Title: Thermal Design Methodology of Power Converters for Electric Vehicle Applications• Compared and performed experiments and simulations to verify and validate analytical work.• Utilized Ansys Fluent to produce simulation results that modeled real world boundary conditions ofinlet velocity/temperature and surface boundary conditions.• Preformed mesh independence and steady state convergence studies• Designed and built an experimental set up to measure desired values such as: fluid velocity,fluid/heat sink temperature, current, and voltage.• Preformed destructive tests to better understand component heat generation.• Created a new thermal methodology of modeling heatsinks that allows for optimization of allheatsink dimensions and fluid characteristics within 10% error. The methodology discretizes the heatsink into Lego like components which allows the designer more degrees of freedom to make quick and accurate decisions without the use of computational fluid mechanics (CFD), saving time and resources.• Operated and preformed thermal couple calibration, milling and drilling machines, Simcenter Powertester 1500A, and FLIR thermal camera.

• Lead and introduced a new process of measuring key characteristics of gear grinding that correlated to failure stresses and failure methods.• Finished and optimized reverse engineering process that allows benchmarking of competitor products and creating digital copies of the gear characteristics.• Conducted multiple detailed teardowns of transmissions to highlight mounting conditions, design volume or gathering desired gear/ring-gear information.• Research and data acquisition about understanding the benefits of powdered metal on noise reduction compared to steel. • Designed, drew, and troubleshooted custom fixtures for fatigue testing and heat-treating fixtures.• Talked and organized with suppliers to work out delivery or any troubleshooting that occurred with fixtures.• Operated Metallurgical Lab equipment, Keyence, Mahr MarSurf, rotary fatigue machines for carriers, and single tooth fatigue bending MTS machines for helical and spur gears. • Created presentations to backlog and summarize research projects that can be sent and understood by different facilities overseas; highlighting lessons learned, project hand offs and detailed troubleshooting steps and solutions.

• Built battery heat exchanger prototypes including degreasing, building, brazing/welding, dry and wet leak testing • Submitted request for performance testing (heat transfer, pressure drop, and pressure cycle) • Operated Metallurgical Lab equipment, band saw, grinding machine borescope, stereomicroscope to investigate quality control, crack propagations, and laser weld finishes • Gained in-depth understanding of manufacturing and product design steps by analyzing failure modes and test specification. • Researched and designed new methods for brazing fittings onto core-plates to cut costs and increase product efficiency. • Created an excel sheet to track brazed parts on a macro and micro level that both engineers and technicians can understand; highlighting what was learnt during each batch, Pareto charts and future improvements

• Built EOC and TOC prototypes including degreasing, building, brazing/welding, dry and wet leak testing • Operated Metallurgical Lab equipment, band saw, grinding machine borescope, stereomicroscope to investigate fractures, turb bonding, and material thinning • Gained in-depth understanding of heat transfer and fluid mechanics by analyzing test results, capable of optimizing product design (Heat transfer and pressure drop) based on available core plates • Searched, Purchased and Benchmarked competing technologies • Updated Benchmarking database by filling datasheets and performance profiles • Scheduled, Prepared and Held internal meetings • Served as an engineering liaison for the Waterloo SAE team