Group lead on all activities related to Additive Manufacturing Materials and Process Development at DTU Construct (Department of Civil and Mechanical Engineering)

I am working in the bounds of academic research and corporate industrial implementation of Metal Additive Manufacturing under the Manufacturing Academy of Denmark (MADE) consortium.

Work package leader for "Additive Manufacturing" within the Villum-funded MicroAM project 2023 - 2029. I am responsible for additive manufacturing activities using open-architecture AM systems.

"Development of NDE techniques for Additively Manufactured components "• Developed a Phase Inversion Harmonic Imaging technique based on nonlinear ultrasonic mixing to visualize and enhance the detection sensitivity of weak bonded interface defects found in Additive Manufacturing.• Conducted research on the feasibility of electromagnetic NDE for in-situ monitoring of AM components.• Supervised undergraduate and graduate students working in the NDE laboratory.

"Acoustic resonance techniques for online certification and offline qualification of metal based additive manufacturing systems", awarded to University of Louisville in collaboration with University of Cincinnati.• Built a model based ultrasonic NDE tool for AM components. Developed finite element models in COMSOL and analytical models in MATLAB to extract material properties nondestructively.• Modeled defects at each interface as finite interfacial stiffness springs under the influence of ultrasonic vibrations. The spring stiffness of each layer was estimated through a model based inversion.• Designed and built an in-situ process monitoring ultrasonic sensor setup on a L-PBF machine and UAM machine to continuously measure the build quality.• Assembled NDE database for certification of titanium (Ti-6Al-4V) and inconel (IN 625) manufactured through EBM and L-PBF. Similar databases were developed for aluminum 6061 made by UAM.

"Acoustic resonance techniques for online certification and offline qualification of metal based additive manufacturing systems", awarded to University of Louisville in collaboration with University of Cincinnati.

"Materials and Process Development for Additive Manufacturing"• Gained expertise in three metal AM processes, Laser Powder Bed Fusion (L-PBF), Electron Beam Melting (EBM) and Ultrasonic Additive Manufacturing (UAM). Obtained Level-II EBM training in Sweden and am also a skilled operator of L-PBF from EOS. • Manufactured Ti-6Al-4V coupons, tensile and fatigue bars in EBM as well as SLM with varying process parameters, build orientation and component quality.• Performed tensile, fatigue tests followed by complete metallurgical analysis including optical, scanning electron microscopy of fracture surfaces.• Manufactured aluminum, copper, and Al-Cu composites through UAM. Performed metallurgical analysis, mechanical push-out and lap-shear tests to optimize process parameters.

"Percolation studies of grain boundary networks in Inconel 718"• Analyzed Electron Backscattered Diffraction (EBSD) data through image processing in MATLAB.• Developed a methodology to identify twin boundaries and triple point boundaries. Performed statistical analysis to identify critical density of such boundary networks.

"Chemical Vapor Deposition of Reflectasol Glass"• Performed theoretical study of CVD process parameters and compared the results to experimentally measured quality standards • Implemented process parameter changes leading to a measured 2% increase in efficiency

"Weld Fixture Life During Automobile Part Manufacturing"• Analyzed metallic weld fixture life data from a Ford Motors manufacturing plant over a period of three years • Conducted a cost-benefit analysis making the case for non-conducting ceramic coatings and assisted with implementation of the same within a section of the manufacturing plant

"Relaxation processes in ABA block co-polymers" (10 citations)• Gained proficiency in material characterization techniques such as X-Ray Diffraction, Dynamic Mechanical Analysis, and Differential Scanning Calorimetry • Tested Poly (tert- butyl acrylate) which is an ABA block co-polymer to observe α and β relaxation behavior near glass transition temperature• Explained experimentally observed phenomena based on the presence of hydrogen bonding