Kellen Traxel, Ph.D. Email & Phone Number

Kirkland, Wa, Us

Richland, Wa, Us

Livermore, Ca, Us

-Designs, fabricates, and tests custom multi-axis robotic motion stage gantry systems for R&D lab AM prototyping platforms used in liquid metal jetting 3D-Printing. Coordinates with fabrication shop on tolerances, materials and manufacturing approaches. -Manages two projects investigating the influence of processing parameters on microstructural evolution, phase transformations, and surface/bulk properties of aluminum and copper alloys processed via liquid metal jetting (LMJ), resulting in better understanding of as-printed material properties, four conference presentations, and two technical papers (in process). -Collaborates directly with external companies and internal laboratory customers to identify areas of AM implementation for prototyping and tooling, modifying existing hardware designs for AM applications and printing test articles. This has created two ongoing development projects for printing aluminum lattice structures and assembly tooling prototypes.-Programs custom AM build files and G-code in Python to individually manipulate parameters of both commercial and custom AM equipment in order to better understand the influence of printing parameters on surface and bulk part characteristics. This has resulted in a successful industry collaboration with Xerox as well as two conference presentations. -Mentors two student interns focused on developing process parameter-property relationships for the Xerox ElemX printer, resulting in build data generation, analysis, and contribution to larger property database for LLNL’s liquid metal jetting efforts.

Pullman/Spokane/Tri-Cities/Vancouver/Everett/Global, Washington, Us

As a MS/PhD student in the W.M. Keck Biomedical Materials Research Laboratory under Profs. Amit Bandyopadhyay and Susmita Bose, my main research focuses involved:1. Understanding process-microstructure-property relationships for multi-material & composite, additively manufactured components produced via powder-bed-fusion (3DSystems Pro 200) and directed-energy-deposition (Optomec LENS, Formalloy X) platforms. Mainly titanium matrix composites.2. Developing site-specific reinforcement/processing strategies in structures via powder-bed-fusion and directed energy deposition.3. Understanding thermomechanical processing phenomena during multi-material additive manufacturing using laser-based directed energy deposition (using ANSYS mechanical).These endeavors were carried out primarily through thermo-mechanical modeling, manufacturing multi-material structures via direct-energy-deposition & powder-bed-fusion processing technology. The types of structures that I work with are mainly metals and composites (metal-ceramic/ceramic), bimetallic components, and functionally/spatially graded components. These structures open the door to application-specific design methodology, and are becoming increasingly used in many advanced environments such as high temperature, corrosive, articulating surfaces, and impact bearing surfaces.Task: Designing experiments and 3D printing titanium-based metal-ceramic composite structures for high temperature and wear-resistant coating applications. -Performing materials testing in accordance with relevant ASTM standards (tribology, hardness, etc.)-Performing microstructural/phase analysis via SEM, XRD techniques-Managing 8+ interdisciplinary research projects at one time, including 2-3 projects with undergraduate students.-Maintenance and operation of two laser-based metal 3D-printers and a Tormach 770M machining center.

Hawthorne, California, Us

Lead investigator on a study identifying effects of recycling + aging on powder feedstock quality for SpaceX’s large-format powder bed fusion additive manufacturing systems. Project resulted in deeper understanding of powder evolution in SpaceX’s AM systems, creation of novel powder characterization and build sequence tools to help drive production scheduling considering powder age in system, and recommendations for additional experiments to substantiate findings.-Coordination of powder handling and powder sample extraction from within AM systems, working heavily with additive engineers and technicians.-Extensive materials characterization of nickel-based superalloy (commercial and SpaceX-proprietary) feedstock powders, soot/condensate, spatter, and corresponding as-printed bulk samples in different conditions using optical microscopy, SEM/EDS, PSD, ICP, Shear Flowability Testing, and TGA Moisture Content, among others.-Design of powder aging experiment to elucidate effects of powder recycling in large-format systems on powder quality and corresponding mechanical properties.-Creation of model (MATLAB™) for mass transfer within large-format powder bed fusion systems to understand effects of part size, # of builds, and build sequence on powder life and quality at different times within the system.-Creation of deep learning diagnostic tool (Tensorflow/Keras/Python) to characterize specific qualities of powder based on optical micrographs, for use in production-level quality control.Other Projects:-Characterization of as-printed contour-hatch parameter quality for high-throughput processing ranges.-Creation of TTT diagram and surface heat tint map for SpaceX-proprietary alloy to support heat treatment efforts and analysis/characterization of hot fired components.-Failure analysis and investigation of 3D-printed and investment cast engine hardware and witness samples (nickel-based superalloys and titanium alloys).

Los Angeles , California, Us

Engine thermal model correlation of the MR-111 (1lb thrust) engine using experimental data from the OSIRIS-REx engine qualification. Correlating experimental preheat, hot-fire, and "soakback" engine temperature data with thermal models using Thermal Desktop (TD) and ANSYS software.Thermal modeling (ANSYS) of the LOX post in the main injector of the RS-25 (Space Shuttle Main Engine) to study the effect of thermal shielding of the post.Creation of computational tools in Mathcad to predict engine component temperatures using engineering first principles analysis (gas dynamics, heat transfer).

Knoxville, Tennessee, Us

Completed the first stage of prototyping a rotary resin/catalyst gear pump for use in one of their catalyst pumping units. I designed, built and tested the prototype while at M.V.P, using off-the-shelf components and a FDM plastic 3D-printer, resulting in a final design-manufacturing-testing report and recommendations for future work. CAD-modeling was performed in Autodesk Inventor, and proficiency in Autodesk Vault (enterprise-based CAD) was achieved.

Doctor Of Philosophy - Phd, Mechanical Engineering

Master Of Science - Ms, Materials Science And Engineering

Bachelor Of Science - Bs, Mechanical Engineering