Vikram Varadaraajan, PhD
Contact Information
Location: Rochester, Michigan
Email: firstnamelastname@gmail.com
Links: LinkedIn | Google Scholar
Professional Summary & Interest
Solution driven problem solver, with hands-on expertise in Thermal systems, Power Electronic Materials, Characterization of materials – composition and structure, Simulation and Computational techniques.
Hands-on Project Management experience and Creativity with delivery of demonstrated results. Seeking opportunities to transform them, from concept to product realization and commercial success.
Professional Experience
Mechanical Engineering Specialist
Aptiv | Troy, Michigan | Jul 2023 – Present
- Spearheaded a 5-member team delivering optimized thermal solutions for OBC+DCFC and dual-DCDC systems, meeting critical temperature targets for high-voltage (>130°C) and low-voltage (<125°C) components
- Enhanced thermal management by strategically isolating high junction temperature components onto dedicated IMS daughter boards
- Boosted power density by 50% through meticulous material selection and validation for over-molded encapsulation with integrated heat pipes
- Engineered a modular prototype for PCB encapsulation using custom epoxy pours, enabling rapid iteration and testing
- Increased power dissipation density from 200W/L to 330W/L by developing advanced, high-efficiency cooling systems
- Designed integrated OBC, dual DCDC, and pDCDC systems with manufacturable cooling channel design focused on DFM
- Reduced materials simulation analysis time by 50% while improving prediction accuracy through streamlined simulation workflows
- Developed a cloud-based simulation platform enabling team-wide access, version control, automated visualization, and bottleneck identification
- Directed the design and optimization of a commercial vehicle connector as a competitive alternative to TE’s 1400 Powertube family
- Reduced field failures by 25% through implementation of crimping improvements and structural-thermo-electric simulations
Lead Design Engineer
Hella Electronics | Northville, Michigan | Jan 2022 – Jul 2023
- Spearheaded mechanical and thermal design for patented GaN-based power conversion systems, driving increased power density through fin optimization and innovative magnetics potting orientation
- Optimized power electronics cooling system, achieving a 22% reduction in pressure drop using adjoint simulation and DFM principles
- Conducted comprehensive material studies on potting compounds and TIM materials through extensive lab tests to develop internal datasheets
Research Project Leader
Somnio Global | Novi, Michigan | Jul 2014 – Dec 2021
- Pioneered laser-assisted cold spray coating technology from concept to production, achieving 95% transmission efficiency at 30bar and 600°C
- Directed DOD contract execution, achieving all material development milestones with detailed bi-weekly reporting
- Designed and deployed a fully automated, PLC-controlled manufacturing cell integrating robotics, precision gas flow, thermal processing, and IoT communication
- Established standardized protocols for coating material synthesis and ASTM-compliant material validation
- Conducted SAE J2522(AK-master) testing to validate rotors
- Designed and optimized an on-vehicle HHO system for emissions reduction, achieving 20% increase in gas production through:
- Development of a thermally optimized 12VDC-100A current limiting device with TVS diode protection
- Optimization of HHO cell electrolyte and surface tension
- Bubble nucleation studies applicable to pool boiling heat transfer (immersion cooling)
Education
Academic Credentials
| Degree | Institution |
|---|---|
| PhD, Automotive Engineering | University of Michigan |
| MS, Mechanical Engineering | University of Michigan |
Certifications
- High Voltage Vehicle Safety Systems (SAE), 2022
- Power Electronics Design Bootcamp, University of Wisconsin-Madison, 2022
AI and Professional Development
- Neural Nets and Deep Learning Specialization (DeepLearning.AI, Coursera)
- Prompt Compression and Query Optimization (DeepLearning.AI, Coursera)
Skills & Expertise
Core Competencies
- Thermal Management: Phase Change Materials, Heat Pipes, Liquid Cooling, TIMs, Potting Compounds, Dielectrics, Thermal Modeling
- Power Electronics Materials: SiC, GaN, Ceramic Substrates (ZTA, AlN), Isolation films
- Materials Characterization: SEM, EDS, EBSD, XRD, DSC, AFM, TEM, Electrochemical & Environmental Testing
- Simulation & Analysis: Ansys Suite, COMSOL Multiphysics, MATLAB (Advanced Modeling)
- Project Management: Cross-Functional Collaboration, Global Team Coordination, Statistical DOE, Proposal Development
- Programming & Automation: Python (Pandas, NumPy, Matplotlib), LabVIEW
Detailed Skill Breakdown
| Category | Skills |
|---|---|
| Thermal & Materials Design | Thermal Management, Materials Characterization, Polymers, Metals, Additive Manufacturing, Phase Change Materials, Heat Pipes, Liquid Cooling, TIMs, Potting Compounds, Dielectrics, Ceramic Substrates, Isolation films |
| AI & Machine Learning | AI model integration, React, Streamlit, AWS, Python |
| Data Visualization | Plotly, PyVis, Apache ECharts, PyDPF |
| Software Development | FastAPI, ArangoDB, Docker |
| Simulation Tools | Ansys (Fluent, CFX, IcePak, Mechanical, LS-DYNA), COMSOL Multiphysics, OpenFOAM, Zemax, MATLAB |
| CAD/Design | CATIA, NX, SpaceClaim |
| Manufacturing | CNC Mill, Lathe, Die Casting, EDM |
Selected Publications and Patents
Patents
-
Composite Metal Alloy Material (#US10392685B2) - Engineered high-durability alloy for wear and galvanic corrosion resistance. Link
-
Cold Spray Apparatus (US Patent App. 15/295,050) - Advanced deposition system for large-area material coatings. Link
-
High Nitrogen Steel Powder (US Patent App. 17/434,273) - Optimized powder formulation through innovative processing. Link
-
Durable Nitrogen Alloy Surface Treatments (US Patent App. US16/976,155) - Durable nitrogen-alloy exceeding typical solubility limits. Link
-
Free Radical Generation Device (US Patent 12,040,164) - Barrierless, efficient radical generation via controlled electrode discharges. Link
-
Wheel and Brake Assemblies (US Patent App. 17/434,269) - Dual electric/mechanical brake system. Link
Publications
- Karmarkar, N.S., Varadaraajan, V., et al. (2023)
- “An Attempt to Understand Stainless 316 Powders for Cold-Spray Deposition”
- Powders 2(1):151–168.
- Description: Analyzes the behavior of stainless steel 316 powders during cold-spray deposition, focusing on particle dynamics and their impact on coating formation.
- Link
- Varadaraajan, V., Guduru, R.K., Mohanty, P.S. (2022)
- “Property Evolution in Amorphous Steel Coatings by Different Thermal Spray Processes”
- Journal of Thermal Spray Technology 31(4):1056–1066.
- Description: Compares different thermal spray methods, demonstrating that nanocrystalline steel coatings offer superior strength and corrosion resistance compared to amorphous coatings.
- Link
- Karmarkar, N.S., Varadaraajan, V., et al. (2022)
- “A Novel High Nitrogen Steel Powder Designed for Minimized Cr₂N Precipitations”
- Metallurgical and Materials Transactions A 53(11):3881–3892.
- Description: Introduces a new high-nitrogen steel powder formulation that significantly reduces the formation of Cr₂N precipitates, enhancing material properties.
- Link
- Varadaraajan, V., et al. (2017)
- “Design and Optimization of Rectangular Cold Spray Nozzle”
- Surface and Coatings Technology 316:246–254.
- Description: Presents the design and optimization of a rectangular cold spray nozzle, demonstrating improved spray deposition efficiency through novel geometry.
- Link
- Varadaraajan, V., et al. (2013)
- “Synthesis and Microstructural Evolution of Amorphous/Nanocrystalline Steel Coatings”
- Journal of Thermal Spray Technology 22(4):452–462.
- Description: Offers a comparative study of various thermal spray techniques, focusing on the synthesis and microstructural evolution of advanced steel coatings.
- Link
- Varadaraajan, V., et al. (2011)
- “Direct Synthesis of Nanostructured V₂O₅ Films Using Solution Plasma Spray”
- Journal of Power Sources 196(24):10704–1071.
- Description: Demonstrates an innovative method for fabricating nanostructured V₂O₅ films using solution plasma spray, relevant to battery electrode development.
- Link
- Mohanty, P.S., Varadaraajan, V., et al. (2010)
- “Ultrafine Particulate Dispersed High-Temperature Coatings by Hybrid Spray Process”
- Journal of Thermal Spray Technology 19(1-2):484–494.
- Description: Details the development of a hybrid thermal-electrochemical deposition technique for creating high-temperature coatings with dispersed ultrafine particulates.
- Link