Lawrence Livermore National Lab | United States
Dr. Shahryar Mooraj is a distinguished Post-Doctoral Researcher at Lawrence Livermore National Laboratory (LLNL), renowned for his groundbreaking contributions to metal additive manufacturing (AM) and advanced materials science. With a Ph.D. in Mechanical Engineering from the University of Massachusetts Amherst, his research spans the development of next-generation materials and fabrication processes that integrate precision engineering, artificial intelligence, and materials design. Dr. Mooraj’s scientific achievements are characterized by innovation in high-entropy alloys (HEAs), refractory materials, and hierarchical nanoporous structures. His research in microstructure control and defect mitigation has provided new insights into the mechanical and thermal behaviors of additively manufactured metals. His work on high-performance refractory alloys contributes to the design of plasma-facing materials for fusion energy systems, while his digital twin models enhance automation and defect prediction in manufacturing processes through AI integration. Notably, Dr. Mooraj developed a custom droplet-on-demand molten metal jetting system for boutique powder synthesis and created a rapid, cost-efficient platform for liquid metal wetting analysis, revolutionizing materials compatibility screening for AM. His investigations into hierarchical 3D architectures fabricated via direct ink writing (DIW) have also expanded the frontier of energy storage and electrocatalytic materials. His collaborations with leading global institutions including A*STAR (Singapore), Max Planck Institute (Germany), and ORNL (USA) underscore his role in advancing interdisciplinary materials research and fostering international scientific innovation. With 381 citations across 355 documents, 17 publications, and an h-index of 11 (Scopus), Dr. Mooraj’s scholarly impact reflects his sustained research excellence and leadership in additive manufacturing and material innovation. His forward-looking vision aims to establish sustainable, AI-driven, and defect-free manufacturing paradigms, aligning with global priorities in advanced materials design and next-generation engineering technologies.
Featured Publications
Mooraj, S., Feng, S., Luebbe, M., Register, M., Liu, J., Li, T., Yavas, B., Schmidt, D. P., et al. (2025). Martensitic transformation induced strength-ductility synergy in additively manufactured maraging 250 steel by thermal history engineering. Journal of Materials Science & Technology, 211, 212–225.
Mooraj, S., Fu, J., Feng, S., Ng, A. K., Duoss, E. B., Baker, S. E., Zhu, C., Detsi, E., et al. (2024). Additive manufacturing of multiscale NiFeMn multi-principal element alloys with tailored composition. Materials Futures, 3(4), 045103.
Mooraj, S., Dong, X., Zhang, S., Zhang, Y., Ren, J., Guan, S., Li, C., Naorem, R., et al. (2024). Crack mitigation in additively manufactured AlCrFe₂Ni₂ high-entropy alloys through engineering phase transformation pathway. Communications Materials, 5(1), 101.
Mooraj, S., Kim, G., Fan, X., Samuha, S., Xie, Y., Li, T., Tiley, J. S., Chen, Y., Yu, D., et al. (2024). Additive manufacturing of defect-free TiZrNbTa refractory high-entropy alloy with enhanced elastic isotropy via in-situ alloying of elemental powders. Communications Materials, 5(1), 14.
Zhang, S., Hou, P., Kang, J., Li, T., Mooraj, S., Ren, Y., Chen, C. H., Hart, A. J., et al. (2023). Laser additive manufacturing for infrastructure repair: A case study of a deteriorated steel bridge beam. Journal of Materials Science & Technology, 154, 149–158.