Dr. Suresh Sundarraj is a Program Manager and Lead R&D Scientist, Advanced Technology at Honeywell Aerospace. He completed his PhD in Mineral Engineering from University of Minnesota in 1994. He currently manages several Government-funded and Honeywell Additive Manufacturing programs, focused on hot-section turbine components, utilizing ICMSE based modeling & simulation tools applied to multiple materials and superalloy systems. He has extensive prior experience in developing and supporting advanced manufacturing processes (refining, casting, forming) using physics-based modeling software development for application in aerospace, automotive, and semiconductor manufacturing sectors. He has developed and applied innovative solutions for mitigating porosity, inclusion and microstructural defects, which form during Liquid/Solid and Solid/Solid phase transformations which occur during processing of advanced metal and alloy systems, namely, Ni-based and Ti-based alloys, aluminum, magnesium and steels among other materials. He has over 40 peer-reviewed publications/presentations, 5 US patents issued, 5 US patent pending, and 22 awards & trade secrets in materials manufacturing processes. In 2019 he received the prestigious Honeywell Technology Achievement Award for his work on development and application of ICMSE models to arrive at optimal AM build process designs.
Designing for AM requires a different mind-set. Designers need to know material limitations not just manufacturing limitations. Moreover, there is little point in producing a part with AM that could be machined. What tools can help this process, what training can be given to designers? From software packages to training courses there is a lot that can be done to generally improve the AM design approach.
Discussion will include: