Title: Project Engineer – Metal Additive Manufacturing Gas Flow and Composite Manufacturing & Performance Simulations
Post Date: 09/14/2023
Location: Princeton, NJ
Expected Start Date: Prefer Immediately
Please provide a resume and cover letter to contact@gem-innovation.com if interested.
Global Engineering and Materials, Inc. (GEM) provides modeling and simulation R&D services for government labs and commercial industries. The research at GEM is at the middle ground between academia and industry with a goal of technology maturation and commercialization. We have in-depth collaborations with universities, industries (from start-ups to major OEMs), and government agencies (NAVAIR and AFRL).
We are hiring for fully-funded research projects in the following areas: (1) Gas flow simulation in metal additive manufacturing and (2) Thermo-chemo-mechanical modeling of composite manufacturing and performance.
You are encouraged to apply if your skill set fits one of the research areas. Please indicate which research area(s) you are targeting in your application and highlight your relevant skills/experience/knowledge to the specific research area. Please also indicate your start date.
We provide support for H1B visa applications. However, due to the immediate start of this position, we do not consider applicants who are currently outside the US.
Gas Flow Simulation in Metal Additive Manufacturing
In this project, we aim to develop a computational tool to simulate the multi-scale gas flow phenomena in laser powder bed fusion and direct energy deposition processes. The simulation tool will be applied to optimize LPBF chamber gas circulation and DED nozzle powder-gas stream.
Responsibilities:
- Develop CFD simulations based on the customized commercial software StarCCM+.
- Develop a discrete element method model that couples with CFD to predict particle motion.
- Analyze gas circulation stagnation zone and powder spatter transport in the LPBF chamber.
- Analyze powder-gas stream, molten pool flow, and powder catchment efficiency in DED.
- Conduct model validation and design studies. Interact with collaborators and exchange information regarding CAD models, experiment data, and simulation results.
Requirement:
- A Ph.D. degree in mechanical engineering or related fields.
- 3+ years of research experience in modeling and simulation for metal additive manufacturing (prefer DED).
- 3+ years of experience in CFD and scientific programming.
Thermo-Chemo-Mechanical Analysis of Composite Manufacturing and Performance Evaluation
In this project, we aim to enhance the existing models to predict the thermo-chemo-mechanical response during composite manufacturing and evaluate the performance of as-built composite structures. The integrated toolkit will be applied to simulate the composite manufacturing process associated with fiber placement and conventional autoclave or non-conventional microwave curing. Relation between the process and performance of the composite parts and their joined structures will be established.
Responsibilities:
- Enhance existing thermo-viscoelastic models in Abaqus UMAT and predict curing-induced residual stress, distortion, and defects such as voids, wrinkling, and warpage.
- Enhance existing damage initiation and failure prediction models to predict fatigue life in tapered parts and composite joint structures.
- Develop multiphysics models for composite ultrasonic welding and friction drilling to predict fabrication-induced defects.
- Develop an interface for coupling between CFD/thermal/electromagnetic simulation (from collaborators) and mechanical response and failure predictions.
- Interact with collaborators and exchange information regarding CAD models, experiment data, and simulation results for toolkit validation and demonstration.
Requirement:
- A Ph.D. degree in mechanical engineering or related fields.
- 3+ years of research experience in residual stress/defects in composite processing or composite damage/fatigue analysis.
- 3+ years of experience in thermal-mechanical modeling with Abaqus UMAT.