Samuel Madden
Managing Engineer at Exponent- Claim this Profile
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Topline Score
Bio
Credentials
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Professional Engineer (PE)
Texas Board of Professional Engineers
Experience
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Exponent
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United States
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Business Consulting and Services
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700 & Above Employee
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Managing Engineer
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Mar 2019 - Present
I support clients by solving technical problems involving materials science, battery science, metallurgy, and electrochemistry. I have conducted research and failure analysis involving energy storage devices, corrosion, environmentally assisted cracking, and hydrogen embrittlement. I have experience in analyzing manufacturing defects in microelectronics (e.g. solder ball void analysis and trace characterization), batteries (e.g. Lithium-ion, lead-acid, Ni-Cd), and medical devices.I have extensive experience with material and analytical surface science characterization techniques including scanning electron microscopy (SEM), electron dispersive spectroscopy (EDS), X-ray diffraction (XRD), Raman spectroscopy, and Rutherford backscatter electron spectroscopy (RBS). I'm also skilled in computed tomography (CT) and 3D volume metrology. I have experience with diffusible hydrogen concentration studies in steels, including barnacle electrode and permeation method analysis. My research has included the use of AC and DC techniques to evaluate the electrochemical behavior of batteries, metals, and coatings. I have experience with mechanical testing techniques, fractography, metallurgical analysis, and microscopy as well as glass and silicon fracture analysis. I have extensive experience in advanced aging of lithium ion cells with focus on damage tolerance and failure modes, including materials characterization, gas generation, thermal properties, and mechanical damage. I have managed the research and analysis behind several reports issued to the CPSC regarding product recalls for lithium ion cells. Show less
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Senior Associate
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Feb 2017 - Mar 2019
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Associate Consultant
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Sep 2014 - Mar 2017
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Education
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University of Virginia
Doctor of Philosophy (Ph.D.), Materials Science and Engineering -
Union College
Bachelor of Science (BS), Physics