Prof. Dr. Thomas Mayer

Personal profile

Management role

Head of Research/Focus Area, Mechanics for Modelling

Position at the ZHAW

Senior Lecturer in Mechanics

www.zhaw.ch/imes

Expertise and research interests

Research & Development in the fields:
- process simulation for additive manufacturing (distortion compensation, residual stresses, in-situ experiments and model calibration)
-thermo-mechanical / thermo-physical characterization and modelling of metals (plasticity, creep, temperature and rate dependencies)
- modelling of damage mechanisms in metals and lifetime prediction (low-cycle and thermo-mechanical fatigue, creep, creep-fatigue interaction)
- FE simulation (nonlinear, thermo-mechanical) and structural optimization

Educational background

2022 ZHAW internal Leadership course
2020 CAS University Didactics, PHZH Zürich
2008 - 2012 Doctorate studies (Dr. sc. ETH) in Experimental and Structural Mechanics, ETH Zurich
2003 - 2008 Bachelor and Master studies (MSc ETH) in Mechanical Engineering, ETH Zurich

Honors:
2009 ETH Medal
2009 Studies Award of SEW Eurodrive Foundation

Professional milestones

2015 - 2018 R&D Engineer (Mechanical Components), General Electric / Alstom, Switzerland
2012 - 2013 R&D Engineer (Centre for Mechanical Integrity), inspire AG, Switzerland
2008 - 2012 PhD Student / Research Assistant, Empa, Switzerland
2007 - 2008 Undergraduate Teaching Assistant, ETH Zurich, Switzerland

Membership of networks

• Plattform Industrie 4.0
• Fachgruppe Mechanik
• FVV Arbeitsgruppe W10 für Hochtemperatur-Materialien

Projects

• Reduced Residual Stresses through Support Structure Optimization in Laser Powder Bed Fusion / Project leader / Project ongoing
• Digital twin of ROSTA rubber spring elements / Deputy project leader / Project ongoing
• Machine Learning Enhanced Process Simulation in Laser Pow­der Bed Fusion (LPBF) / Project leader / Project ongoing
• Development of a Neural Network based Finite Element Method for Thermo-Mechanically coupled Problems / Project leader / Project ongoing
• Evaluation eines Machine Learning Tools in der Mechanik / Project leader / Project completed
• Fertigbarkeitsstudie eines Rotors für neuen Druckwellenlader / Deputy project leader / Project completed
• Machbarkeitsstudie zum Prozessmonitoring mittels smarter Gummifederelemente / Project leader / Project completed
• Optimisation of additively manufactured metallic components with process simulation / Project leader / Project completed

Publications

• Mayer, Thomas; Brändle, Gabriel; Schönenberger, Andreas; Eberlein, Robert,

  2020.

  Simulation and validation of residual deformations in additive manufacturing of metal parts.

  Heliyon.

  6(5), pp. e03987.

  Available from: https://doi.org/10.1016/j.heliyon.2020.e03987

Publications before appointment at the ZHAW

- Dissertation:
Mayer, T, 2012. Characterisation and modelling of the microstructural and mechanical evolution of a steam turbine rotor steel. ETH Diss. Nr. 20752, ETH Zürich, Zürich.
doi.org/10.3929/ethz-a-007593785

- Journal Papers:
Mayer T., Brändle G., Schönenberger A., Eberlein R., 2020. Simulation and validation of residual deformations in additive manufacturing of metal parts. Heliyon, Volume 6, Issue 5, 2020. www.sciencedirect.com/science/article/pii/S240584402030832X

Mayer T., Mazza E., Holdsworth S.R., 2013. A continuous Masing approach for a physically motivated formulation of temperature and strain rate dependent plasticity. International Journal of Pressure Vessels and Piping 102-103,February-March, 1-12.
www.sciencedirect.com/science/article/pii/S0308016112001494

Mayer T., Mazza E., Holdsworth S.R., 2013. Parameter evolution in a continuous Masing approach for cyclic plasticity and its physical interpretation. Mechanics of Materials 57, February, 86-96.
www.sciencedirect.com/science/article/pii/S0167663612001871

Mayer T., Balogh L., Solenthaler C., Müller-Gubler E., Holdsworth S.R., 2012. Dislocation density and sub-grain size evolution of 2CrMoNiWV during low cycle fatigue at elevated temperatures. Acta Materialia 60, 2485-2496.
www.sciencedirect.com/science/article/pii/S1359645411008937

- Book Contributions:
Mayer T., Mazza E., Holdsworth S.R., 2013. A Masing-type modelling concept for cyclic plasticity at elevated temperature, Chapter 24, in: Kruch, S., Altenbach; H. (Eds.), Advanced Materials Modelling for Structures. Springer, 263.
www.springer.com/la/book/9783642351662

- Conferences:
Mayer T., Mazza E., Holdsworth S. R., 2012. A Masing-type modelling concept for cyclic plasticity at elevated temperature. Proc. Conf. on IUTAM Symposium on Advanced Material Modelling for Structures, Paris.

Mayer T., Pham M. S., Solenthaler C., Janssens K. G. F., Holdsworth S. R., 2010. The effect of sub-grain formation and development on cyclic response in engineering steels. Proc. Conf. on 18th European Conference on Fracture Dresden. DVM, pp. AA.02.01-O5.

Mayer T., Davydov V., Holdsworth S. R., Lukás Strunz, P., 2010. Neutron diffraction examination of dislocation density evolution in a bainitic steel after low-cycle fatigue test at elevated temperatures. Eur. Conf. on Residual Stresses ECRS 8, Riva del Garda. Poster.

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