Dr. Ajay Essampally
Senior Metallurgist and Head of Quality Assurance; NADCAP AC7101 Materials Testing Lead, TCR Engineering.
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In brief
Dr. Ajay Essampally heads Quality Assurance at TCR Engineering and is a metallurgical engineer specialising 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 customised test rig fabrication for aggressive environments.
Background and experience
Ajay has played a lead role in consultancy projects for clients including Shell and Element, where he designed and executed high-temperature deaerated corrosion testing systems. The work covered 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 works with Gas Tungsten Arc Welding (GTAW) and Friction Stir Welding (FSW) and their metallurgical and electrochemical performance in marine and desalination service. Ajay’s technical software expertise includes SolidWorks, AutoCAD, EChemAnalyst, and Origin.
He has presented at national and international conferences, has received several Best Paper awards, and publishes in peer-reviewed journals.
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 4 published articles 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.
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Make in India, Test in India: Building a Resilient Domestic Quality Assurance Ecosystem for Aerospace Forgings, Castings and Machining
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TCR becomes the first Indian group with two NADCAP AC7101 accredited laboratories: Navi Mumbai and Vadodara
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TCR Engineering renews NABL ISO/IEC 17025 accreditation to 2030, with 1,483 test methods in scope
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Retained Austenite in SAE 52100 Steel: Why Accurate Measurement Matters for CAM Performance
The rest of the bench
The TCR bench runs to 28 named leaders across TCR Engineering, TCR Advanced and the group functions, and every one of them is on record with their role, their credentials and the work they sign for.
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