Engineer Mechanical

Thomas E. Willard

** ************ ****

Charlestown, Massachusetts 02129

617-***-****, ********@*****.***

EDUCATION:

Massachusetts Institute of Technology, Cambridge, Mass., Master of Science.

Department of Mechanical Engineering, May 1983. Master's Thesis: "An ADINAT

Finite Element Model of a Typical Earth Sheltered Building".

Northeastern University, Boston, Mass., Bachelor of Science, Mechanical

Engineering, June 1978.

SPECIFIC SKILLS:

Thermal, stress, shock and vibration analysis, both by hand using MathCAD

15, and using the finite element method (FEA): ANSYS Multiphysics 14.5,

Maxwell 16.0 Electromagnetics, COSMOSWorks, COSMOS FloWorks.

Electronic packaging design and documentation, sheet metal, vacuum and

dip brazing, welding, injection molding, high voltage, EMI shielding,

waveguide design, hydraulics, laboratory and field testing.

Solid Modeling/ CADD: SolidWorks 2012

EXPERIENCE:

Jefferson Laboratory, Newport News, Virginia, April 2013 - November 2013.

Contract Mechanical Engineer, working in the Experimental Nuclear Physics

Division on the 12GeV accelerator upgrade program. Used ANSYS 14.5

Multiphysics and Maxwell 16.0 to perform a coupled transient

electromagnetic-static structural analysis (quench) of the 4.6 K

Heatshield, part of the superconducting Torus Magnet Assembly.

Thermal analysis of the superconducting Solenoid Magnet Assembly, including

the 4K cold mass and the 80K thermal shield, also part of the 12GeV

upgrade.

Princeton Plasma Physics Laboratory, Princeton, New Jersey, December 2011 -

March 2013

Contract Mechanical Engineer, working on the National Spherical Torus

Experiment (NSTX) spherical tokamak fusion reactor program. Used ANSYS 14.0

Multiphysics and Maxwell 16.0 to: 1.) perform a coupled magnetostatic-

transient thermal-static structural analysis of the Poloidal Field Support

Assembly; and 2.) perform a structural analysis of the Toroidal Field

Umbrella Assemby.

Also helped develop the analysis protocol for a multiphysics analysis of

the ITER port plug diagnostic modules: Neutronics volumetric heating loads

(Attila) exported to a conjugate heat transfer analysis (CFX), with the

exported body temperatures combined with the Lorentz force densities from a

transient electromagnetics analysis (Maxwell) in a static structural

analysis (ANSYS).

Protom International/ MIT Bates Linear Accelerator Laboratory, Middleton,

Massachusetts, April 2011 - November 2011.

Contract Mechanical Engineer, working on a synchrotron system for proton

cancer therapy. Used SolidWorks 2011 and Simulation to help design the

switchyard beam line components connecting the synchrotron accelerator to

the treatment room gantries including: the quadrupole focusing magnets; the

quadrupole and dipole magnet support stands; and the vacuum enclosures.

Princeton Plasma Physics Laboratory, Princeton, New Jersey, May 2009 -

March 2011.

Contract Mechanical Engineer, working on the National Spherical Torus

Experiment (NSTX) spherical tokamak fusion reactor program. Used ANSYS 12.1

Multiphysics and Maxwell 13.0 to: 1.) perform a coupled magnetostatic-

transient thermal-static structural analysis of the Toroidal Field Flexible

Strap Assembly, a 26 lamination C15100 copper-zirconium alloy vacuum brazed

flexible conductor, carrying 130,000 amps in a nominal 1 Telsa toroidal and

a .3 Tesla vertical field; and 2.) perform a coupled transient

electromagnetic-static structural analysis of the Neutral Beam port and

Thomson Scattering port upgrades, determining the magnetostatic forces and

moments produced by the toroidal and poloidal field coils on the vacuum

vessel, and the plasma disruption loads in the vessel from the induced eddy

currents crossing with the coil background fields.

Ballard Power Systems/ University of Maryland, College Park, Maryland,

March 2007- May 2009.

Contract Mechanical Engineer working on a mobile JP-8 fueled 5 KWe fuel

cell genset for the Army. Used SolidWorks to develop the compact design of

a test station for testing the key components of the hydrogen generation

loop, including the integrated fuel processor (ATR, sulfur trap, WGS), the

catalytic burner, and the palladium membrane hydrogen purifier: a 100 tube

assembly, each tube plated with 1-2 micron palladium-gold alloy on an

asymmetric alumina substrate.

Oceaneering, Hanover, Maryland, November 2007- February 2008

Contract Structural Engineer working on the Light Weight Causeway System

(LWCS), an automated rapid deployment floating modular bridge system for

the Navy. Performed COSMOS finite element analysis on various weldments/

frames including: the Receiver Frame; the Grabber Assembly; the Flag Sheave

Assembly; and the Pinch Roller Assembly. Also analyzed required ship

modifications.

Weir Valve, Salem, Massachusetts, June 2007- November, 2007

Contract Mechanical Engineer working in the nuclear power valve group.

Performed a characterization study of the Tricentric family of triple

offset butterfly valves: used ANSYS CFX and COSMOSFloWorks to analytically

determine the flow coefficient Cv and the flow torque coefficient Ct versus

valve disc open angle of a 30" stop valve to compare with measured data;

used ANSYS Mechanical 11.0 and COSMOSWorks 2006 to determine the uniformity

of the contact pressure at the valve seat versus design parameters of an 8"

solid-seal valve. Used SolidWorks 2007 to develop the redesign of an air

cylinder-operated actuator assembly used on a main steam isolation valve

(MSIV) check valve.

Outsource-Engineering, Hyde Park, Mass., June 2001- present

Sole proprietor of a mechanical engineering consulting firm. Specializing

in electronic packaging analysis and design using ANSYS 10.0 Multiphysics

and SolidWorks/ COSMOS 2006.

ANSYS 8.0 shell model to determine the fatigue stresses in the 304

stainless steel perforated deckplate used in a pulp paper roller press.

Gun-drilled coldplate and cooler design for 160 kV scanning electron beam x-

ray tube.

COSMOSFloWorks model of 450 kV high voltage x-ray tank. Simulateously

modeled the flow and heat transfer of both the external forced convection

air cooled heat sink, and the internal natural convection oil cooled tank.

Solidworks design and documention of several EIA standard 19" rack mounted

gas control panels used in a manufacturing test station for a high power

fuel cell and reformer system.

Mechanical evaluation and agency certification testing of a microserver/

storage unit, including thermal, shock and vibration, safety, and EMC for

worldwide compliance: UL, CE, FCC, ISTA.

Developed an on-demand Hydrogen Generator, by means of Al hydrolysis, to be

used with a 55 kWe Stirling engine genset or with PEM fuel cells, for

distributed, backup power, and combined heat and power (CHP) applications.

RectorSeal, Houston, Texas, November 2006- March, 2007

Contract Mechanical Engineer. Developed a battery-powered crimp hand tool

for the construction industry. Responsible for all aspects of the design

including: sizing the ball screw, gearmotor, and battery; the design of the

17-4 PH crimp head; the design of the nylon 66 glass-filled injection

molded housing; and the design and programming of the MOSFET H-bridge motor

power/ microcontroller (PIC16F690) electronics and firmware. Design using

Solidworks 2006; analysis using COSMOSWorks 2006 Advanced Professional.

HYTEC, Inc, Los Alamos, New Mexico, September 2006- October 2006

Contract Mechanical Engineer. Helped develop the design of a 25KW sun-

tracking concentrating solar collector array for commercial application.

Tasks included: preliminary analysis of cast ductile iron two-axis drive

housing; buckling and deflection analysis of acrylic Fresnel lens; and

vendor search and cost estimating. Design using Solidworks 2007; analysis

using COSMOSWorks 2007 Professional.

Massachusetts Institute of Technology, Plasma Science and Fusion Center,

Cambridge, Mass., May 2005- August 2006

Staff Research Engineer in the Mechanical Engineering Department. Thermal

and stress analysis of in-vessel components of the Alcator-C Mod Tokamak

fusion reactor, subjected to extremely high high heat flux (12 MW/m2) and

electromagnetic field (7 Tesla) loads, using ANSYS 10.0 Multiphysics and

COSMOS DesignStar. All solid models created using SolidEdge v17. Specific

analyses included:

Transient thermal/electromagnetic stress analysis of a laminated

tungsten tile design for the Lower Diverter Module assemblies.

Nonlinear residual stress analysis of a vacuum brazed 24 RF window

alumina ceramic/ 304L stainless steel Lower Hybrid Coupler assembly.

Recommended a CTE-matched design using AMC7525 molybdenum copper metal

matrix composite material.

Varian, Vacuum Products Division, Bedford, Mass., March 2005 - May 2005

Contract Mechanical Engineer. Used SolidWorks 2005 and COSMOSWorks to

design and analyze a new scroll vacuum pump. Redesigned the injection

molded inlet air bezel to allow slower DC fan speed, reducing the noise

level 15 dBA.

Foster Miller, Waltham, Mass., June 2004 - October 2004

Contract Mechanical Engineer. Used ANSYS 8.0 to analyze the stresses and

deflections of a space-based optical mirror assembly.

Temptronics, Sharon, Mass., March 2004 - June 2004

Contract Mechanical Design Engineer. Used SolidWorks and COSMOSWorks to

design flexible hose assembly, part of thermal system to temperature stress

printed wiring boards and integrated circuits. COSMOSWorks thermal and

stress analysis of solid model.

iRobot, Burlington, Mass., June 2003- August 2003

Contract Mechanical Design Engineer. Used SolidWorks and ANSYS DesignSpace

to design drive train for mobile robot for military applications. Specific

design duties included the track tensioning mechanism, the bogie rollers

and plastic bearings, and the motor controller sheet metal housing.

Analysis included calculating the PV load of the plastic bearings, and

evaluating the thermal design of the motor controller heat sink.

L-3 Communications, Woburn, Mass., November 2001- April 2003

Senior Mechanical Engineer, Security & Detection Division. Used Solidworks,

COSMOSWorks, and ANSYS DesignSpace (FEA) to design mobile 2.5 MeV x-ray

imaging system for inspection of cargo containers and tractor-trailers.

Responsible for the mechanical design of the detector arrays, including the

sheet metal enclosures (EMI, NEMA 4 watertight), stress, shock and

vibration, thermal, truck road worthiness and rollover stability (top

heavy, lead-lined boom assembly), and documentation.

American Power Conversion, N. Billerica, Mass., January 2000 - March 2001

Senior Mechanical Engineer, NPS Division. Used Solidworks and ANSYS to

develop new 600 lb rack-mounted 16 KVA UPS (uninterruptable power supply).

Responsible for all aspects of mechanical design including sheet metal,

thermal, and shock and vibration.

CIENA Corporation, Marlboro, Mass., November 1999-Decmeber 1999

Contract Mechanical Design Engineer. Used SolidWorks to design a 1U high,

19" rack mounted/ EMI tight, sheet metal enclosure for a PWB for T1

internet connections. Also, thermally evaluated the design of a 1U high

metrobus design for internet applications.

OSRAM Sylvania, Beverly, Mass., September 1999-October 1999.

Contract Mechanical Design Engineer in the Electronic Control Systems

group. Used Solidworks to solid model and document a small injection molded

case for a commercial electronic ballast assembly.

EG&G Electro-Optics, Salem, Mass., June 1999 - September 1999.

Contract Mechanical Design Engineer. Responsible for the mechanical design

and documentation of a 100W fiber optic light source for medical

application. Developed the assembly from quartz arc bubble lamp, to

elliptical dichroic coated ceramic reflector lamp module, to top assembly,

including sheet metal enclosure.

American Science and Engineering, Billerica, Mass., March 1998 - April 1999

Contract Mechanical Design Engineer. Responsible for the hydraulic design

of an Automated Guided Vehicle (AGV) for use in a field deployed cargo x-

ray inspection system for tractor trailers. The design included the

automatic control of steering, braking, as well as hybrid hydraulic/diesel

drive of the transport, which is capable of pulling a total load of over

160,000 lbs with a scan speed accuracy of +/- 2%.

Massachusetts Institute of Technology, Lincoln Laboratories, Lexington,

Mass., May 1996 - March 1998.

Member of Technical Staff, Mechanical Design Group. Senior design engineer

working on a portable, rapid deployment radar system. Primary design

responsibilities included: developing the purchase specification and

control drawings for a 5 meter parabolic reflector; the mechanical design

of an RF feed network, including the waveguide assemblies, feedhorn,

monopulse comparator, and quad polarizer; and the forced-liquid cooling

system.

Varian/ CPI, Beverly, Mass., May 1989-May 1996.

Senior Mechanical Design Engineer, MTS Group. Sole mechanical engineer in a

small design group specializing in custom microwave transmitter/modulator

assemblies for aerospace/military application. Responsible for all aspects

of mechanical design including thermal, stress, shock and vibration, as

well as producing all layout, assembly, and piece part drawings on CAD

(Personal Designer, AutoCad).

Design examples: FRA Modulator, a pod-mounted (airborne) air cooled

Traveling Wave Tube (TWT) mounted to an FEA designed compact heat

exchanger/cold plate, part of a dip-brazed aluminum enclosure; BEL/India

Transmitter, shipboard, forced-air cooled liquid-to-air heat exchanger,

part of dip-brazed aluminum high voltage power supply;

Seimens-Plessey TWT Amplifier, integral heatpipe cooled TWT mounted to

forced-air cooled compact heat exchanger, part of dip-brazed aluminum

enclosure; AEL/Cross TWT Heat Exchanger, isothermal (heatpipe) copper heat

exchanger/cold plate, forced-air cooled, mounted in dip-brazed aluminum

enclosure.

Provided in-house FEA consulting service to microwave tube development and

manufacturing areas. Examples include: microwave window kovar-to-glass seal

thermal stresses; jet impingement/flow boiling cooled CFA vane tip; cathode

assembly combined thermal/random vibration stresses.

Recent training in ANSYS 5.2: Basic; Structural Nonlinearities. ALGOR

training: Basic, Thermal, Structural Dynamics.

AT& T Bell Laboratories, North Andover, Mass., April 1984 - November 1988.

Physical Design Engineer (MTS), Transmission Lines Division. Responsible

for the physical design/electronics packaging of new digital lines and

lightwave telephone transmission equipment.

Received seminar training in Project Management, and EMI/RFI shielding.

GenRad Corporation, Concord, Mass., November 1982 - February 1984.

Thermal Engineer, Corporate Mechanical Engineering Group. Responsible for

evaluating and improving the thermal design of automated LSI semiconductor

test equipment.

Digital Equipment, Maynard, Mass., October 1980 - February 1982

Contract Thermal Engineer, Environmental Engineering Group. Responsible for

evaluating and improving the thermal design of computer equipment,

including disk drives and video monitors.

Raytheon, Missile Systems Division, Bedford, Mass., June 1977 - May 1980.

Thermal/Stress Analysis Engineer. Responsible for evaluating thermal and

structural adequacy of proposed designs. Specific duties included thermal

analysis (SINDA, ADINAT), stress analysis (SAPV), testing, and report

writing.

MEMBERSHIPS: American Society of Mechanical Engineers (ASME)

MILITARY SERVICE

U.S. Air Force, Vandenburg AFB, CA. August 1971 - June 1975,

31750 Instrumentation Mechanic (electronic technician, satellite tracking

station), honorably discharged (E5).

ADDITIONAL TRAINING

East Coast Aero Tech, Bedford, Mass., September 1969 - April 1971,

F.A.A. Airframe and Powerplant licenses.

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