Ravi Muthe

Technically proficient Materials Engineer with comprehensive expertise in primary metal processes, casting metallurgy, heat treatment, and microstructure-mechanical property relationships. Proven track record developing and executing materials testing programmes for safety-critical components in regulated manufacturing environments. Strong foundation in ferrous and non-ferrous alloy metallurgy with hands-on experience bridging design requirements through supplier engagement to final component delivery.

Materials Engineer at Lawson Fuses Ltd (2023-05 – Present)

• Lead materials science laboratory operations with responsibility for materials characterization, mechanical testing, and thermal analysis on safety-critical electrical components.
• Understanding the eutectic behavior of conductive materials by assessing the solid state diffusion and phase transformations of low melting point alloys.
• Develop and execute comprehensive materials testing programmes including tensile testing, hardness analysis, and thermal performance evaluation.
• Interpret complex test data in regulatory context, including anomaly identification and root cause analysis for non-conformances.
• Manage technical compliance with ISO 17025 accreditation and IEC 60269 fuse standards across full product lifecycle.
• Prepare and review detailed technical documentation including material specifications, process requirements, testing reports, and compliance substantiation.
• Lead failure investigation and concession/deviation assessments with auditable engineering reasoning for safety-critical design changes.
• Trained ISO 17025 Internal Auditor; responsible for maintaining laboratory accreditation and quality management standards (ISO 9001:2015).
• Develop technical white papers and detailed research reports informing design and supplier selection strategies.
• Collaborate with suppliers and cross-functional teams (design, quality, operations) to resolve technical issues and non-conformances.
• Define supplier requirements, testing evidence packages, and acceptance criteria aligned to product specifications.
• Support supplier qualification and ongoing technical auditing for material and processing compliance.
• Developed and utilized complex mathematical models to simulate real-world type testing and short circuit current testing scenarios, reducing requirement for expensive physical testing.
• Investigate cost-reduction opportunities through alternative material selection while maintaining mechanical property and safety requirements.
• Track material degradation mechanisms and their relationship to starting microstructure and processing history.
• Lead quality assurance initiatives across materials testing and electrical testing laboratories.
• Mentor junior technical staff on materials characterization techniques, test data interpretation, and standards application.

Quality Engineer & Assistant Manager at Vedanta Aluminum Ltd (2017-11 – 2019-11)

• Spearheaded operational shift management (shift in-charge) overseeing aluminum alloy casting, billet production, heat treatment, and quality assurance for high-volume safety-critical components.
• Developed and optimized casting recipes and heat treatment cycles aligned to customer specifications and mechanical property requirements.
• Applied practical metallurgy to understand microstructure evolution through solidification and thermal processing; conducted failure analysis linking degradation to processing history.
• Managed molten metal handling, dross management, and scrap reduction strategies; coordinated between operations and maintenance teams for production optimization.
• Performed comprehensive mechanical testing programs (tensile, hardness, impact analysis) and root cause analysis on property shortfalls.
• Investigated mechanical property variability across sections and heat lots; linked results to casting defects and heat treatment parameters.
• Applied Six Sigma methodologies and systematic problem-solving to resolve non-conformances and improve process capability.
• Ensured adherence to customer specifications and applicable aluminum alloy standards throughout casting and heat treatment operations.
• Implemented safety-enhancing design modifications and process improvements through KAIZEN team initiatives.
• Coordinated with other departments for regulatory compliance and timely material handover.
• Supported new alloy casting routes and process qualification for emerging customer requirements.
• Tested novel heat treatment approaches to achieve improved mechanical properties and cost efficiency.

Manufacturing Team Member – Thermoforming Operations at Donite Plastics UK (2022-07 – 2023-01)

• Operated vacuum forming facility producing high-precision polymer structures for aerospace and automotive industries.
• Performed quality assurance and design-to-product validation; prepared technical reports on conformance and anomalies.
• Applied CAD (SolidWorks) for design interpretation and 5-axis tool programming through iterative design modifications.

Research Project – Nickel-Based Superalloy Metallurgy at DRDO (Defence Research Development Organisation) (2016-12 – 2017-04)

• Conducted comprehensive metallurgical study on "Effect of Multiple Heat Treatments on Mechanical Properties of Nimonic (Ni-Ti-Al) Alloy" under scientific supervision.
• Performed microstructural analysis and mechanical testing on Nimonic C236 (nickel-based superalloy); consolidated data on precipitation hardening cycles and resulting mechanical property changes.
• Applied characterization techniques to understand microstructure-property relationships in high-temperature alloy applications.
• Produced detailed technical report with scientific conclusions and recommendations.

Summer Internship – Ferrous Metallurgy at RINL Vizag Steel Plant (2016-05 – 2016-06)

• Conducted technical project on "Influence of Tuyere Gas Velocity on Blast Furnace Operations".
• Gained in-depth understanding of iron production, steel-making processes, and ferrous metallurgy fundamentals.
• Studied process metallurgy and its influence on final steel microstructure and properties.

Master's Research Project – Polymer Recycling at Queen's University Belfast, Mechanical & Aerospace Engineering (2021-04 – 2021-09)

• Collaborated with Polymer Processing Research Centre (PPRC) on "Recycling of Synthetic Sports Pitches".
• Executed polymer extrusion, twin-screw injection molding, mechanical testing, and materials characterization.
• Applied mechanical testing interpretation to assess recycled material suitability for structural applications.

MSc in Materials Science and Engineering – Queen's University Belfast (2021 – 2022)

B.Tech in Metallurgical Engineering – JNTU (Jawaharlal Nehru Technological University) (2013 – 2017)