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Additive manufacturing, finite element analysis, solid mechanics

Marietta, Georgia, United States
February 28, 2019

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515-***-**** *** West St. Apt *, Amherst, MA, 01002


• Strong background in mechanics of materials, thermal and structural analysis, mechanical design, manufacturing, and computational material science

• 8 years experiences in Finite Element Implicit/Explicit modeling (ABAQUS/LS-Dyna) for material simulation, multi-physics process simulation, thermal analysis and structural analysis

• Extensive experience in thermo-mechanical processing analysis (e.g. laser machining, resistance spot welding, powder-based additive manufacturing, etc.)

• Proficient in 3D&2D CAD, GT&D and tolerance analysis (Solidworks/Inventor/AutoCAD), familiar with design for manufacturing (DFM) and design of experiment (DOE)

• Expertise in mathematical modeling and data analysis (C/MATLAB/Mathematica/Python/Excel)

• Hands-on experience of material testing (tension, bending, shear, FLC, fatigue, fracture etc.), lab-scale manufacturing experiments (casting, injection molding, metal forming, machining, welding etc.), instrumentation and process measurement (Op-Amp, signal analysis, strain gauge, DIC, thermocouple, etc.)

• Strong knowledge of metal and ceramics, familiar with fundamental material characterizations (SEM/EDS)

• Experienced with project management and customer interactions EDUCATION

Iowa State University (Ames, IA) Dec. 2013 – Jun. 2015 Ph. D. Mechanical Engineering GPA: 3.75/4

Iowa State University (Ames, IA) Aug. 2010 – Dec. 2013 M. S. Mechanical Engineering GPA: 3.75/4

Harbin Institute of Technology (China) Sep. 2006 – Jul. 2010 B. S. Mechanical Engineering & Automation GPA: 3.7/4 WORK EXPERIENCE

Modeling Scientist

Novelis Global Research & Technology Center (Kennesaw, GA) Jul. 2015 – Present

• Manage and participate R&D projects, provide technical support for customers and plant (Automotive industry, Container & packaging industry, etc.) in terms of sheet metal product design, manufacturing and applications using simulation and experimental approaches

• Develop multi-scale computational models and multi-physics process models of thermomechanical manufacturing and joining of aluminum and aluminum composites (e.g. Hot/Cold forming, Resistance spot welding, Adhesive bonding, etc.) using complex material constitutive models

• Characterize material behaviors and microstructure evolution under deformation status and high temperatures

• Perform design and analysis for customers’ product (e.g. automotive body, beverage can/bottle) based on required specifications, investigate product performance (strength, deformation, fatigue life, fracture analyses, crash behaviors etc.) under different loading and boundary conditions using FEA models and hand calculations

• Design experiments including material testing (e.g. uniaxial/biaxial tension, fatigue, fracture, forming limit, etc.), component performance testing (e.g. bend test, crash test, etc.) and measurements of process parameters (e.g. load, displacement, voltage, temperature etc.) for validation of models and development of scientific understandings

• Design tooling (e.g. die, punch) of forming process (Solidworks/Inventor), conduct design of experiment (Minitab) to optimize design parameters

R&D Internship

Alcoa Technical Center (Pittsburgh, PA)

May. 2014 – Aug. 2014

Project 1: Modeling of Laser Additive Manufacturing

• Developed FEA model (ABAQUS and user subroutines) and mathematical model (MATLAB) of thermomechanical analysis during powder-bed laser additive manufacturing process of aluminum alloys

• Analyzed effect of processing parameters (laser power, speed, etc.) on melting pool formation and microstructural evolution during solidification

• Validated FEA model through melt pool measurement and temperature measurement from thermal camera Project 2: Cryogenic Forming of Aluminum Sheets

• Designed tensile tests of Aluminum alloys at different cryogenic temperatures based on ASTM standard

• Analyzed formability-oriented material properties (n-value, strain hardening, uniform elongation, etc.) and found a two-fold increase in both strength and plasticity under low temperatures Design Internship

JINAN SHIJIN Group Corporation (China)

Nov. 2009 – May. 2010

Project: Design of Servo Hydraulic Compression Testing Machine (Model YAW-2000D 2000kN)

• Designed 3D mechanical structure (Solidworks) of the testing machine based on national standard and customer requirement

• Engineering drawing creation utilizing GD&T and tolerance stack analysis RESEARCH/ TEACHING EXPERIENCE

Graduate Research Assistant

Iowa State University (Ames, IA)

Aug. 2010 – Jun. 2015

Project 1: Experiments and Modeling of Laser (with assist media) Machining of Ultra-hard Ceramic Materials

• Designed waterjet/gases assisted laser cutting of ultra-hard ceramic materials (Diamond, CBN) to achieve improvements of cutting quality and cutting speed

• Developed multi-physics FEA model in ABAQUS to analyze fracture propagation due to thermal and phase transformation induced stresses

• Implemented surface deformation measurement with optical profilometry and statistical data processing in MATLAB to validate model

• Performed surface strain measurement with Digital Image Correlation(DIC) in MATLAB

• Programmed analytical stress field of phase transition in Mathematica and numerical thermal analysis in MATLAB

• Conducted fracture surface morphology analysis (SEM) and phase transformation analysis (Raman spectroscopy/EDS) from which a controlled fracture propagation mechanism was deduced Project 2: Heat Treatment and Atomic Simulation of Ultra-hard Ceramic (Polycrystalline Cubic Boron Nitride)

• Designed micro-indentation tests on laser heat-treated PCBN, analyzed microstructural evolution by SEM

• Programmed in C to generate atomic models of PCBN with desired microstructures and grain boundaries

• Performed Molecular Dynamics simulation (shearing, stretching, compression) in LAMMPS to quantify the microstructure and strength correlation

Graduate Teaching Assistant

Iowa State University (Ames, IA)

Aug. 2010 – May. 2013

Lab TA of ME324: Manufacturing process

- Manufacturing lab: mechanical testing, casting, welding, injection molding, metal forming, CNC machining, CMM, optical profilometry, ultrasonic flaw detection, etc. Lab TA of ME370: Measurement and Instrumentation

- Measurement lab: vibration test, filters and noise, Op-Amp, signal analysis/sampling, strain gage, thermocouple, etc. TECHNICAL SKILLS

Software: ABAQUS, LS-Dyna, FE-Safe, Solidworks, Inventor, AutoCAD, LAMMPS, Minitab, Excel Programming: MATLAB, Mathematica, C, Fortran, Python Lab test and Equipment: casting, injection molding, metal forming, machining, tensile test, bending test, fracture test, hardness test, ultrasonic flaw detection, CMM, profilometer, oscilloscope, function generator, strain gauge, thermocouple, CO2 Laser


1. Wu, Z., C. Loy, E. Wang, and V. Hegadekatte. "Predicting FLDs Using a Multiscale Modeling Scheme." Journal of Physics: Conference Series, vol. 896, no. 1, p. 012001. IOP Publishing, 2017. 2. Sazol Das, Hany Ahmed, Ganesh Bhaskaran, and Zhuoru Wu, “Joining of Steel And Aluminum By Means Of Friction Stir Welding Process”, ICAA 16, 2018

3. Wu, Zhuoru, et al. "Hybrid CO 2 laser/waterjet (CO 2-LWJ) cutting of Polycrystalline Cubic Boron Nitride

(PCBN) blanks with phase transformation induced fracture."Optics & Laser Technology70 (2015): 39-44. 4. Zhuoru Wu, Ammar A. Melaibari, Pal Molian and Pranav Shrotriya, “Mechanism governing cutting of Polycrystalline Cubic Boron Nitride (PCBN) with transformation induced fracture”, NAMRC41/MSEC2013, 2013.

5. Ammar A. Melaibari, Zhuoru Wu, Pranav Shrotriya and Pal Molian, “Extreme Hardness Achievements in Binderless Cubic Boron Nitride Tools”, 41ndNorth American Manufacturing Research Conference

(NAMRC41/MSEC2013), 2013.

6. Zhuoru Wu, Ammar A. Melaibari, Pal Molian and Pranav Shrotriya, “The mechanism of machining Polycrystalline Diamond (PCD) with Laser/Waterjet (LWJ) system”, In review 7. Zhuoru Wu, Dinesh Kalyanasundaram, Ammar A. Melaibari, Pal Molian and Pranav Shrotriya, “The processing map of laser cutting of ceramics through thermal shock and phase transition induced stresses”, Under preparation PATENT

ALUMINUM ALLOYS AND METHODS OF MANUFACTURE, Provisional Application No. 62/459,264, Filled on Feb. 15, 2017

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