Composite Materials Engineer

KHAN, Zaffar M., PhD

House: ***, Street: **, Sector: I-8/4, Islamabad, Pakistan

Email: ********@*****.*** ● Tel: 00 92-323-***-**** (M) ● Skype: zaffar.khan1957

SUMMARY STATEMENT

Talented, creative and experienced aerospace and mechanical engineer with extensive professional background in advanced composite materials & smart structures shares the passion for seeking real life solutions to challenges in polymer composite materials. Successfully developed aerospace, automotive bodies, wind mill blades, bullet proof jackets and helmets from polymer composite materials by innovative processes. Proven ability to teach graduate and undergraduate courses in 3Ms i.e. mechanics, materials and manufacturing. Adept at determination of industrial requirements, formulation of research proposals, supervision of research projects, technology management and resource mobilization. Multiple certifications include composites design for manufacturing, fiber optic smart structures, multifunctional polymer nanocomposites, ballistic body/ vehicle protection & electromagnetic composites. I have strong management, presentation & communication skills.

EDUCATION:

● Postdoctoral Research as Fulbright/ IDB Scholar.

Department of Aerospace Engineering and Engineering Mechanics, Iowa State University, Ames 50011 Research: Improving compression strength of carbon-epoxy laminate by assessing the layer waviness defect through mechanical testing and fiber optic sensing, www.aeem.iastate.edu

● Doctorate of Philosophy, Aerospace and Mechanical Engineering.

Department of Aeronautical and Mechanical Engineering, Salford University, Manchester M5 4WT, UK. Dissertation: Drilling induced defects in CTBN toughened carbon epoxy composite materials as part of Euro fighter program for British Aerospace Manufacturing Division, www.salford.ac.uk.

● Master of Science, Aerospace Engineering, Major Area: Structures, Minor area: Fluid Mechanics.

Research Paper: Thermoset/ thermoplastic Comparison, Department of Aerospace Engineering, Wichita State University, Kansas 67208, CGPA: 3.58/4.00, www.wichita.edu

● Bachelor of Engineering, Aerospace.

Department of Aerospace Engineering, College of Aeronautical Engineering, National University of Sciences and Technology (NUST), Risalpur, Pakistan. CGPA: 2.88/4.00 www.nust.edu.pk

● Intermediate & Secondary Education, Cadet College Kohat, Pakistan,1st Division, www.kohatian.com

PROFESSIONAL COURSES

● Composite Design, Professor S. W. Tsai, Stanford University Aeronautics & Astronautics, Grade: A

● Optic Fiber Sensors & Smart Structures, Professor Eric Udd, Portland University. Oregon, USA

● Industrial Composites Design and Applications, Professor Mariani, ICST, Trieste, Italy.

● Surfaces in Engineering Materials, Professor J. T. Grant, University of Dayton/ Quaid-i-Azam Univ.

● Polymer Nanocomposites, FEM & Composite Design, Profs Koo, Adams SAMPE Long beach, CA

● Composites Fabrication, Mechanical Testing, SAMPE Tutorial, Prof. Dan Adams, Long beach, CA.

● Light RTM Close Mold Technology, Composite Manufacturing Technology Center, Cornwell, UK.

● Distributed Computer Systems, Tokyo Institute of Technology/ NUST, Islamabad, Pakistan.

● Autodesk Mechanical Desktop, Autodesk Asia Pte Ltd, Pakistan, Grade: A

● Composite RTM 2004, Pole De Plasturgie de l’ Est, Forbach, France.

● Composites and Ceramics, GIK Institute of Science and Technology, Toppi, Pakistan

International/ National Awards, Fellowships and Scholarships:

● Fulbright Postdoctoral Research Awards, US Education Foundation, 1995-96.

● IDB Postdoctoral Research Awards, Islamic Development Bank, Jeddah, 1996-97.

● NSF Award to attend Smart Structures Workshop, Portland University, 1996.

● Robert Blackburn Award by the Royal Aeronautical Society, London for PhD research, 1989-91.

● Thomas Jefferson Award by US Agency for International Development for MS studies, 1988.

● Honorary Fellowship Australian Institute of Materials, Monash University, 2010.

● Name on the HONOUR WALL, American Institute of Aeronautics & Astronautics, Washington DC.

● Ministry of Science & Technology Award, Government of Pakistan, for PhD/ MS studies, 1986.

● Sitar-e-Imtiaz, Government of Pakistan, 2011.

● Higher Education Commission Postdoctoral Research Award, 2003 (NOT AVAILED).

Commendation Cards* and Letters of Appreciation.

● Pioneered academic collaborative program, Iowa State University, US Senator Tom Harkin, 1996*.

● Development of 1st all composite body of Shell Eco Marathon Car for GIKI, Rector GIKI, 2010.

● Publishing first research paper having NUST name, Rector NUST, 1993.

● Development of 1st all composite body of Society of Automotive Engineer’s Formula-1 Car, 2012*.

● Development of Ballistic Vehicles Protection Systems, Chief of Air Staff, Pakistan Air Force, 2010.

● Organizing first international PAK-ASEAN Conference about Composites, Rector NUST, 2003*.

● Active participation in 9th International Symposium on Advanced Materials, DG, AERO, 2005.

● Active participation as Member of Committee of Fulbright Selection Committee for PhD/ MS.

Acknowledgment letter, Sectoral Committee on Future Technologies, Prof S. Naqvi, HEC, 2003.

● Editor: Advanced Engineering Materials for Applied Science and Technology, Vice Chancellor, Aerospace Institute of Technology and Member, Technology, NESCOM, Islamabad, 2012.

● Development of 1st all composite airframe system of Unmanned Aerial Vehicle, DG, AERO*.

● Development of 1st all composite airframe system of aerospace vehicle, DG AERO*.

● Successful flight test of indigenously the all composite aerospace vehicle, DG, AERO*.

PROFESSIONAL EXPERIENCE:

1. Founding Director, Technology Expert, Chief Engineer and Professor*

(a) Advanced Materials Research Center, Advanced Engineering Research Organization (AERO/AWC), National Engineering and Scientific Commission, Wah, Pakistan

(Nov 2001 – Present).

Pioneered establishment of fully functional, purpose built, AS 9100C certified, 35000 sq. ft. Center. Successfully developed primary & secondary structural systems of aerospace/ automotive vehicles, windmill blades, bullet proof jackets, ballistic plates, PASGAT helmets and vehicle protection from ultra light, engineering materials using affordable process. This involved design validation, materials selection, process optimization, NDT and mechanical testing. Developed smart structural systems through innovative design, prototype, pre production qualification to full scale production according to NASA TRL level 1 through 9 using building block approach. I have the necessary technical expertise and commercial know-how to lead my peers and senior faculty members, engineers, scientists and managers. I am capable of growing the technology portfolio and playing an instrumental role in maintaining its position as a leader in product development in collaboration with universities. I have also demonstrated excellent communication and relationship skills with different universities such as NUST, GIKI, Air University, Institute of Space Technology, UET Texila, Textile University, Mehran. I have wide ranging composites experience and R&D knowledge to deliver the vision, strategy & make recommendations on the future direction, define benchmarks, lead the initial assessment of IP and identify opportunities for technology growth.

Research: Supervised PhD*/ MS research in the composite materials for (i) National University of Science and Technology, (ii) Air University, (iii) GIK Institute of Sciences & Technology, (iv) University of Engineering & Technology, Taxila at Advanced Composites Research Center as Higher Education Commission Approved Supervisor. http://sc.hec.gov.pk/aphds/submit.asp?supid=356

● Design and Fabrication of Lab Scale Vacuum assisted Resin Transfer Molding.

● Nanocarbon particles-carbon-epoxy composites for Electromagnetic properties.

● Characterization of Honeycomb Sandwich Composites by Mechanical Testing.

● Fractographic Analysis of Carbon Fiber Composite Materials using SEM.

● Mechanical characterization of CTBN modified toughened carbon-epoxy composites.

● Development of helmet, ballistic plates for body, vehicle protection.

● Wind mill turbine blade from carbon/ epoxy composites.

● Fracture Mechanics of Polymer Composite Materials.

● Photonic Bandgap of Nanopolymer Composites.

(b) Adjunct/ Visiting/ Honorary Professor of Advanced Materials and Solid Mechanics

(Nov 2001 – Present):

Teaching: Taught/ teaching graduate courses at (i) Department of Mechanical Engineering, Faculty of Mechanical & Aeronautical Engineering, University of Engineering & Technology, Taxila, Pakistan (ii) College of Electrical & Mechanical Engineering/ School of Chemical & Materials Engineering/ School of Mechanical and Manufacturing Engineering, National University of Sciences & Technology, Islamabad, Pakistan.

● Finite Element Analysis

● Structural Design and Stress Analysis in Composite Structures

● Stress Analysis and Design of Rotating Machines

● Processing of Composite Materials

● Structural Design and Analysis

● Stresses in Plates and Shells

● Advanced Strength of Materials

● Mechanics of Materials

2. Dean of Engineering (Chief Instructor)/ Professor (27/9/1999 – 07/11/2001)

3. Founding Chair/ Associate Professor (12/11/1993 - 14/8/1995 & 3/2/1997 to 26/9/1999).

4. Assistant Professor (31/05/1992 – 11/11/1993):

Department of Mechanical Engineering, College of Electrical & Mechanical Engineering, National University of Sciences and Technology, Peshawar Road, Rawalpindi, Pakistan. Pioneered establishment of fully functional Department to start graduate (MS/ PhD) program in Mechanical Engineering specializing in Mechanics and Materials in collaboration with Mechanical Engineering & Materials Science Department, Michigan State University, East Lansing, USA. NUST ranked 350 in World University ranking in engineering education. http://www.topuniversities.com/U

Teaching: Taught following graduate* and undergraduate courses.

● Design for Composite Manufacturing*

● Mechanics of Composite Materials*

● Advanced Strength of Materials*

● Advanced Materials*

● Theory of Vibrations*

● Material Science and Engineering

● Mechanical Vibrations

● Industrial Materials

● Composite Materials Manufacturing and Processing

● Mechanics of Materials-I, II and III

● Experimental Stress Analysis

● Engineering Statics and Dynamics

● Fluid Mechanics

Research: Supervised following PhD**/ MS*/ UG research.

● Characterization of Composite Materials by Mechanical Testing*.

● Stress Analysis of Composite Semi Spherical Shell under Impact Loading*

● Design & Development of Helmet from Polymer Composite Materials*

● Converging-Diverging Nozzle Design by Method of Characteristics in C-language*

● High Strain Deformation in Composites against high KE projectile

● Design and Development of Ballistic Protection Systems, NIJ Level-IIIA

● Comparative Study of Stresses in Pressure Vessel using Strain Gauges.

● On-line Crack Detection Technique for Inspection of Pressure Vessels.

● Strain Gauge & Photo elastic Stress Analysis of automobile components.

● Development of Car Bumper from Polymer Composite Materials.

● Flow Induced Mechanical Vibrations in Heat Exchangers**

Services:

● Initiated graduate (PhD & MS) program, course development, faculty/ staff induction, laboratory improvement, accreditation and staff training in collaboration with Mechanical Engineering, Materials Science and Mechanics Department, Michigan State University, USA.

● Academic/ financial/ administrative management of Electrical/ Mechanical/ Computer and Mechatronics Engineering Departments according to requirements of accreditation commission, local industry and collaborating foreign university.

5. Visiting Fulbright Professor (8/1995 – 02/1997).

Department of Aerospace Engineering & Engineering Mechanics, Iowa State University of Sciences and Technology, IA 50010

Teaching:

● Mechanics of Composite Materials (Selected Topics)

Research:

● Assessment of layer waviness defect by fabricating wavy layers in carbon fiber - epoxy laminates and compression tested according to ASTM standards.

● On-line Structural Health Monitoring System by embedding micro bend fiber optic sensors in composite laminates for assessing layer waviness defects.

● Double cantilever beam adhesion testing according to ASTM standards.

Services: Established academic collaborative program in aerospace engineering and engineering mechanics between Iowa State University and National University of Sciences and Technology

6. Research Assistant/ Demonstrator, Lecturer (10/1988 – 09/1991)

Department of Aeronautical & Mechanical Engineering, Salford University, UK in collaboration with British Aerospace as part of Euro fighter Aircraft (Typhoon) structural development program.

Teaching:

● Solid Mechanics

● Engineering Drawing

Research:

● Drill life determination in carbon-epoxy laminates by drill dynamometer, photo elastic stress analysis in relation to flank wear.

● Fractographic analysis of carbon fiber surface morphology and damage mechanics in tensile, compressive, shear modes using SEM and linear elastic fracture mechanics.

● Characterizations of tungsten carbide/cobalt microstructure by SEM and pin-on-disk wear.

RESEARCH INTERESTS AND EXPERTISE

● Design, analysis, processing and mechanical testing of energy efficient polymer composite materials.

● On-line health monitoring of smart composite structures by using fiber optic sensors.

● Vehicle survivability through composites ballistic protection systems.

● Nanopolymer composites, green materials and multifunctional structure for sustainable development.

TEACHING INTERESTS AND EXPERTISE

● Graduate Courses: (i) Structural Mechanics (ii) Advanced Strength of Materials, (iii) Structural Design and Analysis (iv) Stresses in Plates and Shells (v) Design for Composites Manufacturing

● Undergraduate Courses: (i) Composite Manufacturing & Processing, (ii) Advanced Engineering Materials, (iii) Strength of Materials, (iv) Stress Analysis (v) Aircraft Structural Analysis

CONSULTANCY SERVICES

● All Composite Sports Goods: The United Nations Industrial Development organized my visit to International Center for Science and High Technology, Trieste, Italy to present the country report about status of Composite Technology in Pakistan. The presentation recommended endogenous capacity building in composite materials science and technology. As a result of this interaction, the MoST initiated series of dialogues between academia, industrial and private/ public stakeholders for improving the socio-economic conditions under program ‘Endogenous Capacity Building in Science and Technology’ in collaboration with United Nations Center for Science and Technology. Undersigned prepared a feasibility report for establishing the sports good industry using polymer composite material in Pakistan as CONSULTANT, 1994

.INDUSTRIAL/ ACADEMIC PROJECTS SUCCESSFULLY COMPLETED

● Affordable Manufacturing of all Composite Aerospace Systems:

Sustained research and development efforts has led to successful design, development and production of polymer composite airframe systems of aerospace vehicles, radoms, antennas, payload platform cover and hundred of complex structural components from carbon fiber composites, nomax/ polyurethane foam sandwich structures according to AS 9100C quality standards. The composite structural components passed the stringent mechanical/ flight tests and are presently in full scale production. The junior engineers were imparted training about composite science and technology. Optimal resource mobilization & tight process control reduced part rejection and saved millions of US$.

● All Composite Bodies of Automotive Vehicles: Automobile car bodies were developed from carbon-epoxy composites skin, nomax/ foam sandwich floor and acrylics wind shield using single step resin infusion process for GIK Institute of Science & Technology, National University of Sciences and Technology and NED University. The Formula-1 car for NED University participated in the car race organized by Society of Automotive vehicles at Melbourne, Australia, Dec, 2011. The GIKI car made valid run and performed remarkably well by securing 27th out of 107 positions in the Shell Eco Marathon Asia, Malaysia, July 2010. The design and manufacturing process has been published in the conference proceedings of 42nd SAMPE Conference, Salt Lake City, Utah, Oct 10-13, 2010. http://www.sampe.org/store/paper.aspx?pid=6280.

● Ballistic Body and Vehicle Protection: The research about damage tolerance and energy absorbing mechanisms led to successful development of prototype of bullet proof jackets and PASGAT helmets. The Advanced Composite Research Center produced 2,000 bullet proof jackets, NIJ level, IIIA, III and VI to meet the ballistic protection requirement of Ranger, PAF, Scouts. Feasibility reports were submitted for protection of jeeps, helicopter and cars in coordination with Aries Protection (subsidiary of Ten Cates), France. Undersigned successfully installed ballistic protection systems on 10 VVIP cars using Kevlar, polyethylene fabric and laminates,

ESTEEM INDICATORS:

● Member of Review Panels: (i) Carnegie Mellon University, Metallurgical & Materials Transaction, (ii) Journal of Composite Materials, (iii) Polymer Engineering.

● Approved PhD supervisor by Higher Education Commission, Government of Pakistan. Supervised/ supervising 4 PhD, 12 MS and 20 UG research about composite materials and structural mechanics for NUST, Air University, UET Taxila, GIK Institute.

● Pioneered academic collaborative program between Iowa State University and National University of Sciences and Technology that was appreciated by Senator T. Harkin.

● Established student chapter, Society of Experimental Mechanics, College of E&ME, NUST.

INTERNATIONAL/ NATIONAL CONFERENCES ORGANIZED:

● Successfully organized the 9th, 8th, 7PthP & 6PthP International Bhurban Conferences on Applied Science & Technology (Advanced Materials), www.ibcast.org.pk, Jan 2012, 2011, 2010 and 2009.

● Chief Resource Person & Principal Speaker: Pak-ASEAN International Workshop, Industrial Composites Design & Applications, Best Western, Islamabad, Pakistan, 2002.

● Chief Resource Person & Principal Speaker: International Workshop on Composites in Ballistics, sponsored by DuPont, USA at College of E&ME Campus, NUST, Peshawar Road, Rawalpindi, 1998.

● Organizer & Principal Speaker of 3 National Workshops, Composite Design-for-Manufacturing at College of E&ME Campus, NUST, Peshawar Road, Rawalpindi, Pakistan, Summers, 1999, 1995, 1994.

MEMBERSHIP OF NATIONAL PROFESSIONAL BODIES:

● Member of Committee on Future Technologies, Higher Education Commission, Pakistan.

● Executive Committee-Pakistan Materials Research Society.

● Member of Fulbright Selection/ Review Committee.

● National Steering Committee-Advanced Materials.

● COMSTECH Expert Group on Engineering Materials

● Peer Review Committee, Pakistan Council of Science & Technology, Islamabad.

● Board of Undergraduate Studies, Wah Engineering College, Wah, Pakistan.

● Board of Graduate Studies & Advisory Council in Mechanical Engineering, UET, Texila.

● Registered Professional Engineer- Pakistan Engineering Council.

● Sectoral Committee on Future Technologies, Higher Education Commission.

● Technical Committee-International Workshop on Emerging Technologies.

● Member of National Steering Committees - Advanced Materials.

MEMBERSHIP OF INTERNATIONAL PROFESSIONAL BODIES:

● Membership Society for Advancement of Material & Process Engineering.

● Membership Canadian Association for Composite Structure and Materials.

● Membership American Institute of Aeronautics & Astronautics.

● Membership of the Royal Aeronautical Society, UK – Pak. Branch, (RAeS)

● Pi Mu Epsilon, US Mathematical Fraternity, Kansas.

PERSONAL:

● Date of Birth: 12 Sep 1957 (54 years and 11 months).

● Married with 03 kids.

REFERENCES

● Professor Daniel Adams, Director: Composites Mechanics Laboratory, Department of Mechanical Engineering, University of Utah, Salt Lake City, Utah. T: 801-***-****, E: *****@****.****.***

● Professor M. Javed Khan, Aerospace Science Engineering Department, Tuskegee University, Tuskegee, AL 36088, T: 334-***-****, E: **********@*******.***

● Professor Shahab Khushnud, Dean, Faculty of Aeronautical and Mechanical Engineering, University of Engineering and Technology, Texila, Pakistan. T: +92-51-904****, E: *********@*****.***

● Professor Ihtesham ur Rehman, Reader in Biomedical Materials, The Kroto Research Institute, North Campus, University of Sheffield, Broad Lane, S3 7HQ, Tel: ++44 (0-114-***-****, *.*.******@*********.**.**.

● Professor Thomas Rudolphi, Chairperson, Department of Aerospace Engineering and Engineering Mechanics, Iowa State University, Ames, Iowa 50011, US, T: 515-***-****, E: ********@*******.***

Contributions to Compiled Volumes and Books [Refereed]

● Contributory Book Chapter; Cross-Flow-Induced-Vibrations in Heat Exchanger Tube Bundles: A Review. NUCLEAR POWER PLANTS, Editor: Soon Heung Chang, Publisher INTECH, Croatia.

● Editor TransTech, Switzerland, Journal of Advanced Materials for Applied Science and Technology, (2012), ISBN: 978-3-03785-483-9 ISSN: 1022-6680 (CD and print) and 1662-8985 (web) (Under Print)

● Editor TransTech, Switzerland, Journal of Advanced Materials for Applied Science and Technology, ISBN:-13: 978-3-03785-227-9, ISSN: 1022-6680, Vol: 326, (2011), http://www.scientific.net/AMR.326.

● Editor Conference proceedings of 7th International Bhurban Conference on applied Science and Technology, ADVANCED MATERIALS, 11-14 Jan 2009, 2010. ISBN 978-***-****-08-2 Volume-1.

● Editor Conference proceedings of 6th International Bhurban Conference on applied Science and Technology, ADVANCED MATERIALS, 19-22 Jan 2009, 2009. ISBN 978-***-****-06-8 Volume-1.

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