Amir Motallebzadeh applies advanced materials science to real world grinding media performance, helping Molycop translate laboratory research into measurable outcomes for mineral processing operations.
Key facts
- Amir Motallebzadeh is a Metallurgical Lab Engineer at Molycop, based in Australia, supporting grinding media innovation through advanced materials science.
- He holds a PhD in Metallurgical and Materials Engineering and has published 80+ peer reviewed papers focused on wear resistance, coatings, and alloy performance.
- At Molycop, his work links laboratory characterisation, predictive metallurgy, and failure analysis to improve grinding media durability and milling efficiency.
Amir Motallebzadeh, Metallurgical Lab Engineer based in Australia, brings a depth of expertise that sits at the intersection of advanced materials science and practical application—supporting the development of high-performance grinding media for demanding mineral processing environments.
A foundation built on advanced materials research
Amir’s journey into metallurgy began with a PhD in Metallurgical and Materials Engineering, where he focused on wear-resistant coatings, tribology, and materials characterisation.His doctoral research centred on developing composite hardfacing coatings using plasma transferred arc (PTA) welding—paired with detailed microstructural analysis and wear testing under both ambient and elevated temperatures. The objective was clear: improve durability and extend the service life of components operating under severe conditions.
Following his PhD, Amir continued to build his expertise across both academic and industrial settings. He led and contributed to industry-aligned projects focused on improving the wear resistance and longevity of metallic components. This included work on advanced coating technologies such as PVD and molybdenum coatings, optimisation of heat treatment processes, and thermochemical treatments including nitriding and boriding.
His work also extended into the design and pilot-scale production of bimetallic components, as well as research into advanced alloy systems such as high-entropy alloys—materials engineered for exceptional performance in extreme environments.
With more than 80 peer-reviewed publications and over 20 international conference presentations, Amir brings a strong research foundation to Molycop’s innovation efforts.
Applying science to industrial performance
For Amir, joining Molycop represented an opportunity to apply advanced materials science in a real-world context.As a global leader in grinding media, Molycop operates at the intersection of materials performance, large-scale manufacturing, and mineral processing—an environment where innovation directly translates into operational value for customers.
Within the Innovation team, Amir’s role focuses on metallurgical investigations to improve the performance of grinding media. His work includes detailed materials characterisation using optical and electron microscopy, linking microstructural features to wear behaviour and overall product performance.
He also contributes to failure analysis and continuous improvement initiatives, supporting both product development and plant-level optimisation.
A key area of his work involves collaboration with Queen Mary University of London, where he is helping develop a predictive metallurgical program. This initiative aims to forecast the final microstructure and properties of steel alloys based on chemical composition and heat treatment conditions—bridging the gap between experimental data and predictive modelling.
Driving product development through laboratory insight
The laboratory plays a critical role in translating innovation into performance.Current areas of focus include the development and evaluation of new alloy systems, impact resistance testing of SAG grinding media using Charpy methods, and the development of faster, more reliable grain size measurement techniques.
These activities are essential in ensuring that newly developed products meet performance requirements before being deployed in the field.
By linking laboratory results to real-world outcomes, Amir and the team help improve service life, reduce grinding media consumption, and enhance milling efficiency—delivering both economic and environmental benefits to customers.
Looking ahead: Predictive metallurgy and next-generation materials
What excites Amir most is the opportunity to combine experimental work with predictive modelling.As ore grades decline and processing conditions become more challenging, the demand for high-performance grinding media continues to grow. Meeting this demand requires not only better materials, but also faster and more accurate ways to design and validate them.
Amir is particularly interested in developing tools that can predict microstructure and performance based on composition and processing conditions—enabling more efficient product development and stronger alignment with customer needs.
He is also focused on understanding fracture mechanisms in SAG balls, particularly how chemical composition and heat treatment influence grain boundary behaviour and overall durability.
