Materials and Processes /Analytical Engineer with over 16 years industrial experience in a variety of sectors including: space industry, materials science, semiconductor, manufacturing sectors. Experience in Materials failure analysis, analytical techniques, space environmental simulation testing, materials characterisation and analysis. Experience in ESA International Space Station (ISS) payload safety reviews along with materials and processes support. MSc. in advanced ceramics. Strong materials analytical background.
Materials Failure and Damage analysis
International Space Station ESA/Industrial ISS payload safety reviewer
Materials and Processes project support
Materials properties testing and characterisation- (metals, ceramics, polymers, biomaterials) including thermal analysis, destructive and non-destructive testing.
Space simulation testing and materials characterisation
Non Destructive Testing and characterisation of materials
Advanced Ceramic processing background (MSc-research).
Semiconductor laser micro-machining materials analysis
ISO 9001 Internal Auditing Training/ Quality Procedure documentation.
Technical and Procedural documentation writing
Safety Training in the areas of industrial laser, chemical and gas use.
Languages: English (fluent), Spanish (intermediate), Irish (intermediate), French (basic)
CAREER & ACHIEVEMENTS
ESA, European Space Research & Technology Centre ESTEC 2007- to date
Materials and Processes Engineer
Currently I am employed as a Materials and Processes Engineer working in the Materials Space Evaluation and Radiation Effects Section, TEC-QTE at ESTEC, European Space Agency (ESA) in the Netherlands. My duties currently include: support as a materials and processes safety expert and a technical expert to the ESRP (ESA safety review panel) for ISS ESA payloads since 2014 as well as project/ system and materials support and focal point for ESA projects including MetOpC, Columbus payloads, ACLS, ASIM, ACES and MPCV (Orion multi purpose crew vehicle- (NASA/ESA involvement) where I directly interface with system engineers, PA and project managers.
Currently my role involves reviewing of safety and materials aspects of ESA payloads which form part of the Columbus Laboratory systems hardware on board the ISS and include life sciences, materials science, robotic sciences, biological sciences and educational payloads. Part of this role involves guidance and advice to payload developers in compliance to ECSS, JSC,NASA and international ISS safety standard for project safety reviews. Recently I have been involved in ongoing NASA safety coordinated meetings (RISE), safety workshops and standardisation review meetings within ESA. In addition my role also involves project materials support at materials review stages including SRR, PDR, CDR, QR and FAR as well as project PA+S materials support at MIP/KIP reviews, MRRs, NRBs, MPCBs, RID collocations and technical materials expert reviews.
Prior to this my duties have included environmental testing and materials characterisation, materials screening, materials process investigations/ failure analysis and new materials evaluation. As part of the environmental testing group my duties include the use of thermal, high vacuum and UV/ VUV source facilities among other equipment. Materials properties such as thermo-optical, reflectance and out-gassing properties were also assessed by me. In the recent past I have been involved in the qualification stages of space environmental simulation test materials (including ATJ (advanced triple junction solar cells- as part of the Bepi Colombo Mercury Mission and qualification test program), thin film cells, high temperature polymeric films for space application, ceramics and a variety of other materials) and also qualification testing for the Galileo project. Scientific technical and procedural report writing, project/ test planning and materials failure analysis are also core activities covered as well as liaising with produce suppliers, vendors and equipment/ technical sales personnel. Fractography and surface damage analysis of various materials have also been performed by me as well as contact angle and vacuum technologies. In addition I have supported projects such as the AMO Bepi Colombo VTC 1.5 facility solar cell qualification testing and have supported the contamination and cleanliness group recently within this role.
Achievements to date include:
·Screening, testing and characterisation of advanced materials (e.g. triple junction solar cells, thin film cells etc) during space simulation environmental testing
Maintenance and use of various environmental testing facilities within Estec, TEC QTE including SUV, BOF and Cross environmental test facilities.
Third party activities/ project management (CPQ activities) for various materials testing campaigns including in-situ-thin film solar cell testing, thermal cycling of composites and characterisation of space hardware materials. Additional activities have included the testing of novel materials including aero gels, metallic foams, CIGS thin solar cells.
I have also been involved in material testing and screening for various ESA projects during my time at Estec including, Bepi Colombo (solar cells space environmental simulation testing) , VEGA (launch simulation testing of materials components), Meteosat MSG-4 (uv degradation of polymers) and recently Sentinel 1 (thermal cycling of waveguides) and SMALL Geo Sat. (characterisation of polymeric and thermal control coatings). Other project work has involved UV studies of adhesives for use as alternative coverglass materials
Conference paper contributions towards materials screening of space qualification of silicone adhesives, and the characterisation of high temperature heat resistance polymeric foils for shielding/ thermal control applications (e.g. Upilex, Elasosil S690, STAMET) for space applications.
Use of advanced scanning electron microscopy techniques ( including INCA/ EDAX software) and optical microscopy techniques, quadropole mass spectrometery (contact angle and X-Ray Diffraction techniques as well as various NDT techniques including laser profilometery, cSAM (scanning acoustic microscopy) and X Ray tomography 3-D imaging techniques.
Multiple external project involvement in fracture and materials analysis (NDT techniques etc) of ceramic and glass materials within Estec and with industry over the past few years with ESA projects, including project work for SODI, Expose R- EuTEF program (Columbus-ISS experiment),
Workshop presentation on Non Destructive Inspection of Glasses and Ceramics at the Fracture Control Technical Interchange Meeting (TIM), Estec March 2011.
Supervision of PhD student within TEC QTE on environmental materials testing as part of NPI programme with TEC EPG (2011).
Expert review panel member for Met-Op C long term storage campaign and long term storage space materials investigation.
Increased exposure to adhesive bonding and materials interface investigations- e.g. Galileo thermal doubler investigation.
Sentinel 2 and Bepi Colombo member as part of the Tufnol Reaction Wheel Cage materials investigation team and company audit.
Galileo Thermal Doubler and connector qualification testing.
member in a long term storage review panel (as part of Met-Op project support- 2013)
Previous Employer #1:
Hewlett Packard (HP) Manufacturing Ltd. 2005- 2006
Materials Scientist (Analytical Engineer):
I was previously employed as an Analytical Engineer (Materials Scientist) at Hewlett Packard (HP). Here I worked as part of the Product Development department where my role involved working closely within the Analytical lab which is part of the testing solution group. My role involved leadership of analytical technicians with speciality in thermal analysis and characterisation of materials, processing issues and failures involving ink pen manufacturing with respect to process implementation and trouble shooting. Further responsibilities included expanding the technical scope of analysis, instrumentation procurement and reviewing of technical reports as well as liaising with product engineer regarding material issues. I was also involved in data quality and process monitoring. Achievements included:
Review and assessment of vendors for Analytical Instrumentation
Implementation and updating of data quality procedures
Method development in relation to thermal analysis procedures.
Previous Employer #2:
Xsil Ltd., Ireland. 2001- 2005
Another previous position was as Materials Engineer working at Xsil Ltd, Ireland. This Irish based company produced laser automation systems for precision micro-machining within the semiconductor industries. As a Materials Engineer in the Technology Development Group I reported directly to the CTO where my responsibilities included materials analysis of customer samples with a view to optimising processes for improved product yield. I was also involved with mechanical testing of the product and the sourcing of external materials analytical facilities as well as materials and equipment sourcing from vendors. Other roles I was involved in, included working within the EHS (Environmental, Health and Safety) department on various company safety issues and initiating the development of safety training presentations within Xsil. Achievements included:
Implementation of wafer singulation process- control of dicing strategies, laser process development with respect to laser-materials interaction and optimisation. Testing and analysis of various semiconductor and electrical devices including through and blind via structures, MEMS devices, micro fluidic devices, FC-BGA, thin silicon wafer processing were processed for Fortune 500 semiconductor companies.
Scientific customer reports and quality procedural documentation
Control, development, sourcing and use of In-house and external materials characterisation for the materials analysis/ characterisation of customer samples.
Equipment and Materials sourcing and validation and qualification
Lab Management-Laser and Chemical/ Gas safety Officer- including technical procedural documentation, in house training to personnel
Internal Auditor- ISO certified in-house auditing of Production, Mechanical , Technical and IT departments.
EHS involvement which included: development of safety training presentations on chemical, gas and laser use.
Previous Employer #3:
Materials Ireland, University of Limerick, Limerick, Ireland 1999- 2001
Previous employment in the MIRC-Limerick (Materials Ireland Research Centre- Limerick) was as a Research Associate. I was involved with working directly on materials issues with industries both in Ireland and abroad in collaboration with the senior engineers. My responsibilities included customer consultation and queries in relation to various materials testing and screening campaigns. Other roles included materials analysis and testing of customer products including metals, ceramics, biomaterials and polymers along with customer written reports. I also gained a greater understanding of materials testing standards including ASTM and ISO standards. I reported directed to the Centre Manager and Centre Director during my work period at MIRC. Materials testing included thermal, destructive and non-destructive testing. Achievements included:
Failure and damage analysis of materials
Materials testing and training (a full range of thermal, destructive and non-destructive tests used-including tensile, micro-hardness, impact, sintering techniques, SEM, DTA/TGA, DSC, XRD, Dilatometery, FTIR, particle size analysis)
Customer reports on a variety of materials issues including corrosion, wear and coatings.
Sample preparation optical and electron microscopy.
Customer Projects in areas of catalytic converter studies and Dental Restorative Materials.
Previous Employer #4:
Analog Devices B.V., Ireland 1996
Failure Analysis Engineer:
As part of my degree course I was employed as a Co-op student within the QA/FA (Quality Assurance/ Failure Analysis) Department in Analog Devices, Limerick. I reported directly to the Senior Failure Analysis Engineer. Responsibilities included materials analysis of customer samples and electrical failure analysis of received parts after the lifetime of the sample. Training was received on many of the materials analytical tools. Achievements included:
FA reports on failed devices
Electrical failure analysis including training on SAM, LCA, X-Ray Imaging, SEM training and plasma etching.
Previous Employer #5:
PPI Adhesives, Ireland 1995
During my degree course I was employed as Research Assistant at PPI Adhesives, Waterford Industrial Estate, Co. Waterford during a summer period. Whilst in the testing lab I received training on the testing of adhesive tape products, adhesive testing standards and the testing of various adhesive qualification tests included electrical, mechanical and tensile testing of the various products. I was also involved with working on the process line. Achievements included:
General adhesives testing -Creep testing, tensile testing; peel testing and electrical testing of adhesive tape products.
General operation and production of adhesive tape product.
EDUCATION, QUALIFICATIONS & PROFESSIONAL MEMBERSHIPS
M. Sc. (by research): Postgraduate: University of Limerick, Ireland 1997- 1999
Research Title: Preparation and Characterisation of Oxynitride Based Glass and Ceramic NanoComposites.
Research Areas covered: Advanced Ceramics, liquid phase pressureless sintering of Si3N4/SiC nano-composites. Research involved glass and ceramic processing including synthesis, ceramic sintering optimisation and preparation and characterisation of wear resistant ceramics. Ceramic processes including high temperature pressureless sintering and crystallisation studies The influence of sintering parameters on mechanical strength properties of materials were also investigated. Analytical techniques such as XRD, SEM, Dilatometery and micro hardness techniques were used. Additional roles during this period included laboratory practical set-up for experimental sessions, lab demonstrations and exam corrections of undergraduate students.
B Sc. (Materials Science) Hons (Grade 2): Undergraduate: University of Limerick 1993- 1997
Subjects Studied Include: High temperature materials, failure and damage analysis, advanced analytical techniques, ceramics and glass structure/ materials properties, polymer processing, materials selection and design, bio-materials, composites, physical chemistry, light alloys materials science. Laboratory practicals were a major part of undergraduate course. Final Year Project Thesis: materials properties/ characterisation of bio-active dental restorative materials using glass ionomer cements.
Second Level: 1987-1993
CBS Secondary School, New Ross, Co. Wexford.
Leaving Certificate Results: 6 Honours at higher level. Subjects: Maths C+, Irish Language Studies B, Chemistry B, Physics B, Technical Drawing B+ and French C
Professional Membership / Certification and Training Courses (CPD- continual professional dev)
City and Guilds Certificate in Marketing and Customer Relations, Waterford June 1994
Prof Graduate of the Institute of Materials (Prof Grad IOM3) since June 1999
Associate member of the Institute of Engineers of Ireland (AMIEI) since Aug 2000
ISO 9001:2000 Internal Auditor Training Course, Xsil Ltd., May 2002
Electrical Safety Training Nifast Nov 2003
CMA Unit. Trinity College Dublin, SEM Training Dec 2003
Laser Safety Management Course, NRPB, Loughborough University, UK Feb 2004
Nifast Chemical Safety Training, Dublin 17 April 2004
BOC Industrial Gas Training, Dublin May 2004
Thermal Analysis Seminar, Dublin Sept 2005
Basics of Vacuum Technology, Pfeiffer Vacuum Course, Asslar, Germany Aug 2007
ESA/ Estec Internal training- Operation of Contact Angle facility- Kruss Jan 2009
ESA/ Estec Internal training- Laser Safety course Feb 2010
ESA/ Estec Internal training Fire Safety Course March 2010
Working with Quadroploe Mass Spectrometers, Pfeiffer Vacuum, Asslar, Germany June 2010
ESA/ Estec Internal training- Operation of Leo VP SEM + INCA software July 2010
Advanced Contact Angle measurements course, Bristol University, UK July 2011
ESA/ Estec Internal training Effective Meeting- Taking Minutes of Meetings Feb 2012
ESA/ Estec Internal training X -Ray Tomography 3D Imaging Sept 2012
IEI, Technical Report Writing March 2013
ESA/ Estec Internal training- Advanced Operation of FEI VP SEM Jan 2014
IAASS ISS Payloads design and operational safety course, Livorno , Italy March 2015
Prof Member of the International Association for the Advancement of Space Safety Nov 2016
FURTHER PROFESSIONAL ACTIVITY
Technical presentation at the Unidare final year project competition,
University of Limerick, Limerick, Ireland March 1997
Poster Exhibition at NEDO Ceramics Conference, Japan Jan 1999
Poster Exhibition at NEDO Ceramics Conference, Japan Jan 1999
Poster/ Paper(s) presented at the International Symposium on Materials in
Space Environments (ISMSE) 11, Aix-en –Provence, France Sept 2009
Technical presentation at the Technical Interchange Meeting (TIM) on fracture control of
Spacecraft, launchers and their payload and experiments, Estec, Noordwijk, The Netherlands March 2011
Poster/ Paper(s) presented at the International Symposium on Materials in
Space Environments (ISMSE) 12, Estec Sept 2012
“Degradation mechanism of silicone glues under UV irradiation and options for designing materials with increased stability”
Journal Polymer Degradation and Stability , Volume 98 (3) – March 2013
“Protection of Materials and Structures From the Space Environment-Accelerated testing of thermal control coatings using synchrotron radiation and evaluation of materials performance”
Astrophysics and Space Science Proceedings Volume 32 2013, ISBN: 978-3-642-30228-2 2013
Poster/ Paper(s) presented at the International Symposium on Materials in
Space Environments (ISMSE) 13, Pau, France June 2015
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