Simon Joshi

• Corrosion: o Big data analysis using python on hundreds of corrosion testing dataset to develop a statistical model to forecast the life of automotive cooler. o Develop salt spray testing methods to evaluate the material corrosion resistance. o Develop unique electrochemical testing methods that can quantify the difference in corrosion resistance between different types of alloys and plating. • Design of Experiments: Designed 2^3 factorial design experiment to perform cross-validation between suppliers and Dana results. • Electroless nickel phosphorous (ENP) plating: o Lead the ENP plating process from lab setting to industrial high volume.  Develop engineering specification to communicate testing criteria requirements to suppliers and customer.  Design experiments using statistical methods to validate process  Perform ANOVA analysis to determine if there is any statistically significant difference in measurement obtained between Dana and Dana’s suppliers. • Characterize braze kinetics by using DSC: o Characterize liquidus/solidus behavior of metals. o Elucidate the brazing reaction mechanism by quantifying the melting event and the solidification event. • Failure analysis: o Perform data analysis on hundreds of coolers salt spray testing results to show properly brazed production-of-record coolers meet industry requirement and any premature failure is due to either manufacturing defect or certain types of design change. o Routinely perform root cause failure analysis to establish metallurgical cause of the failure and design improvement recommendations. • Client Interaction: Interaction with industrial and academic partners to carry out projects based on the needs of the business. Liaison with internal and external customers, government representatives, academia, testing laboratories and industry subject matter experts to develop technical requirements and evaluation/testing scope of innovation projects, success criteria and testing protocols.

1. Led the scale-up project of depositing protective Mn1.5Co1.5O4 spinel coatings on solid oxide fuel cell from lab to manufacturing for commercialization. Planned the project scope, time, budge, risks, quality, and resources to ensure project objectives were met. • DOE to optimize coating deposition trials using ultrasonic and electrostatic spray methods. • DOE to optimize sinter trials using 100% H2 atmosphere on continuous belt furnace. • Metallurgical analyses of coatings and substrate using optical microscopy, SEM, XRD, etc. • Study kinetics of Cr-oxide growth at the operating temperature and atmosphere of SOFC. 2 Tribology of Automotive Rotary-Vane Oil Pump Oxide: Lead scientist in characterizing wear resistant oxide developed on Fe-C-Cu and Fe-C-Cu-Ni alloys using superheated steam treatment. • Research on optimizing furnace de-oiling process and steam treatment conditions (time, temperature, and atmosphere) to grow ideal wear resistant oxide. • Investigate the effect of various lubricant oils used to machine parts on growth of oxide layer. • Investigate alloy impurities detrimental effect in the growth of wear resistant oxide. • Developed metallographic polishing method to obtain surface finish comparable to FIB polishing for TEM so that the oxide grain structure, phases, and porosity can be clearly revealed in SEM. • Characterize the oxide and substrate using XRD, EBSD, TEM, micro-hardness testing, etc. • Correlate tribology testing results and oxide characteristics to identify steam treatment conditions that are responsible for producing optimal wear resistant oxide layer. 3 Advanced Engineering Metallurgist: Support manufacturing by performing metallurgical failure analyses. Analyze mechanical testing results such as density, microhardness, transverse rupture strength, etc. to determine materials properties. Perform fractography analysis on as-received and/or post-mechanical testing fractured parts using SEM to pin-point failure modes.

Develop manganese-based spinel protective coatings on SOFC using electroplating method followed by appropriate thermal treatment • Optimize surface treatment solution chemistry to activate stainless steel and chromium alloy to electroplate Ni, Cu, Co, Mn, and Mg(OH)2 • Optimize Ni, Cu, Co, Mn, and Mg(OH)2 electroplating solution chemistry to effectively deposit uniform coatings of desired thickness • Develop an efficient Mn electroplating process to prevent oxide scale formation on anode so plates 10cm×10cm can be plated without using anode bag • Use Factsage software to model and simulate the binary and ternary phase diagrams to determine spinel oxide stability zone for thermal treatment • Evaluate different types of thermal treatment methods to form spinel oxide from the electroplated metal layers without oxidation of the substrate: o Oxidation of electroplated coatings in air at 800° C o Sinter coatings in pure hydrogen atmosphere followed by oxidation in air • In-situ XRD analysis at 500-1000° C to determine phase transformation and extrapolate the data to FactSage software to construct phase diagram • Research on Mn-based spinel coating cation distribution, conductivity, and phase • TGA experiments of chromium alloy to determine nitrides formation • Formulate ceramic ink to produce ceramic bars for in-situ electrical conductivity testing of various spinel oxides from 600-1000° C • Study kinetics of chromium oxide growth post-thermal treatment of the coatings at the operating temperature and atmosphere of SOFC

Determine reactivity and/or corrosion of gold in alkaline sulfide solution • EQCM CV testing of gold in alkaline sulfide solution to determine gold solubility • Determine gold concentration using atomic absorption spectroscopy • Create E-pH diagram of gold in sulfide solution using HSC software

Research corrosion protection mechanism of cerium-based conversion coatings (CeCCs) on Al 2024-T3 and Al 7075-T6 to meet MIL-DTL-81706B standard. • Research on the effect of different acidic and alkaline surface treatment methods on deposition mechanism of CeCCs • Research on optimizing CeCCs deposition solution chemistry to form coating of desired thickness and characteristics provide adequate corrosion protection which can meet MIL-DTL-81706 salt spray testing standards • Characterize CeCCs and aluminum alloy using electrochemical techniques such as EIS, potentiondynamic testing etc. and correlate results with salt spray testing • Develop micro-electrochemical cell for corrosion testing of CeCCs • Investigate solubility of cerium species in salt water using UV-vis spectroscopy • Research sub-surface crevices formation of Al alloy during CeCCs deposition • Research on microstructural change of the substrate such as sub-surface crevice formation due to coating deposition process. • Proved corrosion protection mechanism of CeCCs is not based on diffusion and migration. • Characterize coatings and substrate corrosion potential using electrochemical methods.

Led Quality Management System in development, standardization, and implementation of quality initiatives for coatings deposition on aluminum alloys. Build good customer relationship by educating customers on coatings process and standards to prevent defect and improve quality. • Maintained the quality of chromate coating and anodizing baths so that the deposited coatings can meet MIL-DTL-5541 standards. • Used statistical process control to evaluate process performance metrics for continuous improvement programs and to proactively prevent non-compliance. • Coordinate documents and procedure to comply with NADCAP standards • Provide training to employees on company’s quality initiative • Perform internal audits of organization and also audit suppliers • Provide customer support on any non-compliance and educating customers on our process capability

• Coordinate documents and procedure to comply with ISO standards • Direct safety programs to comply with MOSH/OSHA • In-charge of receiving department and inspection of all incoming materials • Perform internal audits of organization Provide training to employees on company’s safety plan and quality initiative