Senior Fuel Cell Stack Test Engineer
Nikola Corporation
Total years of experience :20 years, 8 Months
• Heavy-duty (HD) fuel cell system (FCS) and subsystems testing in a real HD Semi Trucks.
• Developed and implemented changes to FCS, subsystems, and stack designs based on daily test data.
• Hands on FCS and stack maintenance and troubleshooting for HD semi-trucks with the suppliers.
• Training engineers from different backgrounds on troubleshooting the HD FCS and Stack.
• Conduct daily meetings with different suppliers for design and development of the FC Engine.
• Analyzing the data of the HD FCS, subsystems, and stack and take the appropriate actions for safe, durable, and cost-effective operation.
• Prepare product specs for HD FCS, subsystems, and stack components.
• Plan and conduct experiments to validate new components, optimize startup protocols, and reduce conditioning time
• Failure analysis of the HD FCS, subsystems, and FC stack based on prolonged collected real time test data.
• Preparing specs for FC stack test rigs.
• Prepare testing plans and DVP & Rs for FCS and subsystems.
• Developing and integrating sub systems such as Air intake System, Coolant system, Exhaust system…etc.
• Participating in designing and developing complex fuel cell system. And subsystem.
• Working on preparing Nikola Corporation (NC) FCS and HD FC truck Dyno test facility with major provider such as AVL and Greenlight.
• Working with the GC to prepare NC test facility building and help the GC to get the required permit.
• Helped the safety department for planning the NC test facility safety plan during testing and operation.
• Worked on DOE proposals with FCS and MEA suppliers.
• Led the experimental work of Turbulence-Inducer project which eventually cumulated in a new patent.
• Worked as a team member on E-Store Project resulting in characterizing the PEM water electrolysis.
• Conducted IV, EIS, water balance measurements and tests for PEM Fuel Cell and Water Electrolysis.
• Improving the performance of the air-cooled PEMFC using flow grid.
• PEM Water Electrolysis in-situ and operando current and temperature measurement distribution.
• Instructor for PhD electrochemical conversion course- Theory and Experimental.
• Enhancing hydrogen production through leading Power2Gas project.
• Direct supervision for master students’ thesis titled:
• CFD analysis to determine the local Nusselt number over a heated micro wire in multicomponent flow,
• Modelling of transient heat change in fuel cell stack,
• Improving the performance of air-cooled fuel cell stacks by inducing turbulence
• Conducting different research projects directly related to PEMFC and PEMWE.
• Fluid dynamics, temperature and current distribution of PEMFC/WE.
• Hands on testing and designing PEMFC/WE.
• In-situ testing for PEMFC & PEMWE for different applications.
• Built in house test set-up for an atomized and remotely controlled PEMFC/WE.
• Patented an Ex-situ technology for accurate and real time PEMFC water balance measurements.
• Developed real time PEMFC water balance measurements for commercial PEMFC stack.
• Thermal fluid numerical calculations and experimental measurements.
• Hands on hot wire anemometer technology.
• Helped and supervised PhD and master students group on different projects.
* Developed course level outcomes, objectives and curriculum for
Robotics and Automation program.
* Created Course Scope and Sequence.
* Escalated complex operating issues and requests to gain
cooperation at levels of mid- management.
* Ensured that the media aspects of the course are consistent with
the learning outcomes and learning needs for the desired program.
* Selected as a TA (Tutor) for Thermodynamic course for few times
for undergrad students of Mechanical Engineering Department
* Prepared a curriculum for Fuel Cell Technology Course and
taught the course for grad students from different engineering
disciplines.
* Designed, and assembled HFC with different sizes, layouts, and
materials for enhancing water and thermal management.
* Conducted a material surface modifications and characterization
for HFC components to produce cell components with different
surface wettabilities.
* Tested and characterised different carbon paper samples using
automated method of standard Porosimetry (MSP) to understand
the effect of different carbon paper samples on cell performance.
* Prepared test stations, instrumentation, or data acquisition
systems for use in specific tests of fuel cell components or
systems.
* Characterized components or HFC performances by generating
operating maps, defining operating conditions, identifying design
refinements, or executing durability assessments.
* Designed and built experimental set-ups for testing water
removal rate through different carbon paper samples and to
characterize the two-phase flow in HFC.
* Analyzed HFC or related test data results, using statistical
software, to generate the performance maps and to understand
the related physical phenomena for the cell behavior.
* Taught and trained the Thermodynamic of Materials Research
Group on how to many software and techniques for
thermodynamic modeling
* Performed and directed materials evaluation testing, including
micro structure evaluations, physical and mechanical properties
testing using Tensile, Compression, Impact, Torsion test and
thermal analysis.
* Performed a numerical modeling computation to optimize multi-
magnesium based alloys for usage engine blocks and some car
body components at high temperature and high impact force.
* Used and advanced commercial software for 3D-Modeling, such
as PANDAT and FACT-SAGE to calculate, simulate, and optimize
high temperature magnesium based alloys.
* Developed and designed new techniques for Mechanical and
Heat treatments for Nitinol alloys to achieve the treatment of
different Nitinol alloys with minimum cost and time.
* Wrote technical reports or proposals related to engineering
projects.
* Selected as TA (Tutor) for Operation Research, Reliability
Engineer, and Safety & Human Factor
* Taught CAD/CAM Lab., Properties of Materials Lab., Strength of
Materials Lab., and Safety Lab.
* Designed many webpages to deliver and post the materials for
students.
* Administrated and taught Materials Labs resulting in high
performance and multi purposes facilities with an organized
documentation.
* Performed Material failure analysis for academic and industrial
purposes. Areas of expertise include fracture, deformation, wear,
corrosion, and heat treatment.
* Developed and taught strength and properties of materials
laboratory course.
* Directed and performed routine material tests based on ASME.
Mechanical Engineering
Master of Applied Science in Mechanical Engineering
Bachelor of Applied Science in Industrial Engineering