Development Engineer

Sailei Zhang

Mailing Address: *** S. Curson Ave., Apt 02E, Los Angeles, CA 90036 (willing to relocate)

Contact: Phone: 765-***-**** Email: *********@*****.***

Work Authorization: US Permanent Resident (Green Card Holder)

Objective

To obtain a Metallurgical Engineer position in an organization to develop advanced metal processing

techniques, design and study new alloys; or conduct failure analysis during product development.

Qualifications

Strong theoretic background in solidification and alloy development, processing and characterization.

Intensive experience in riser design.

Meticulous experimental skills in precise casting aluminum and titanium alloys, post-cast heat

treatment and high temperature deformation; familiar with VIM, ESR and VAR melting technology.

Proficiency in conducting metallurgical, materials, and mechanical failure analysis with various

characterization tools including SEM, EDS, GDS, XRF, EBSD and XRD.

Solid knowledge in heat transfer and fluid flow during metal processing with an excellent

understanding of thermodynamics and phase metallurgy.

Familiar with Six Sigma concept.

Effective communicator with strong analytical, problem solving and multitasking abilities.

Education

Purdue University, West Lafayette, Indiana, US Jan.2010 - May 2013

PhD in Materials Science and Engineering GPA: 3.62

Thesis Title: Macrosegregation and Shrinkage Pipe Formation in Static Castings

Purdue University, West Lafayette, Indiana, US Aug.2007- Dec. 2009

Master of Science in Materials Science and Engineering GPA: 3.62

Thesis Title: Study on Solidification Microstructure Development in a TiAl Alloy

Harbin Institute of Technology, Harbin, China Aug.2003- July 2007

Bachelor of Science in Composite Materials Science and Engineering GPA: 84/100

Research Topic: Corrosion Resistance of NiCrAl Coatings

Professional Experiences

Purdue University, West Lafayette, Indiana, US Jan.2010 - Present

Subject: Macrosegregation and Shrinkage Pipe Formation in Static Castings

Advisors: Prof. M. J. M. Krane and Prof. D. Johnson

Developed a riser design principle that significantly reduced macrosegregation level in static castings.

Studied the influence of riser parameter and cooling conditions on macrosegregation development and

shrinkage pipe formation in an Al-5 wt. % Cu alloy.

Investigated the effect of macrosegregation pattern on microstructure evolution and phase selection

during solidification of -TiAl alloys in a precise casting mold.

γ

Established a special calibration curve in GDS measuring algorithm for -TiAl alloys and highly

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improved the accuracy of composition profile.

Purdue University, West Lafayette, Indiana, US Aug.2007 - Dec.2009

Subject: Study on Solidification Microstructure Development in a TiAl Alloy

Advisors: Prof. M. J. M. Krane and Prof. D. Johnson

Modified a solid-liquid interface tracking model for microstructure development during alloy

solidification and improved the simulation efficiency by 8%.

Applied a height function algorithm to calculate interface curvature of the dendritic microstructure, so

that both hexagonal and cubic symmetry crystallography phases can be simulated on the same

Cartesian grids.

Investigated directional solidification of -TiAl alloys through straight ceramic channels with spacing

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on the order of the dendritic tip radius.

Discovered for hypo-peritectic -TiAl alloys in narrow channels, growth conditions that lead to

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dendritic bcc-(Ti) -phase growth can result in hcp-(Ti) -phase nucleation and growth.

β α

Harbin Institute of Technology, Harbin, China Jan.2007-July.2007

Subject: Corrosion Resistance of NiCrAl Coatings

Advisor: Prof. Y. Li

Investigated the corrosion resistance of NiCrAl coatings on Ni-based superalloy under the conditions

of salt spray test and high-temperature oxidation.

Performed SEM on post-test NiCrAl coatings and discovered the corrosion resistance of the coating is

notably reduced due to the multi-cracks and loose texture in its microstructure caused by salt spray.

Teaching Experiences

Purdue University Teaching Assistant School of Materials Engineering

MSE 250 Physical (Mechanical) Properties in Engineering Systems Jan.2008-May 2008

MSE 367 Materials Processing Laboratory (Metal Processing) Jan.2010-May 2010

Publications and Presentations

S. Zhang, M. J. M. Krane and D. Johnson, “Effects of geometric constraint on solidification

microstructure development of peritectic TiAl alloys”, submitted to International Conference on

Processing & Manufacturing of Advanced Materials, Las Vegas, NV (Thermec’2013).

S. Zhang, J. Yanke, D. Johnson, and M.J.M. Krane, A Volume of Fluid Method to Study the

Interaction of Shrinkage Pipe and Macrosegregation Development in Static Alloy Castings”, The

International Journal of Numerical Methods for Heat and Fluid Flow, In Press.

S. Zhang, D. Johnson, and M. J.M. Krane, “Effects of Geometric Constraint on Phase Selection and

Segregation in Cast TiAl”, Materials Research Society Symposium Proceeding, v. 1295, pp. 183-188

(2010).

S. Zhang, J. Yanke, D. Johnson, and M. J. M. Krane, (Invited Talk) “Influence of Feeding Flow and

Shrinkage Pipe Formation on Macrosegregation of Investment Cast -TiAl Alloys”, in symposium on

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“CFD Modeling and Simulation in Materials Processing”, TMS Annual Meeting, Orlando, FL (2011).

J. Zhao, D. Ge, S. Zhang and X. Wei, “Studies on Thermal Property of Silica Aerogel/Epoxy

Composite”, Materials Science Forum, pp. 546-549 (2007).

S. Zhang, Y Li, L. Yang, Y. Sun and J. Zhao, “Silica Aerogels Doped with TiO2 Powder Using Rice

Hull with Sol-Gel Processing”, at International Conference on Aerospace Materials, Beijing (2006).

Languages and Computer Skills

Languages: Chinese: Native English: Fluent

Computer Skills: Fortran, ANSYS, AutoCAD, Mathcad, Microsoft Office, Tecplot, Solidworks, Procast

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