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Rahul Jain
Associate Professor
Department of Mechanical Engineering
Email: rahul@iitbhilai.ac.in
Office address: Room no. 411B, Third floor Bhardwaj (ED-2) Building, IIT Bhilai, Kutelabhata, Dist. Durg, (CG) (491002)

Research Area


  • Numerical modeling of manufacturing processes
  • Friction stir welding/processing
  • Machining
  • Additive manufacturing
  • Materials characterization


  • PhD, 2017, Indian Institute of Technology Kharagpur
  • M.Tech (Manufacturing science and engineering), 2010, Indian Institute of Technology Kharagpur
  • B.E. (Mechanical engineering), 2008, Government engineering college Bilaspur



  • ME551/Advance Manufacturing process
  • IC601/Research Methodology
  • ME270/ Manufacturing science I
  • ME633/Finite element method
  • ME201/Design of Experiment
  • ME251/Manufacturing science
  • ME403/Operation research
  • ME372/Mechanical Engineering Lab-II
  • ME-151/Fundamentals of Metallurgy



  • Sep 2010 to Jul 2012: Manager, ERC (Transmission design), Tata Motors, Pune
  • Apr 2013 to Feb 2018: Research Engineer, Indian Institute of Technology Kharagpur
  • May 2018 to November 2024: Assistant Professor, IIT Bhilai
  • November 2024 to Till date: Associate Professor, IIT Bhilai


  1. Ketha Jaya Sandeep, Pilli Jaya Teja, Atul Kumar choudhary, Rahul Jain, ‘Development of correlation between temperature, liquid life span, molten pool, and porosity during wire arc additive manufacturing: A finite element approach’, CIRP Journal of Manufacturing science and technology, 2022, Vol. 38, pp-274-287

  2. MP Iqbal, Rahul Jain, SK Pal, P Mandal, ‘Numerical modelling of friction stir welding of pipes: Effect of tool shoulder on mechanical property and metallurgical chacterization’, Journal of Manufacturing processes, Vol. 79, 2022, PP: 326-339

  3. Atul Choudhury, Rahul Jain, ‘Numerical prediction of various defects and their formation mechanism during friction stir welding using coupled Eulerian Lagrangian technique’, Mechanics of advanced materials and structures, 2022 (Published online on 21st March 2022)

  4. Md. Perwej Iqbal, Ashish Tripathi, Rahul Jain, Raju P Mahto, Surjya K Pal, Partha Mandal, ‘ Numerical modeling of microstructure in friction stir welding of aluminum alloys’, International journal of mechanical sciences, 2020, Vol. 185 I.F. 4.631

  5. Md. Perwej Iqbal, Rahul Jain, Surjya K Pal, ‘Numerical and experimental study on friction stir welding of aluminum alloy pipe’, Journal of materials processing Technology, 274, (2019)

  6. Rahul Jain, Surjya K Pal, Shiv B Singh, ‘Investigation on effect of pin shapes on temperature, material flow and forces during friction stir welding: A simulation study’, IMECHE Part B: Journal of Engineering manufacture, 2019, vol. 233 (9), pp: 1980-1992. IF: 1.982

  7. Shilpi Kumari, Rahul Jain, Ujjawal Kumar, Inderjeet Yadav, Nitin Ranjan, Kanchan Kumari, Ramkumar Kesharwani, Sachin Kumar, Srikanta Pal, Surjya K. Pal, Debashish Chakravarty, ‘Defect identification in friction stir welding using continuous wavelet transform’, Journal of Intelligent Manufacturing (2016) (Published on September 17, 2016), February 2019, Volume 30, Issue 2, pp 483–494

  8. Prashant Chauhan, Rahul Jain, Surjya K Pal, Shiv B Singh, ‘Modeling of defects in friction stir welding using coupled Eulerian and Lagrangian method’, Journal of manufacturing processes, 2018, Vol 34 (Part A), pp: 158-166. I.F. 4.086

  9. Rahul Jain, Kanchan Kumari, Surjya K. Pal, Shiv B. Singh, ‘A novel counter rotating twin tool system in a friction stir welding process: a simulation study’, Journal of materials processing and technology, 255 (2018), pp-121-128

  10. Rahul Jain, Surjya K. Pal, Shiv B. Singh, ‘Finite element simulation of pin shape influence on material flow, forces in friction stir welding’, International Journal of Advanced Manufacturing and Technology, 94 (Feb 2018), pp 1781-1797

  11. Rahul Jain, Surjya K. Pal, Shiv B. Singh, ‘Finite element simulation of temperature and strain distribution during friction stir welding of AA2024 aluminum alloy’, Journal of Institution of Engineers Series C. 98 (2017), 37–43.

  12. Chirag Parikh, Ravi Ranjan, Aaquib Reza Khan, Rahul Jain, Raju Prasad Mahto, Debashish Chakravarty, Srikanta Pal, Surjya K. Pal. ‘Volumetric defect analysis in friction stir welding based on three dimensional reconstructed images’, Journal of manufacturing processes, 29,(2017),96-112

  13. Rahul Jain, Surjya K. Pal, Shiv B. Singh,‘ A study on the variation of forces and temperature in a friction stir welding process: A finite element approach’, Journal of Manufacturing Processes 23 (2016), 278–286.

  14. Prakash Kumar Sahu, Sukhomay Pal, Surjya K. Pal, Rahul Jain, ‘Influence of plate position, tool offset and tool rotational speed on mechanical properties and microstructures of dissimilar Al/Cu friction stir welding joints’, Journal of Materials Processing Technology 235 (2016), 55–67.

  15. Ravi Ranjan, Aaquib Reza Khan, Chirag Parikh, Rahul Jain, Raju Prasad Mahto, Srikanta Pal, Surjya K. Pal, Debashish Chakravarty, ‘Classification and identification of surface defects in friction stir welding: An image processing approach’, Journal of Manufacturing Processes. 22 (2016) 237–253.

  16. Ujjawal Kumar, Inderjeet Yadav, Shilpi Kumari, Kanchan Kumari, Nitin Ranjan, Ramkumar Kesharwani, Rahul Jain, Sachin Kumar, Srikanta Pal, Debashish Chakravarty, Surjya K. Pal, ‘Defect identification in friction stir welding using discrete wavelet analysis’, Advances in Engineering Software 85 (2015), 43-50



  • Investigations into the dynamic fracture behavior of friction stir welds in aluminum alloys (RIG-IIT Bhilai)- Completed

  • Application of Thermal Radiography and Artificial Intelligence for detection of surface defects in Blooms/Billets during continuous casting process(Ongoing)




Message From Director

I am pleased to extend my greetings to students and their parents as well as colleagues near and far. IIT Bhilai was established on 7 August 2016. We are located in Chhattisgarh, the rice bowl of India, in a state rich in natural resources as well as cultural memory and heritage. Read More

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