Graduate Student Spotlight: Henry Stanton

After completing an undergraduate degree in mechanical engineering, Henry Stanton wanted to continue to expand his engineering knowledge, particularly as it related to additive manufacturing. In addition to his coursework, Stanton has capitalized on opportunities for hands-on research, working closely with assistant professor of mechanical engineering Sneha Narra on a project related to Wire Arc Additive Manufacturing (WAAM). WAAM allows for the economical production of complex metal parts from high-strength alloys, however, inconsistencies in the final products as evidenced in their microstructure and properties can arise due to changing conditions and environmental disturbances.

Henry’s research has focused on working with samples in order to create a process map for Plasma Arc Welding Wire Arc Additive Manufacturing (PAW-WAAM) with a material that is not commonly used in additive manufacturing. A process map is a plot that shows the relationship between the parameters that you use to build your part, such as laser power and travel speed, and the quality of the part that is created at the end. By quantifying defects in samples and linking them to variables such as power, travel speed, and wire feed speed, the map aims to identify the optimal window for printing. 

“Between the two additive manufacturing classes that I have taken and the research work with Professor Narra, I have learned a great deal about AM processes and have a strong grasp on what factors must be considered when printing parts or designing a new process,” said Stanton.

Between the classes that I have taken and the research work, I have a strong grasp on what factors must be considered when printing parts or designing a new process.

Henry Stanton, MSE M.S. Student

The project that Stanton has worked on during the past year has made him well-acquainted with the tools available in Carnegie Mellon’s Materials Characterization Facility, where he has been using optical microscopes to capture high-resolution images of the samples in order to identify defects. He also performed energy dispersive x-ray spectroscopy (EDS) with the scanning electron microscope (SEM) to look for impurities and solute segregation in the samples, which could explain how cracks in the samples formed. 

As Henry prepares to graduate and enter the workforce this spring, he is well-prepared for what the next opportunity could bring. From his coursework in additive manufacturing and materials science, to amplifying his coding skills, to mastering various materials characterization tools, the year-long program has been beneficial to meeting his professional goals.

“I went from having no experience with research or working in a lab to working closely with the other students in my group to complete a project over the course of this year,” he said. “The skills that I have learned in the lab and in data analysis are invaluable.”