Jose Santo

Over the course of my Ph.D., I served as a Teaching Assistant (TA) for multiple undergraduate and postgraduate courses, gaining extensive experience in laboratory instruction, tutorial sessions, curriculum delivery, and student mentoring. My role included assisting in course design( Lab activities of advanced composites ), preparing teaching materials( Advanced Manufacturing and Composite courses), conducting assessments, and providing academic support to students across different academic levels.

Undergraduate Courses:

Materials Science (Tutorials and Laboratory Sessions)

• Delivered tutorial sessions explaining fundamental concepts in materials structure, properties, and applications.
• Guided students through experimental techniques such as metallography, mechanical testing, and microstructural analysis.

Manufacturing Processes (Tutorials and Laboratory Sessions)

• Instructed and did hands-on training of students in traditional and advanced manufacturing techniques( CNC, EDM, and Micro milling).
• Supervised hands-on laboratory work, including casting, welding, Machining, and additive manufacturing demonstrations.

Advanced Manufacturing Processes (Laboratory Sessions)

• Instructed students in advanced methods such as powder metallurgy, rapid prototyping, and non-traditional Machining ( electrochemical Machining).
• Instructed and did hands-on training of undergraduate students in the use of CMM(Accurate Spectra) as per ASTM E2309 and VMM(Mitutoyo, Quick Scope-L2010Z/AFC), following ASTM E456 standards for dimensional inspection of CNC-machined and EDM cut components, reinforcing GD&T principles and measurement accuracy in a hands-on laboratory setting.
• Key Contribution:-Designed and introduced an undergraduate laboratory experiment enabling students to compare Minimum Quantity Lubrication (MQL) versus flood lubrication on aluminum, steel, and titanium workpieces, systematically evaluating surface finish, material hardness, and tool wear to foster hands-on understanding of lubrication strategies.

Postgraduate Courses:

Advanced Composites (Laboratory and Tutorial Sessions)

• Conducted detailed sessions on the processing and characterization of composite materials and mechanical testing.
• Supervised experimental work involving fiber-reinforced polymers and nanocomposite fabrication techniques.
• Key contribution : Designed and implemented a postgraduate laboratory experiment comparing the performance of adhesively bonded patch and prepreg patch repairs in pultruded polymer matrix composites. Integrated Digital Image Correlation (DIC) to evaluate strain evolution, damage progression, and mechanical performance in Epoxy Composites

Materials Testing (Laboratory Sessions)

• Guided students through electrochemical(corrosion), mechanical, and thermal testing of materials according to ASTM standards.
• Trained and supervised postgraduate students in the independent execution of materials characterization experiments in accordance with ASTM standards, ensuring consistent data quality and adherence to standardized procedures.
• Assisted in interpreting results from corrosion testing, hardness(Vickers and Rockwell), tension, impact, DMA, and TGA-DSC experiments.

• Led the comprehensive operations of arc and induction furnaces, ensuring the precise refining of steel to meet stringent quality standards for casting into various forms, including slabs, blooms, and billets.
• Established a materials characterization lab with FE-SEM, metallurgical and optical microscopes, spark spectroscopy, XRF, and analyzers for carbon/sulfur and oxygen/nitrogen/hydrogen.
• Directed a process control team dedicated to enhancing machine utilization, effectively minimizing downtime, and maximizing operational efficiency across the production line.
• Formulated and implemented systems, policies & procedures to streamline steel melting shop operations.
• Authored SOPs for new steel grades, ensuring ISO/TS compliance and improved product quality.
• Established and implemented robust In-Process (IQC) and Outgoing Quality Control (OQC) systems for steel melting operations, ensuring consistent raw material quality, process stability, and final product compliance with stringent metallurgical specifications.
• Planned and carried out brownfield and greenfield expansion projects, managing installation and commissioning.
• Collaborated with cross-functional teams to identify and implement process improvements, enhancing productivity and reducing operational costs.
• Successfully led a project achieving a 20 % reduction in time of LRF-Degaser processing through process control measures and equipment upgrades.
• Provided technical support to sales teams and directly interfaced with key customers to understand application requirements, deliver material solutions, and ensure product quality met client specifications
• Played a lead role in commissioning a new Electric Arc furnace and Continues Caster.
• Recognized for leadership and project management; received the JSW Excellence Award for managing multiple high-impact projects.