate Trainees (3-completed and placed),

PGTP (1-completed), JRF (collaboration-3) and  Summer interns/Diploma projects- ~10

Research Areas of Interest

cold spray and plasma spray coating/build solutions, structure-property correlations especially in coatings, mechanical behavior of materials at extreme conditions, process diagnostics in thermal spray, post treatment strategies for thermal spray coatings

Highest Qualification

Ph.D

List of Publications

  1. Naveen Manhar Chavan and Shaik Rahil, Cost effective method to obtain high conductivity Copper coatings, Under preparation
  2. Swarna Madugula; Manoj kumar P; Naveen Manhar Chavan; G Sivakumar, Adepu Kumar; S M Shariff, Rapid Infrared Radiation processing for Synergistic Microstructural Optimization and Tribological Enhancement of HVAF Ni-Alloy Coatings, Under review, Surface and Coatings Technology 2025
  3. Naveen Manhar Chavan, U.Vamshi, Akash Chavan, KV Girish, S Kumar, JP Gautam, Grain refinement in cold spray coatings: A microstructural, parametric and mathematical analysis, 179573  Journal of Alloys and Compounds, Volume 1021, 5 April 2025, 179573.
  4. Hembram, Shilabati; Roy, Avishek; Naveen Manhar Chavan, S Kumar, Ghosh, Manojit; Majumdar, Abhijit, Optimising properties of a cold sprayed CuAlFeB powder on EN AW 7075 substrate, Journal of Materials Engineering and Performance, Journal of Materials Engineering Performance, Jan 2025, 1-11
  5. Yogeswar K, S Kumar, Naveen Manhar Chavan, Nozzle materials solution to clogging in cold spray, Manufacturing Letters, 40, 2024, 22-25
  6. S Kumar, G Neelima Devi; M Tarun Babu; Gidla Vinay; Naveen Manhar Chavan; A Venu Gopal, Assessing critical process condition for bonding in cold spraying, Surface and Coatings Technology, Volume 470, 15 October 2023, 129839
  7. Naveen Manhar Chavan, Prita Pant, G Sundararajan and P Sureshbabu, Post treatment of cold sprayed coatings using high-energy infrared radiation: First comprehensive study on structure-property correlation, Surface & Coatings Technology 448 (2022) 128902
  8. Vinay G, Naveen Manhar Chavan  (corr. Author), S Kumar, A Jyothirmayi and Bolla Reddy B, Improved microstructure and properties of cold sprayed zinc coatings in the as sprayed condition, Surface and Coatings Technology (2022),
  9. S Kumar, A Dhawale, Naveen Manhar Chavan, S Acharya, Superconducting niobium coating deposited using cold spray, Materials Letters(2022), 132, 113715. 
  10. Kumar, S., Bodapati, B.R., Vinay, G., Vamshi Kumar, K., Chavan, N.M., Suresh Babu, P., Jyothirmayi, A., Estimation of inter-splat bonding and its effect on functional properties of cold sprayed coatings(2021),  Surface and Coatings Technology, 420, art. no. 127318.
  11. Vinay, G., Kumar, S., Chavan, N.M. Generalised bonding criteria in cold spraying: Revisiting the influence of in-flight powder temperature (2021), Materials Science and Engineering A, 823, art. no. 141719
  12. Chavan, N.M., Phani, P.S., Ramakrishna, M., Venkatesh, L., Pant, P., Sundararajan, G. Role of stacking fault energy (SFE) on the high strain rate deformation of cold sprayed Cu and Cu–Al alloy coatings,(2021) Materials Science and Engineering A, 814, art. no. 141242
  13. Chavan, N.M., Vinod Kumar, M., Sudharshan Phani, P., Pant, P., Sundararajan, G.Influence of Nozzle Throat Cross Section on Microstructure and Properties of Cold Sprayed Coatings(2019) Journal of Thermal Spray Technology, 28 (7), pp. 1718-1729.
  14. Anupam, A., Kumar, S., Chavan, N.M., Murty, B.S., Kottada, R.S. First report on cold-sprayed AlCoCrFeNi high-entropy alloy and its isothermal oxidation(2019),Journal of Materials Research, 34 (5), pp. 796-806.
  15. Krishna, L.R., Madhavi, Y., Sahithi, T., Wasekar, N.P., Chavan, N.M., Rao, D.S. Influence of prior shot peening variables on the fatigue life of micro arc oxidation coated 6061-T6 Al alloy (2018) International Journal of Fatigue, 106, pp. 165-174.
  16. Kumar, S., Ramakrishna, M., Chavan, N.M., Joshi, S.V. Correlation of splat state with deposition characteristics of cold sprayed niobium coatings (2017), Acta Materialia, 130, pp. 177-195. Cited.
  17. Kumar, M., Singh, H., Singh, N., Chavan, N.M., Kumar, S., Joshi, S.V. Development of Erosion-Corrosion-Resistant Cold-Spray Nanostructured Ni-20Cr Coating for Coal-Fired Boiler Applications(2015) Journal of Thermal Spray Technology, 24 (8), pp. 1441-1449.
  18. Kaur, N., Kumar, M., Sharma, S.K., Kim, D.Y., Kumar, S., Chavan, N.M., Joshi, S.V., Singh, N., Singh, H. Study of mechanical properties and high temperature oxidation behavior of a novel cold-spray Ni-20Cr coating on boiler steels (2015) Applied Surface Science, 328, pp. 13-25
  19. Kumar, M., Singh, H., Singh, N., Hong, S.-M., Choi, I.-S., Suh, J.-Y., Chavan, N.M., Kumar, S., Joshi,S.V. Development of nano-crystalline cold sprayed Ni-20Cr coatings for high temperature oxidation resistance (2015) Surface and Coatings Technology, 266, pp. 122-133.
  20. Sundararajan, G., Chavan, N.M., Kumar, S. The elastic modulus of cold spray coatings: Influence of inter-splat boundary cracking (2013) Journal of Thermal Spray Technology, 22 (8), pp. 1348-1357.
  21. Chavan, N.M., Kiran, B., Jyothirmayi, A., Phani, P.S., Sundararajan, G. The corrosion behavior of cold sprayed zinc coatings on mild steel substrate(2013) Journal of Thermal Spray Technology, 22 (4), pp. 463-470.
  22. Venkatesh, L., Chavan, N.M., Sundararajan, G. The influence of powder particle velocity and microstructure on the properties of cold sprayed copper coatings(2011), Journal of Thermal Spray Technology, 20 (5), pp. 1009-1021.
  23. Chavan, N.M., Ramakrishna, M., Phani, P.S., Rao, D.S., Sundararajan, G., The influence of process parameters and heat treatment on the properties of cold sprayed silver Coatings (2011), Surface and Coatings Technology, 205 (20), pp. 4798-4807.
  24. Sundararajan, G., Chavan, N.M., Sivakumar, G., Sudharshan Phani, P. Evaluation of parameters for assessment of inter-splat bond strength in cold-sprayed coatings (2010), Journal of Thermal Spray Technology, 19 (6), pp. 1255-1266.
  25. Sen, D., Chavan, N.M., Rao, D.S., Sundararajan, G. Influence of grit blasting on the roughness and the bond strength of detonation sprayed coating (2010), Journal of Thermal Spray Technology, 19 (4), pp. 805-815.

Conference Proceedings

  1. G Sundararajan, Naveen M Chavan and G Sivakumar, “Effect of heat treatment on properties of thick thermal spray coatings”, International Conference on Metallurgical Coatings & Thin Films, April- May 2008, San Diego, USA.
  2. Naveen M Chavan, PS Phani and G Sundararajan, Effect of Process Parameters and Heat treatments on the properties of cold sprayed silver coatings, Proceedings of the Asian Thermal Spray Conference, November 2008, Nanyang Technological University, Singapore. (Oral Presentation)
  3. Naveen M Chavan, A Jyothirmayi, Kiran B, G Sundararajan, Corrosion behavior of Cold sprayed Zinc coatings”, 14th National Congress on Corrosion Control in India, September 2008, Hyderabad, India
  4. Kumar, M., Singh, H., Singh, N., Chavan, N.M., Kumar, S., Joshi, S.V ,Development of Erosion-Corrosion-Resistant Cold-Spray Nanostructured Ni-20Cr Coating for Coal- Fired Boiler Applications, 6th Asian Thermal Spray Conference (ATSC 2014), Hyderabad, India
  5. Naveen Manhar Chavan, , L Venkatesh, P Suresh Babu, Prita Pant, G Sundararajan, Cold Sprayed Copper and Copper Aluminium Alloys: Influence of Stacking Fault Energy on the Structure and Properties, SMT 30-Politecnico Di Milano- Milan, Italy-July 2016
  6. Kumar, M., Singh, H., Singh, N., Joshi, S.V., Chavan, N.M., Kumar, S. Evaluation of high temperature oxidation behavior of a cold spray Ni-20Cr nano-structured coating(2016), Proceedings of the International Thermal Spray Conference, 1, pp. 220-225.
  7. Kumar, M., Singh, H., Singh, N., Chavan, N.M., Kumar, S., Joshi, S.V. Development of high-performance cold-sprayed nanostructured ni-20cr coatings for harsh environment of power plant boilers (2017) Proceedings of the International Thermal Spray Conference, 2, pp. 1061-1066.

Patents

  1. An improved gas dynamic cold spray device and method of coating a substrate, Naveen M Chavan, S Kumar, PS Phani and DS Rao, Indian Patent Application: 201711006749, granted with 572055 on 14/10/2025
  2.  An improved gas dynamic cold spray device and method of coating a substrate, Naveen M Chavan, S Kumar, PS Phani and DS Rao, Russian Patent Application:2744008 (Granted—May 2021)
  3. An improved gas dynamic cold spray device and method of coating a substrate, Naveen M Chavan, S Kumar, PS Phani and DS Rao, Chinese Patent Application: 201880013832.3, Under examination
  4. An improved gas dynamic cold spray device and method of coating a substrate, Naveen M Chavan, S Kumar, PS Phani and DS Rao, Patent Cooperation Treaty Application: WO2018154599 (Filed in 2018)
  5. Anti-Clogging Cold-Spray Nozzle to deposit Clog-Prone Materials, S Kumar, , Naveen M Chavan and Yogeswar Kovvuru, Filed in India (March 2022)

Major Projects / Technologies Developed

  1. Development of high conductivity-oxidation resistant 3 mm thick pure silver coatings on SS boiler tubes using cold spray facility, 2007-2008, Duration: 6 months Funding agency: BHEL Trichy -INR 6 Lakh (as PI) 
  • Process Parameters for Silver coating using cold spray were optimized to achieve high electrical conductivity
  • A 3 mm thick Ag coated tube on half circumference were supplied
  1. Development of Zn and Sn based composite coatings on Al busbars for Siemens India for friction stir welding applications, 2010-2011, Duration: 3 months, Funding agency: Siemens India, Bengaluru - INR 5 lakh (as co-PI) 
  • Process Parameters for Zn and Sn based composite using cold spray were optimized to achieve high electrical conductivity
  • Coatings deposited on 1 m long Aluminium bus bars were delivered to M/s Siemens, Bangalore
  1. Developmental studies on feasibility to deposit Ni-Cr and Inconel coatings for repair applications, 2013, Duration: 3 months, Funding agency: GE Bengaluru - INR 3.5 lakh (as co-PI)
  • Exploratory study to deposit Ni based coatings
  1. Development of superconducting Niobium coatings on Cu cavities-Phase 1, 2015-2017, Duration- 24 months, Funding agency: BRNS, BARC Mumbai, INR 23 lakh (as co-PI)
  • Optimised process parameters and post treatments to achieve super conducting Nb coatings at ~9.3K
  • Detailed tests carried out at BARC
  1. Development of thick and highly conductive copper coatings on six sides of cubical shape SS for plasma facing applications, 2014, Duration: 3 months, Funding agency: IPR Gandhinagar – IIT Ropar, INR 3.5 lakh (as PI)
  • Optimised process parameters to deposit 3 mm thick Cu coatings on SS304 
  • High electrical conductivity was achieved
  • Cube specimens coated on all 6 sides were supplied to IITR-IPR for Plasma facing applications (Tokamak type mock ups) 
  1. Structural repair of Al aerospace alloys using cold spray, 2015-2017, Duration: 3 years  Funding agency: Boeing India Bengaluru, INR 78 lakh (as co-PI)
  • Process parameter optimization trials for deposition of three Aluminium alloys viz., AA2024, AA6061 and AA7075
  • Developed nozzle that is clog proof (prior to start of this activity)
  • Repaired damaged plates and performed mechanical/tensile tests by extracting tensile specimens from repaired areas and proposed roadmap for future work on bigger structural members of aircraft.
  1. Development (and supply) of Cu and refractory based composite coatings for electromagnetic rail gun applications, 2015-2017, Duration: 3 years, Funding agency: ARDE, DRDO, Pune, INR 37 lakh (co-PI)
  • Powder preparation using different blending methods
  • Optimized process parameters and heat treatments to deposit Cu based refractory metal composite coatings on pure Cu.
  • Extensive tribological studies carried out at RT and high temperature (500oC)
  • Optimised compositions were deposited on 4 nos of 4 m long Cu rails and delivered to ARDE Pune
  1. Development of biocompatible Ti coatings on SS, PEEK substrates and implants for invitro and invivo studies, 2017 to 2020, Duration: 1 month on three to four occasions, Funding agency: M/s Wissenkraft Pune, INR- 3 lakh (as PI and co-PI)
  • Optimised process conditions to deposit Titanium with varied porosity
  • Coatings deposited on two different substrates such as SS and PEEK
  • In Vitro and In Vivo tests conducted on nearly 40 samples with promising bioactivity
  1. Development of high entropy alloy coatings using cold spray as potential bond coat replacements, 2015-2020, Duration: 5 years (our share 1st and 2nd year) Funding agency: ARDB, Bengaluru, INR 50 lakh (as co-PI)
  • Optimised process conditions to deposit ball milled powders of two high entropy alloys viz., CoCrNiFeMn and CoCrNiFeAl
  • Extensive oxidation studies conducted showed ability of coating to protect substrate 
  • Published the work in JMR which was the first ever article in the world depositing HEA using cold spray
  1. Development and supply of repaired Al, Ti, Steel and Inconel parts—Stage-1 (3 months), 2021-2022, Funding agency: VSSC Trivandrum, INR- 4.99 lakh (as PI)
  2. Optimised process conditions to deposit into grooved tensile samples and supplied after fine grinding and polishing to funding agency.
  3. Also a part of the NCCORD project in the formative stages (~10 Crores), 2020-2024

Awards & Honours

GATE rank 35 

BRICS Young Scientist (2011 and 2023)

Affiliation to Professional Societies

Life member Indian Institue of Metals

Life member MAterials Research Society of India