James Malas

Adjunct Professor



Email: James Malas
Phone: 937-656-9215

Kettering Laboratories Room 524


Selected Publications

  • Gallagher, J.P., C.A. Babish, and J.C. Malas. 2005. Damage tolerant risk analysis techniques for evaluating the structural integrity of aircraft structures. Proceedings of the Structural Integrity in Transportation Systems Symposium, 11th International Conference on Fracture, March, in Turin, Italy.
  • Sundararaman, S., D.E. Adams, K. Jata, and J.C. Malas. 2004. Incipient damage identification using elastic wave propagation through a friction stir welded Al-Li interface for cryogenic tank applications, Proceedings of 2nd European Workshop on Structural Health Monitoring, July, in Munich, Germany.
  • Malas, J.C., S.Venugopal, and T. Seshacharyulu. 2004. Effect of microstructural complexity on the hot deformation behavior of Aluminum Alloy 2024. Materials Science and Engineering 368, nos. 1-2 (March 15): 41-47.
  • Seshacharyulu, T., Y.V.R.K. Prasad, S.C. Medeiros, W.G. Frazier, J.C. Malas, and B. Dutta. 2003. High-speed deformation processing of a titanium alloy. Advanced Engineering Materials 5, no. 9: 667-669.
  • Malas, J.C., W.G. Frazier, H.L. Gegel, and V. Srinivasan. 2003. Optimal design of thermomechanical processes. In the Handbook of Workability and Process Design, ed. by G.E. Dieter, H.A. Kuhn, and S.L. Semiatin, chapter 23, Materials Park, OH: ASM International.
  • Malas, J.C., C.V. Kropas-Hughes, J.L. Blackshire, T. Moran, D. Peeler, W.G. Frazier, and D. Parker. 2003. Micro and nano material systems for aircraft: Great things in small packages. Plenary paper at SPIE Conference on Testing, Reliability, Application of Micro-Nano-Material Systems, March, in San Diego, Calif.
  • Prasad, Y.V.R.K., T. Seshacharyulu, S. Medeiros, W.G. Frazier, J.T. Morgan, and J.C. Malas. 2000. Titanium alloy processing, advanced materials & processes. ASM International 157, no.6: 85-89.
  • Y.V.R.K. Prasad, T. Seshacharyulu, S.C. Medeiros, W.G. Frazier & J. C. Malas. 2000. Hot deformation mechanisms in Ti-6Al-4V with transformed beta starting microstructure: Commercial v. extra low interstitial grade. Journal of Materials Science and Technology 16, no.9 (September): 1029-1036.
  • Sensors and modeling in materials processing. 1997. Ed. S. Viswanathan, R.G. Reddy, and J.C Malas. Warrendale, Pa: The Metallurgical Society of AIME.
  • Malas, J.C., and W.G. Frazier. 1999. Trajectory optimization of thermomechanical processes using ideal material deformation concepts. In the Integration Of Material, Process And Product Design, ed. N. Zabaras, R. Becker, S. Ghosh and L. Lalli, 229-236. Rotterdam, Netherlands: A.A. Balkema Publishers.

Research and Work Experience

  • Adjunct Professor, University of Dayton, 2003-present
  • Deputy Chief Engineer, Materials and Manufacturing Directorate, Air Force Research Laboratory, 2007-present
  • Branch Chief and Core Technology Area Leader, Nondestructive Evaluation, Metals, Ceramics, and NDE Division, Materials and Manufacturing Directorate, Air Force Research Laboratory, 1999-2007
  • In-House Research Leader, Process Design Group, Materials Process Design Branch, Manufacturing Technology Division, Materials & Manufacturing Directorate, Air Force Research Laboratory, 1991-1999
  • Materials Research Engineer, Processing Science Group, Processing & High Temperature Materials Branch, Metals & Ceramics Division, Materials Laboratory, 1978-1991

Honors and Awards

  • Air Force Research Laboratory Fellow
  • Fellow of ASM International - The Material Information Society
  • Fellow of Society of Manufacturing Engineers
  • Federal Laboratory Award for Excellence in Technology Transfer
  • Air Force Association's Outstanding Civilian Manager at Wright-Patterson AFB Award
  • Dayton Foundation's Affiliate Societies Council Award for Outstanding Research Engineer
  • The Ohio University Alumni Association C. J. Ping Award for Leadership in Career Field
  • Exemplary Civilian Service Award


  • Ph.D., Integrated Engineering, Ohio University, 1991
  • M.S., Systems Engineering, Wright State University, 1985
  • B.S., Materials Science and Engineering, Wright State University, 1980

Research Interests

  • Modeling and simulation of deformation, thermal and solidification processes
  • Constitutive relationships and microstructural evolution
  • Microstructure/processing relationships of titanium, nickel, aluminum, and intermetallic alloys and their composites
  • Modeling and control of material processing equipment
  • Metallurgical synthesis and advanced process design methods