In the 2024–2025 academic year, I assisted the Senior Design Team working on the Low Current Crack Arrest System project, part of the Mechanical Engineering Senior Design Program at Louisiana Tech University.  This project was sponsored by American Electric Power (AEP) and Southwestern Electric Power Company (SWEPCO), aimed to reinforce boiler tubing systems by electroplating a layer of iron onto the internal cracked surfaces of pipes. This technique can arrest fatigue crack propagation without requiring full tube setup replacement. 

I worked closely with my colleague Andy Hudson, P.E., to set up a full-scale 200-foot plating setup at the university’s Trenchless Technology Center (TTC). We hosted a live demonstration and technical discussion with the Senior Design team and their faculty advisor, Dr. John Matthews, to help launch their year-long project. I was truly impressed by the dedication and ingenuity of the senior design team, Erin Peco, Emma Agan, Afinju Bailey, and Zachary Barron, whose brilliant minds and hard work led to the successful realization of this complex, real-world project.

I collaborated with a team of electrical engineers on the design, implementation, and testing of a minimalist broadband RF Noise Generator for signal jamming applications. Our goal was to develop a compact, transistor-based circuit capable of disrupting unwanted communication signals by producing random wideband noise across frequency bands. Utilizing a 2N5089 BJT and a combination of passive components, we successfully generated an output noise signal observable up to 100 MHz.

Interestingly, our hardware implementation exceeded initial simulation expectations, demonstrating the critical importance of empirical testing in RF circuit design. This project was made possible through the expert guidance of Dr. Jinyuan Chen and with lab access generously provided by Dr. Steven A. Jones. I was fortunate to work alongside Md Shafayet Alam, Yead Rahman, and Amjed Hass Elsyed Yousif, whose collaboration and teamwork contributed greatly to the success of this project.

During my undergraduate studies at BUET, I worked with Rafsan Ahmed and Navid Shadab Jamil on the design and fabrication of a Double Pipe Heat Exchanger (DPHE) as part of a thermal systems project. Our objective was to construct a reliable and cost-effective exchanger suitable for moderate pressure and temperature ranges in small-scale industrial applications.

We designed and tested a 2-pass counterflow configuration using steam as the hot fluid and water as the cold fluid, with the system constructed from mild steel for durability and accessibility. Two elbows and welded flanges were integrated to facilitate assembly and maintenance. Alongside fabrication, we developed a Solidworks 3D model to support inspection, modeling, and future modifications.

The completed unit was tested for thermal performance, pressure drop, and flow dynamics. Although the exchanger performed reliably, we noted that the use of two single-flow paths led to relatively lower flow rates and moderate temperature differences, which were design trade-offs we had anticipated. We also identified that stainless steel could offer improved thermal conductivity over mild steel in future versions. Despite these limitations, the system was easy to operate, maintain, and adapt for various applications, such as juice pasteurization, ethanol sterilization, and turbine protection in food and energy industries.

In 2018, I co-developed a Semi-Automated Firefighting Robot designed to detect and extinguish localized fires using flame sensors and a water-pumping mechanism. The system was built around an Arduino Uno microcontroller, a 9V battery, integrating DC motors, a servo-controlled water pump, and three flame sensors arranged to detect fire directionally. When fire is detected within range, the robot automatically positions itself and activates the pump to extinguish the flames. For longer distances, users could manually navigate the robot via a Bluetooth module connected to a mobile app. 

This prototype was developed in collaboration with Abu Horayra, Md. Shahriar Islam, Abhrajeet Biswas, and Saykat Kumar Biswas. We particularly aimed at enhancing fire safety in garment factories, chemical plants, and domestic settings. We also proposed future upgrades such as obstacle avoidance, camera vision, and GSM-based alert messaging to improve autonomy and emergency response capabilities.