Mechanical Engineering R&D
Resume:
Chao Li
*** **** ** * *** **D 205-***-****
Tuscaloosa, AL 35401 *****@*******.**.***
OBJECTIVES
To obtain a full-time engineering position while concentrating on research and development in the medical device manufacturing field with future opportunities for advancement. EDUCATION
Ph.D., Mechanical Engineering GPA 4.0/4.0 Expected May. 2017 The University of Alabama, Tuscaloosa, AL
Dissertation: Multiscale Investigation on Surface Integrity and Performance of Metal Parts by Selective Laser Melting (SLM)
Advisor: Y.B. Guo, Ph.D.
M.S., Material Processing Engineering GPA 3.7/4.0 Aug. 2013 Jilin University, Changchun, China
B.S., Material Forming and Control Engineering GPA 3.3/4.0 (Top 15%) Aug. 2010 Jilin University, Changchun, China
AWARDS
First-class Postgraduate Scholarships (Top 10%) Dec. 2010, 2011 and 2012
First-class Scholarship of Jilin University (TOP 5%) Nov. 2007
Third-class Scholarships of Jilin University (TOP 15%) Nov. 2008, 2009
Honor of “Outstanding Graduates” of Jilin University (TOP 3%) Feb. 2013 SKILLS
Languages: English (Proficient) Chinese (Native)
Modeling/Programming: Finite element analysis (ABAQUS), Matlab, Fortran, CNC, CATIA, SolidWorks, AutoCAD
Manufacturing: Laser-based additive manufacturing (3D Printing), laser cutting, laser welding, classical machining (milling), surface treatments, and heat treatments
Material Prep/Testing: Electron microscopy X-ray diffraction Micro-hardness Optical microscopy Strength Corrosion
Electro-polishing Electro-etching Fatigue
Surface topography
RESEARCH & WORKING EXPERIENCE
Research Engineer, Surface Integrity LLC Aug. 2014 - Present Birmingham, AL
Supervisor: Michael P. Sealy, Ph.D.
Mechanical Surface Treatment for High Performance Biodegradable Implants
– Applied three surface treatment methods for MgCa implants: CNC milling, ball burnishing, and shot peening to improve corrosion and fatigue behavior
– Characterized surface topography, subsurface hardness profile, subsurface microstructure, and surface residual stress of MgCa implants
– Measured 3-point bending strength of MgCa implants under different treatments and the burnished samples were proved to have the highest bending strength
– Measured residual stress profiles (using XRD) and successfully showed that the highest compressive residual stress was found in the subsurface Resume / Chao Li
– Performed 3-point bending fatigue tests and fatigue performance was significantly improved by burnishing and shot peening compared to CNC milling
– Conducted corrosion test in a simulated body fluid and showed that corrosion rate of MgCa implants was reduced by burnishing and shot peening
– The controllable corrosion rate and improved fatigue life of surface treated MgCa samples were successfully established and showed great potential application in biodegradable orthopedic implant industry
Research Assistant, Consortium for Surface Integrity & Functionality Aug. 2013 - Present The University of Alabama, Tuscaloosa, AL
Advisor: Y.B. Guo, Ph.D.
Selective Laser Melting (SLM) of IN625 for Aerospace Applications
– Designed and built a $40,000 in-house selective laser melting facility, which includes a fiber laser (IPG) system, two XYZ tables (controlling boxes), a building platform, a powder layering system, and a local argon gas shielding system
– Characterized SLM processed IN625 single track melt pool geometries, microstructure, grain size, grain orientation, and mechanical properties
– Investigated the process map for SLM of IN625 to enhance surface integrity
– Fabricated 3D printed samples from IN625 using the in-house developed facility, anisotropic microstructures and mechanical properties were significantly improved, and residual stress was successfully reduced by heat treatments
Finite Element (FE) Modeling of 3D Printing Process Using ABAQUS
– Proposed a novel multiscale FE modeling approach, and successfully solve the problem of predicting distortion and residual stress of large scale 3D printed parts
– Successfully developed a moving heat source model to predict temperature field during a 3D printing process by programming DFLUX in Fortran
– Successfully modeled the material state changing phenomenon (powder-liquid- solid) during a powder bed 3D printing process
Laser Cutting of Biodegradable MgCa Implants
– Optimized process parameters of laser cutting MgCa biodegradable stents
– Characterized microstructure, roughness, and hardness of the cutting surface, measured kerf width, recast zone and heat affected zone thickness
– Successfully established a standardized laser cutting procedure for fabricating a high quality MgCa biodegradable stent
Fatigue Behavior of Nitinol after Electro-Discharge Machining (EDM)
– Co-designed experiment for EDM of Nitinol from main cut to finish trim cut
– Measured fatigue life of Nitinol under different EDM condition and finish trim cut samples showed better fatigue performance than main cut
– Successfully applied shot peening method to improve fatigue performance of Nitinol by peeling off the porous white layer leftover from EDM
Research Assistant, Roll Forging Institute Aug. 2010 - Aug. 2013 Jilin University, Changchun, China
Advisor: Kou Shuqing, Ph.D.
FE (Finite element) Simulation of Assembled Camshaft and Equipment Development
– Co-design and built a fixture for manufacturing assembled camshafts
– Simulated the tooth formation and residual stress of the shaft during the knurling process and compared to the experiment results
– Performed knurling, joining, and torsion failure test using 3 types of knurling tooth shape and 45 tooth was proved to exhibit the best torsion strength Resume / Chao Li
Undergrad. Research Assistant, Dep. of Mater. Science & Eng. Aug. 2007 - May. 2010 Jilin University, Changchun, China
Advisor: Hong Xu, Ph.D.
Designing and Modeling of an Enclosed Speed Reducer
– Designed and 3D modeled an fully enclosed speed reducer using CATIA which included selection of bearings, shaft diameter, and gear ratio
– Predicted life time of the speed reducer based on different loading conditions
Designing and Manufacturing of a Punching Die for Automobile Industry
– Designed, 3D modeled, and manufactured a punching die
– Investigated effect of gaps between punch and die on residual stress and facture surface quality, and successfully showed that a smaller gap (7% of the sheet thickness) would generate better facture surface
PUBLICATIONS
Journal Articles in Preparation
[1] C. Li, Y.B. Guo, 2016, “Effect of Heat Treatment on Surface Integrity and Mechanical Properties of Inconel 625 by Selective Laser Melting,” Mater. Des.
[2] C. Li, D. Brown, Y.B. Guo, 2016, “Surface Integrity and Part Performances of Laser- based Additive Manufactured Metal Parts: A Critical Review,” Mater. Des.
[3] J.F. Liu, C. Li, Y.B. Guo, 2016, “Fatigue Performance of Electrical Discharge Machined Nitinol Alloys,” Int. J. Fatigue.
[4] M.P. Sealy, C. Li, Z.Y. Liu, Y.B. Guo, 2016, “Surface Integrity, Fatigue, and Corrosion Performance of Surface Treated Biodegradable MgCa Alloys,” CIRP Ann. Manuf. Technol.
[5] M.P. Sealy, C. Li, Z.Y. Liu, Y.B. Guo, 2016, “Surface Integrity in Burnishing of Biodegradable Mg/Ca Alloys: Numerical Modeling and Experimental Validation,” J. of Mater. Process. Techno.
Journal Articles
[1] C. Li, Y.B. Guo, 2016, “Interfacial Phenomena between the Deposited Material and Substrate in SLM Inconel 625,” J. of Mater. Process. Techno. (in review)
[2] C. Li, J.F. Liu, Y.B. Guo, 2016, “Efficient Predictive Model of Part Distortion and Residual Stress in Selective Laser Melting,” Comput. Mater. Sci. (in review)
[3] M.P. Sealy, Y.B. Guo, J.F. Liu, C. Li, 2016, “Pulsed Laser Cutting of Magnesium- Calcium for Biodegradable Stents,” Procedia CIRP. 42: 67-72.
[4] C. Li, C.H. Fu, Y.B. Guo, 2016, “A Multiscale Modeling Approach for Fast Prediction of Part Distortion in Selective Laser Melting,” J. of Mater. Process. Techno. 229: 703-712.
[5] C. Li, J.F. Liu, Y.B. Guo, 2016, “Prediction of Residual Stress and Part Distortion in Selective Laser Melting,” Procedia CIRP. 45: 171-174.
[6] C. Li, C.H. Fu, Y.B. Guo, 2015, “Fast Prediction and Validation of Part Distortion in Selective Laser Melting,” Procedia Manufacturing, 1:355-365.
Conference Proceedings & Presentations
[1] C. Li (speaker), C.H. Fu, Y.B. Guo, 2015, “Fast Prediction and Validation of Part Distortion in Selective Laser Melting,” Proc. of the 43rd SME North American Manufacturing Research Conference, Jun. 8-12, Charlotte, NC. Resume / Chao Li
[2] C. Li (speaker), C.H. Fu, Y.B. Guo, 2015, “Stress-Thread Multiscale Modeling of Deflection and Residual Stress for Metal Parts by Selective Laser Melting,” Proc. Of the 26th Solid Freeform Fabrication Symposium, Aug. 10-12, Austin, TX.
[3] C. Li (speaker), J.F. Liu, Y.B. Guo, Z. Y. Li, 2015, “A Temperature-Thread Multiscale Modeling Approach for Efficient Prediction of Part Distortion by Selective Laser Melting,” Proc. Of the 26th Solid Freeform Fabrication Symposium, Aug. 10-12, Austin, TX.
[4] C. Li (speaker), J.F. Liu, Y.B. Guo, 2016, “Efficient Predictive Model of Part Distortion in Selective Laser Melting,” Proc. Of the 27th Solid Freeform Fabrication Symposium, Aug. 8-10, Austin, TX.
[5] C. Li (speaker), J.F. Liu, Y.B. Guo, 2016, “Prediction of Residual Stress and Part Distortion in Selective Laser Melting,” 3rd CIRP Conference on Surface Integrity, June 8- 10, Charlotte, NC.
[6] M.P. Sealy, G. Madireddy, C. Li, Y.B. Guo, 2016, “Finite Element Modeling of Hybrid Additive Manufacturing by Laser Shock Peening,” Proc. Of the 27th Solid Freeform Fabrication Symposium, Aug. 8-10, Austin, TX.
REFERENCES
Dr. Yuebin Guo
Professor, Mechanical Engineering
The University of Alabama
****@***.**.***
Dept. of Mechanical Engineering
The University of Alabama
Attn: Dr. Yuebin Guo
Box 870279
Tuscaloosa, AL 35487
Dr. Mark Barkey
Professor, Aerospace Eng. & Mechanics
The University of Alabama
*******@***.**.***
Dept. of Aerospace Eng. and Mechanics
The University of Alabama
Attn: Dr. Mark Barkey
Box 870280
Tuscaloosa, AL 35487
Dr. Michael P. Sealy
Asst. Professor, Mech. & Matls Eng.
University of Nebraska-Lincoln
*****@***.***
Mechanical & Materials Eng. Dept.
University of Nebraska-Lincoln
Attn: Dr. Michael Sealy
W342 Nebraska Hall
Lincoln, NE 68588
Dr. Luke N. Brewer
Assoc. Professor, Metallurgical & Matls Eng.
The University of Alabama
*********@***.**.***
Dept. of Metallurgical & Matls Eng.
The University of Alabama
Attn: Dr. Luke Brewer
Box 870202
Tuscaloosa, AL 35487
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