Materials Scientist - Physicists

Max-Planck-Institut für Eisenforschung GmbH Nov 2015-Jan 2016
Work student internee| Department of Microstructure Physics and Alloy Design| Theory and Simulation
Düsseldorf, Germany

Forschungszentrum Jülich Nov 2014-Aug 2015
Internee | Jülich Centre 
for Neutron Science JCNS und Peter Grünberg Institut PGI - JCNS-2| 
PGI-4: Streumethoden. 
Jülich, Germany

 Umicore AG & Co. KG Jun 2014-Sep 2014
Researcher | Technical Materials Business Unit | Material & Process Development.
Hanau, Germany

Hyundai Motor Europe GmbH Feb 2014-May 2014
Graduate Research Assistant | Engineering Design Department | Material Research & Development 
Russelsheim, Germany 

Robert Bosch GmbH Aug 2013-Jan 2014
Graduate Research Assistant, Applied Research 1 | Advanced Functional and Sintered Materials 
Metallic Functional Materials | Composites (CR/ARM3)
Stuttgart, Germany 

NED University of Engineering Sciences and Technology Oct 2010-Sep 2011
Lecturer & Research supervisor in Material Science & Engineering Department, Karachi, Pakistan.

Arrhenius Labs - Stockholm University Jun 2008-Aug 2008
Researcher in Department of Physical, Inorganic and Structural Chemistry, Stockholm, Sweden.

Diamorph AB .Inc. Jun 2008-Aug 2008
Researcher & Market Analysts, Stockholm, Sweden.


PROJECTS

Forschungszentrum Jülich Gmbh

Photoemission Spectroscopy beyond He-II on complex materials and structures
Producing epitaxial BaTiO 3 layers by laser MBE. Characterization of layers means piezo-response atomic force microscopy 
(PFM). Preparation and test ferroelectric structure for the in-situ during operation of the PEEM analysis. Attended PEEM 
synchrotron beam time in Berlin (BESSY).

Plasma diagnostics of High Oxygen Sputtering Process with an Optical spectrometer [OES]
Correlation between the pressure and the power input to the plasma to the variation of the characteristic oxygen intensities.
Correcting the wavelength inaccuracy due to pressure and Doppler broadening [fitting with Gaussian, Lorentzian and Voigt 
profiles – choosing the best one for every spectrum obtained from Oxygen pressure and Power variation]. Correction of linear 
imprecision in the power / pressure correlation. Obtaining the correct number of data points by averaging for different 
oxygen pressures and power input values. Monitoring of time resolved plasma intensities for deposition cycles. Identification
of the optimal region for control of thin film deposition with optical diagnostics of plasma – Signal to Noise Ratio. Correction 
of Signal to Noise Ratio in accordance with new data points obtained to correct sudden dips in power input. Application of th e 
Power/Pressure correlation to actual multilayer growth and measurement of thickness. Collision Radiative Model for Oxygen 
in High Oxygen Sputtering Process. Integration of model into the Python program for controlling deposition rate. 

Optimization of deposition parameters for LSMO/STO[111] heterostructure.
Deposition of LSMO on STO [111] has been carried out and the process control by variation of oxygen, on oxide film thickness,
has been investigated. XRR and XRD measurements to ascertain the thin film thickness and degree of strain during 
deposition, has been inspected, respectively. The surface roughness and quality of the deposited thin films under different 
oxygen pressure conditions, has been determined by AFM. Conclusions have been drawn for the best oxygen ranges for the 
deposition of LSMO thin films with minimal strain and optimal surface quality.


Umicore AG & Co. KG, Germany
 
Synthesis and joining of contact materials 
First commissioning of the ThermProTec plant. Review of the positioning, review of process repeatability, development of 
Standardlötprofilen for different geometries, programming of evaluation tools, creation of patterns for switching experiments
with VSP contacts. Preparation of samples at low and high brazing temperature, metallographic evaluation of the joint zone, 
depending on the process parameters, switching experiments and development of the optimum soldering profile per contact 
geometry in dependence and correlation of results. 

Hyundai Motor Technical Centre Europe, Germany

Precision Adhesion Test and Microstructural Evaluation of Engine Bore liners [Ferrous coating on Aluminium substrate]
Evaluation of coating surface and interfacial parameters through various thermal spray coatings. Pull off adhesion testing of
Ferrous coated Aluminium engine liners through the PAT 6.3kN Adhesion tester (DFD Instruments Norway) to asses coating 
adhesion strength. Fabrication of adhesion testing sample holder to apply constant pressure throughout the adhesive film 
FM1000® curing cycle and adhesion strength test protocol formulation. Adhesion strength evaluation through the use of 
adhesive film and adhesive liquid [mono]. Experimental study on the optimal choice of adhesive to acquire optimal adhesion 
strength. Scanning electron microscopy, Optical Microscopy and X-ray diffraction analysis of the interfacial zone, grain 
enlargement at interfacial boundary, grain impingement in the interface and percentage crystallinity of the interface.

Material Procurement
Material procurement for the Material Research section of the Engineering Design department. Selection of appropriate 
suppliers, quality assurance and supervision of material delivery.

Robert Bosch GmbH, Stuttgart, Germany

Development of Nanostructured Magnetic Materials from Novel Rare Earth [RE] Magnetic Phases. 
Alloying additions to increase coercitivity and remanence by obtaining novel phases and increased grain wetting. Use of 
mechanical alloy/milling [MA] to synthesize enhanced solubility rare earth magnetic phase. Glove box handling of the 
reactive Rare Earth [RE] elements to synthesize master alloy in Button Arc Furnace. Button Arc Furnace parameter 
optimization to reduce sudden quenching and oxygen contamination. Powder fabrication of the master alloy through MA and 
subsequent Pressure less Sintering in inert atmosphere after manual encapsulation of the green body in vacuum. Evaluation 
of the magnetic phase through Polarized Kerr Microscopy, MFM, SEM and XRD. Carrier gas hot extraction analysis - oxygen 
and carbon content on the surface and interior of the sample. Process optimization to enhance coercitivity by decreasing 
grain size and liquid phase, enhancement of soft-hard magnetic coupling effect through experimental proportioning of atomic 
percentages of elements with appropriate alloying additions [Mo, Ga, Cu, Co, Zn, Sn, Al, V, Si], to increase magnetic density.

NED University of Engineering Sciences and Technology, Pakistan

Course instructor on Physical Metallurgy, Joining of Materials and Biomaterials. Supervised 2 research projects on HAP 
Synthesis by Sol Gel methodology and Bio-Glass Ceramics Synthesis. Responsible for the setup of Atomic Force Microscopy 
Equipment and Friction Stir Welding.

Bio Glass Ceramic Synthesis and Characterization
Thesis project supervision of Bio Glass Ceramic with 45 mol. % SiO2, 35 mol. % CaO, 20mol. % Na2O composition and 
subsequent heat treatment for crystallization in amorphous matrix. Inducement of secondary nucleation in formed glass through 
heat treatment resulting in a crystalline phase in an amorphous matrix. Determination of nucleation rate and viscosity to 
optimize heat treatment cycle. Mechanical attrition and subsequent melting process in heat treatment furnace was carried out 
leading to glass formation and recrystallization. Characterization through XRD was done to ascertain the formation of a 
crystalline phase in amorphous matrix. Hardness testing to ascertain the variation in hardness to distinguish between the 
crystalline and amorphous phases was also a fundamental part of the project.

Hydroxyapatite synthesis [HAP] using biological template
Thesis supervision of Hydroxyapatite synthesis through Sol Gel method using bovine serum albumin [BSA] as biological 
template to control the particle size of the nucleated HAP.

Setup of Friction Stir Welding machine [FSWM]
Engineering design of the rotating tool geometry, multiple screw structures. Modification, control and optimization of the tool
rotational torque to minimize heat affected zones [HAZ]. Material flow tracking by a marker material. Modeling of temperature
distribution.

Ghulam Ishaq Khan Institute of Engineering Sciences & Technology, Pakistan

Fabrication and characterization of a Functionally Graded Material of Hydroxyapatite and Stainless Steel 316L via Cold
Isotactic Pressing [CIP] & Spark Plasma Sintering [SPS] 
Synthesis of the functionally graded material (FGM) of hydroxyapatite/stainless steel 316L (HAP/SS 316L) for bio – medical 
applications was carried out using Spark plasma sintering process (SPS) and pressure-less sintering. Uniform variation in 
composition along the longitudinal direction of the sintered specimen was achieved through the powder metallurgy route (dry 
method), providing the required mechanical strength and biocompatibility attributed to SS 316L and HAP respectively. Sintering 
at temperature of 900ºC and 1200ºC for SPS and pressure-less sintering respectively, was carried out for micron sized (5?m) 
and Nano sized powders. X - ray diffraction study of both the sintering techniques indicated no decomposition of HAP into tri 
calcium phosphate and tetra calcium phosphate at high temperatures. A constant pressure of 100 MPa was applied during 
sintering in the SPS route, while a pressure of 250 MPa was applied to obtain a green body of the layered structure before 
sintering in an enclosed silica tube in a vacuum of 10-2 torrs. Results indicated a higher densification and hardness achieved by 
the SPS route due to the simultaneous application of pressure and heat. Microstructure analysis indicated no significant grain 
growth for both the sintering routes, although the SPS technique resulted in a more effective grain size control due to a 
comparatively lesser time required for densification.

Stockholm University, Sweden

Synthesis and Characterization of Functionally Graded Materials of HAP/SS316L via Spark Plasma Sintering [SPS]
Synthesis and mechanical property evaluation of Hydroxyapatite [HAP]/Stainless Steel [SS 316L] functionally graded 
materials [FGMs] for sporadic localized bone replacement of any ball and socket joint comprising of the cartilage, focusing 
particularly on knee implants. Powder Metallurgy Route, Spark Plasma Sintering.

Single crystalsynthesis of Aluminum Phosphate
Single crystal synthesis of Aluminum Phosphate doped with Antimony [Sb] and Boron [B] to enhance thermoelectric 
properties of the system.

Synthesis and characterization of Oxynitride glasses
Synthesis and characterizationof Oxynitride glasses with Ca and Mg as the modifying cations.

Diamorph AB .Inc., Sweden

Implementation of research in the industry and marketing. Assessment of a particular market demand and strategical 
formulation of research groups to fulfil them.

TECHNICAL SKILLS
• Microscopy (Optical, SEM, XRD, AFM) 
• Thin film deposition – Sputtering, MBE
• Thin film characterization
• Plasma diagnostics in thin film systems
• Optical Spectroscopy 
• Injection molding machine
• Spark Plasma Sintering of Ceramics 
• Materials Evaluation Techniques (NDT and DT)
• Heat treatment and Casting of various metals 
• Nuclear Magnetic Resonance Spectroscopy
• Glove Box Working 
• Single crystal fabrication
• FTIR Analysis