Xinchang Zhang

1. Established functionally gradient material system to join SS316L with Inconel 625 alloy
2. Performed analysis to study deposits with SEM/EDS, XRD, hardness test and tensile test
3. Conducted heat-treatment on the FGM and significantly improved mechanical properties

1. Developed methodologies for pre-repair machining of directly non-repairable metal parts to guarantee they are ready for repair through additive manufacturing process
2. Targeted typical defects including impact dents, surface erosion, corrosion, wear, cracking and deformation. Candidate parts are aluminum casting dies/molds, jet engine turbine and compressor blades, engine camshafts and engine blocks
3. Conducted a series of machining using CNC and EDM based on the proposed methods

1. Led a team to research and develop a 4-axis wire feed additive manufacturing equipment for printing Titanium for GKN aerospace and conducted maintenance, troubleshooting, guidelines and training
2. Validated robustness, precision and process control of the system for reliable 3D printing
3. Determined key techniques and process parameters for wire deposition of Titanium with cost reduction and good material utilization to demonstrate the benefits of using wire-feed 3D printing… Show more

1. Led a team to research and develop a 4-axis wire feed additive manufacturing equipment for printing Titanium for GKN aerospace and conducted maintenance, troubleshooting, guidelines and training
2. Validated robustness, precision and process control of the system for reliable 3D printing
3. Determined key techniques and process parameters for wire deposition of Titanium with cost reduction and good material utilization to demonstrate the benefits of using wire-feed 3D printing process
4. Successfully fabricated titanium parts with good mechanical properties Show less

1. Integrated a 3D scanner with a Nachi industrial robot to realize scanning automation to obtain STL models of worn die
2. Developed Python programs for damage reconstruction and generated repair tool path for laser metal deposition
3. Coated Ni-based alloys on damaged die for restoration and improving corrosion and wear resistance
4. Conducted microstructure characterization, SEM, EDS, XRD, and mechanical testing to validate repair quality
5. Successfully passed quality inspection… Show more

1. Integrated a 3D scanner with a Nachi industrial robot to realize scanning automation to obtain STL models of worn die
2. Developed Python programs for damage reconstruction and generated repair tool path for laser metal deposition
3. Coated Ni-based alloys on damaged die for restoration and improving corrosion and wear resistance
4. Conducted microstructure characterization, SEM, EDS, XRD, and mechanical testing to validate repair quality
5. Successfully passed quality inspection by Toyota Quality Inspection Facility and re-inserted into production line to maximize service life to save cost Show less

1. Successfully coated Ni-based (Inconel 625, Colmonoy 88L) and Co-based (Wallex 40/50) alloys on fuel injectors for enhancing wear and corrosion resistance with hardness increased from 200 HV to 870 HV
2. Performed design of experiments for laser metal deposition and obtained optimized processing parameters to guarantee excellent coating quality by analyzing micro-structure and mechanical testing

1. Investigated the feasibility of coating several Co-based and Ni-based alloys on H13 tool steel die/mold for improving wear and corrosion resistance
2. Conducted a three-factor three-level design of experiment and established processing parameters windows for coating the alloys using laser metal deposition
3. Analyzed coatings through microstructure, microhardness, tensile test, four-point bending test, Charpy impact test and XRD (residual stress analysis)

1. Automatically located defects on Ti6Al4V part from GKN using cameras. Reconstructed missing volume using a laser displacement sensor and generated toolpath for material deposition
2. Conducted repair experiments and analyzed repaired part quality

1. Developed kinematic mathematical model of the upper die in cold orbital forging process.
2. Verified the proposed model by measuring the real motion of the upper die. Analyzed trajectories of the upper die using Mathematica and DEFORM software.

1. Simulated material deformation in cold orbital forging process using the proposed kinematic mathematical model
2. Predicted stress and strain of the deformed gear and load of the upper die

1. Proposed mathematical model for design and optimize non-rotation upper die for cold orbital forging process
2. Designed upper die for forging automotive gears using cold orbital forging process

1. Designed a Two-Speed Automatic Transmission for Low-Speed Electric Vehicle
2. Designed transmission gear ratios, structure and hydraulic circuit of the transmission
3. Validated strength of each part based on mathematical calculation and modeled each part, assembled and motion simulated in SolidWorks

1. Led and designed a flyable vehicle and adaptive hybrid truck for 4th and 5th China National 3D Innovative Design Competition (Won Grand Prize and First Prize), and a small vehicle kinematic energy recycling system (Won First Prize) for 2011 Shandong Province College Students Mechanical and Electrical Products Innovation Design Competition
2. Modeled and assembled projects in SolidWorks, Creo and NX. Simulated motion of the systems in SolidWorks. FEA Simulated in SolidWorks. Manufactured… Show more

1. Led and designed a flyable vehicle and adaptive hybrid truck for 4th and 5th China National 3D Innovative Design Competition (Won Grand Prize and First Prize), and a small vehicle kinematic energy recycling system (Won First Prize) for 2011 Shandong Province College Students Mechanical and Electrical Products Innovation Design Competition
2. Modeled and assembled projects in SolidWorks, Creo and NX. Simulated motion of the systems in SolidWorks. FEA Simulated in SolidWorks. Manufactured parts for the small vehicle kinematic energy recycling system using CNC and EDM Show less