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.
