Dr. Jose M. Castro
Professor

 

StatemenT

Education

Courses

Experiences

Collaborators

Honors

AREAS OF INTEREST

Grants

Publications

CHAPTER IN EDITED BOOKS

Polymer and composite research group

SERVICE TO THE DEPARTMENT

 
 
ADDRESS
210 Baker Systems
Department of IWSE
1971 Neil Avenue
Columbus, Ohio 43210

OFFICE
Room 222 Baker Systems

PHONE
(614) 688-8233

FAX
(614) 292-7852

E-MAIL
castro.38@osu.edu
A BRIEF STATEMENT ABOUT MY WORK

My research focuses on modeling and optimization of industrial processes and developing novel environmentally friendly alternatives to current processes. In the area of modeling we used both physics based and empirical (mainly neural networks based) mathematical models. For optimization we use Data Envelopment Analysis (DEA). Areas of expertise in my group are SMC Compression Molding, In-Mold Coatings, Reactive Liquid Molding, and Injection Molding.

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EDUCATION

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COURSES TAUGHT

  • ISE 311 Manufacturing Processes.

  • ISE 617 Applications of Mathematical Modeling In Materials Processing.

  • ISE 618 Polymer Processing Fundamentals.

  • ISE 894 Fundamentals of Composites Manufacturing

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ACADEMIC EXPERIENCE

  • 2003 to date, Professor of Industrial, Welding and Systems Engineering. The Ohio State University. Columbus, OH. Member of “Center for Advanced Polymer and Composite Engineering (CAPCE).

  • 1998 to 2003 Associate Professor of Industrial, Welding and Systems Engineering. The Ohio State University. Columbus, OH. Member of “Center for Advanced Polymer and Composite Engineering (CAPCE).

  • 1983 to 1984, Associate Professor of Chemical Engineering University of The South, Bahia Blanca, Argentina.

  • 1980 to 1983 Assistant Professor of Chemical Engineering University of The South, Bahia Blanca, Argentina

INDUSTRIAL EXPERIENCE

  • 1996 to 1998, Process Technology Skill Center Leader, AlliedSignal Laminate Systems, LaCrosse, Wisconsin.

  • 1984 to 1996, various positions of increased responsibility in GenCorp Corporate Technology Center, ending as Chief Technologist. Akron, Ohio

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INDUSTRIAL COLLABORATORS

  • Dr. Ignatz-Hoover, Market Development Manager, FLEXSYS, Akorn, OH

  • Mr. Elliott Strauss, Manager Technical Service, Omnova Solutios, Akron, Ohio

  • Mr. Dennis Chung, Principal Engineer, Honda R and D, Marysville, Ohio

  • Mr. Bud Leach, Principal Chemist, Ashland Chemical, Dublin, Ohio

  • Dr. Chuck Wilkes, President Pilgrim Composites, Akron, Ohio.

UNIVERSITY COLLABORATORS (from outside of IWSE department)

  • Prof Jim Lee, Chemical Engineering Department, Ohio State, Columbus, Ohio

  • Prof Tim Osswald, Mechanical Engineering Department, University of Wisconsin, Madison, Wisconsin

  • Professor Bhavik Bakshi., Chemical Engineering Department, Ohio State, Columbus, Ohio

  • Professor Blaine Lilly, Industrial, Welding and Systems Engineering Department, Ohio State, Columbus, Ohio

  • Professor John Kardos, Chemical Engineering Department, Washington University, Saint Louis, Missouri

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HONORS AND AWARDS

  • In 1961 was awarded GenCorp’s most prestigious Technology Achievement award for the development of GenCorp’s CAE package and successful application

  • 2002 McQuigg outstanding teaching award

  • 2002 Lumley individual research award

  • 2002 Lumley interdisciplinary research award

 

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AREAS OF RESEARCH

  • Polymer and Composite Processing: Modeling, Analysis and Design.

  • Environmentally Friendly Manufacturing

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GRANTS

  • Laminates with Improved Dimensional Consistnecy for Electronic Applications.
    NSF funded proposal for $360,631. Also participating as Co-PI are Prof. Jim Lee Chemical Engineering and Prof. Tim Osswald Mechanical Engineering. University of Wisconsin. Duration of 36 months, starting date: April 1, 1999.

  •  Solvent-less pre-pregs for Electronic Applications
    OSU seed grant in the same general target area as above, but focusing more in chemo-rheology and its effect on Processing Windows. $19,941 plus graduate associate fees. One Year. Starting date Jan 1, 1999.

  •  Modeling and Optimization Studies in Reactive In-Mold Coating
    NSF funded proposal for $284,262. Co-PI is Blaine Lilly. Duration 36 months, starting date; August 1, 02.

  •  Premise: Ecologically and Economically Conscious Manufacturing of Polymer Composites. Coating Process Selection.
    NSF funded Proposal for $100,000. PI is Bhavik Bakshi.
    Flexsys Corporation, joined CAPCE at the level of $25,000 per year plus tuition and fees to support work under my supervision in the area of rubber accelerated aging. Starting date Jan 1,1999 Total so far $85,000

  •  In mold coating of thermoplastic substrates
    GenCorp, provided equipment valued at about $30,000 and provides  $25,000 per year to support a fellowship for work under my supervision in the are of In-Mold- Coating. Starting Date May 1999

  • DamlerChrysler Corporation
    $110,000 to develop flow simulation studies on IMC of thermoplastic body panels.

  •  Honda
    $25,000 per year starting 2002 through CAPCE to work on In-Mold Coating for thermoplastic parts, plus tuition and feess

  •  EPIC
    EPIC funding through CAPCE of  $8,000 per year.

  • Consortium for Novel Microfabrication Methods of Mesoscale Devices in Non-Silicon Materials.
    The Ohio Board of Regents with Case Western Reserve University and University of Cincinnati. Prof. Marc Madou PI, oter participating Co-PI’s from OSU are Prof. Jim Lee, Prof. Kurt Koilling, Prof. Schwendeman and Prof. Epstein. The total amount is $1,400,000. OSU’s part will be about $700,000

  • NSF Center for Advanced Polymer and Composite Engineering Renewal funding from NSF $70,000 per year for five years, PI is Prof L Lee and other Co-Pi’s are Prof Koelling and Prof Luscher.

  • Ashland Chemical funding for one fellowship to work in SMC molding
    $    25,000 per year plus tuition and fees

  •  Honda Initiation Grant: Effect of Carbon Fibers and Nano-particles on the Porcessibility, Surface Quality and Physical Properties of Fiber Reinforced Composite Materials for Transportation Applications.
    $50,000 for one year starting November 1 2002. Co-Pi is James Lee

  •  IGERT proposal.
    Participating faculty, PI is James Lee. I have funding assured for one IGERT fellow.

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PUBLICATIONS

Peer Reviewed Journal Articles

  1. Mauricio Cabrera Rios, Jose M. Castro and Clark Mount-Campbell, “Multiple Quality Criteria Optimization in Reactive In-Mold Coating (IMC) with A Data Envelopment Analysis Approach II: A Case With More Than Three Performance Measures”, Accepted for Publication in Journal of Polymer Engineering

  2. Permadi anad J. M. Castro, “Development of an Environmentally Friendly Solventless Process for Electronic Prepregs”, Accepted for Publication Journal of  Applied Polymer Science (2003).

  3. S Boylan and J M Castro, “Effect of Reinforcement Type and Length on Physical Properties, Surface Quality and Cycle Time for Sheet Molding Compound (SMC) Compression Molded Parts” Accepted for publications to Journal of Applied Polymer Science (2003)

  4. C. Castro, M Cabrera-Rios, B Lilly, J Castro and C Mount-Campbell, “Identifying the Best Compromises Between Multiple Performance Measures in Injection Molding using Data Envelopment Analysis”, accepted for Publication.

  5. Sarah Boyland, Abrams, L and J M Castro, “Predicting Molding Forces in SMC Compression Molding II: Effect of SMC Composition ”, Accepted Polymer Composites (2002).

  6. Xu Chen and J. M. Castro, “Numerical Simulation of the In-Mold Coating Process for Injection Molded Thermoplastic Parts”, Accepted Journal of Injection Molding Technology.

  7. L. M. Abrams and J. M. Castro, “Predicting Molding Forces in SMC Compression Molding I: Model Development”, Accepted for Publication in Polymer Composites

  8. K Zuyev and J. M. Castro, “Applications of Chemo-Rheology to establish process windows fro Reactive In-mold Coating”, Accepted for Publication in Journal of Polymer Engineering.

  9. Mauricio Cabrera Rios, Jose M. Castro and Clark Mount-Campbell, “Multiple Quality Criteria Optimization in Reactive In-Mold Coating (IMC) with A Data Envelopment Analysis Approach”, Journal of Polymer Engineering, Vol 22 # 5 (2002).

  10. B. J. LaCount, J M Castro, F. Ignatz-Hoover, “Development of a service-simulating aging test method for exterior tire rubber compounds part II: design and development of an accelerated ourtoor aging simulator”, Accepted for Publication Polymer Degradation and Stability (2002).

  11. N. Derose, M. Yuan, T. A. Osswald and J M Castro, “Simulation of Resin Flow During Compression of Copper-Clad Thermoset Composite Laminates”, Accepted for Publication to Polymer Plastics Technology and Engineering (2002)

  12. S Li, L J Lee and J Castro, “Effective Mass Diffusivity in Composites” Accepted for Publication in Journal of Composite Materials (2002).

  13. D Huang, B. J. LaCount, J M Castro, F. Ignatz-Hoover, “Development of a service-simulating aging test method for exterior tire rubber compounds part I: Cyclic Aging” Polymer Degradation and Stability, 74, 353 (2001).

  14. M Cabrera-Rios, K Zuyev, S Chen, J M Castro and E Straus, “Optimizing Injection Gate Location and Cycle Time for the In-Mold Coating (IMC) Process”, Accepted for Publication Journal of Polymers Composites (2002).

  15. K. S. Zuyev, X. Chen, M. Cabrera-Rios, Castro, J. M. and E. Straus, “In- Mold Functional Coating of Thermoplastic Substrates: Process Modeling”, Journal of Injection Molding Technology, 5(2), 80 (2001).

  16. L. M. Dehnke, Permadi and J. M Castro, “Applications of Chemo-Rheology to establish a Process Window for a New Solventless System to Manufacture Pre-pregs and Laminates for Electronic Applications”, Journal of Applied Polymer Science, 82, 601 (2001).

  17. R. Hogade, M. Li, J. M. Castro, “Development of an Isothermal Lubricating Layer Model For Injection Pultusion of Electronic Pre-pregs”, Polymer Composites (2001).

  18. L. M. Abrams and J. M. Castro, “Powder Coating of Sheet Molding Compound (SMC) Body Panels”, Polymer Composites, 22(5), 702  (2001).

  19. L. M. Abrams and J. M. Castro “Practical Guidelines for Predicting Steady State Cure Time During SMC Compression Molding”, Polymer Composites 21 (6), 931 (2000).  

  20. R. P. Theriault, T. A. Osswald and J. M. Castro “A Numerical Model of the Viscosity of an Epoxy Prepreg Resin System”, Polymer Composites, 20(5), 628(2000).

  21. R. P. Theriault, T. A. Osswald and J. M. Castro, “Processing Induced Residual Stresses in Asymmetric Laminate Panels”, Polymer Composites, 20(3), 493 (1999).

  22. R. P. Theriault, T. A. Osswald and J. M. Castro, “Measurement and Prediction of the Glass Transition Temperature During the Processing of Copper Clad Epoxy Laminates”, Polymer Composites, 20(6),  (1999).

  23. J. M. Castro, S. Conover, C. E. Wilkes, K. Han and L. J. Lee, “Manufacturing of Composite Links by Structural Reaction Injection Molding”, Polymer Composites, 18(5), 585 (1997).

  24. N. A. Dziewtkiski, J. Xu, L. J. Lee and J. M. Castro, “Effect of Two Stage Pressure Molding on Surface Quality of Sheet Molding Compound,“ Polym. Com., 15, 106 (1994). 

  25. J. M. Castro, “Applications of Flow Simulation in Reactive Processing for Cases in Which the Filling Stage Can be De-coupled from Heat Transfer and Chemical Reaction,“ Polymer Eng. Science (1992).

  26. J. M. Castro, E. G. Melby and R. M. Griffith, “SMC Technology: Present and Future,” Automotive Polymers and Design, 8, 28-34 (1988).

  27. J. M. Castro and G. Tomlinson, “Predicting Molding Forces in SMC Compression Molding,” Polymer Eng. and Science (1990).

  28. J. M. Castro and R. M. Griffith, “Mathematical Modeling of the In Mold Coating Process,” Polym. Eng. And Sci., 30, 677 (1990).

  29. J. M. Castro and R. M. Griffith, “SMC Compression Molding Flow,” Polym. Eng. And Sci., 29, 632 (1989).

  30. G. Astarita, J. M. Castro and C. P. Filipich, “The Stokes Paradox,” Quad. Ing. Chem. Ital., 21, (4-5), (25-8) (1985).

  31. J. M. Castro and E. J. Straus, “Monitoring Cure in SMC Processing,” Polym. Eng. And Sci., 29, 308 (1989).

  32. J. M. Castro and C. C. Lee, “Thermal and Cure Analysis in Sheet Molding Compound Compression Molds,” Polym. Eng. And Sci., 77, 218 (1987).

  33. J. M. Castro, C. P. Filipich and R. L. Fosdick, “The Creeping Motion of a Simple Fluid Past a Submerged Sphere,” Lat. Am. J. of Chem. Eng and Appl. Chem, 15, 93 (1985).

  34. J. M. Castro and R. L. Fosdick,” Elementary Implications of Viscometry on the Free Surface Profile for the Problems of Climbing and Channel Flow,” J. Non Newt. Fluid Mech, 15, 127, (1984).

  35. M. J. Schmidt and J. M. Castro,” Continuous Reactive Processing I: Reactive Coating,” Polym. Eng. And Sci., 25, 541 (1985).

  36. J. M. Castro, C. W. Macosko and F. E. Critchfield, “Effect of Processing Conditions on Premature Gelling, Knit Line Strength and Physical Properties for the RIM Process,” Journal of Appl. Polym. Sci., 29, 1959 (1984).

  37. J. M. Castro, “Predicting the Pressure Rise During the Filling of a Rectangular Mold wiith a Point Source Gate for the RIM Process, Using Complex Variable Techniques,” Lat. Am. Journal of Chem. Eng. And Appl. Chem., 14, 229 (1984).

  38. S. Estevez and J. M. Castro, “Applications of a RIM Process Model in the Analysis of Premature Gelling, Demold Time and Maximum Temperature Rise,” Polym. Eng. And Sci., 24, 428 (1984).

  39. J. M. Castro, S. J. Perry and C. W. Macosko,” Viscosity Changes During Urethane Polymerization with Phase Separation,” Polymer Communications, 25, 82 (1984).

  40. S. J. Perry, J. M. Castro and C. W. Macosko, “A viscometer for Fast Polymerizing  Systems,” Journal of Rheology, 29, 19 (1985).

  41. O. Del Pino, J.A. Romagnoli and J. M. Castro, ” Predicting Conversion Using Temperature as the Meassured Variable in the RIM Process II: Implementation of the on-line Corrective Algorithm,” Polym. Eng. Sci. 23, 895 (1983).

  42. J. A. Romagnoli and J. M. Castro, “Predicting Conversion Using the Temperature as the Measured Variable in the RIM Process.  Part I: Simulation and Measurement Structure,” Polym. Eng. And Sci., 23, 106 (1983).

  43. J. M. Castro, “On the Mathematical Modeling of the Reaction Injection Molding (RIM) Process,” Latin American Journal of Heat and Mass Transfer, 6, 67 (1982)

  44. J. M. Castro, S. D. Lipshitz and C. W. Macosko, “Laminar Tube Flow with a Thermosetting Polymerization,” AIChE J, 28, 973 (1982).

  45. J. M. Castro and C. W. Macosko, “Studies of Mold Filllng and Curing in the Reaction Injection Molding (RIM) Process,” AIChE J., 28, 250 (1982).

  46. J. M. Castro, V. M. Gonzalez and C. W. Macosko, “Mixing vs. Thermally Activated Systems for Reaction Injection Molding,” Latin American Journal of Chem. Eng. And Appl. Chem., (1987).

  47. J. M. Castro, F. Lopez-Serrano, R. Camargo, C. W. Macosko and M. Tirrel, “The Onset of Phase Separation in Segmented Urethane Polymerization System,” J. Appl. Polym. Sci., 26, 2067, (1981).

  48. E. C. Steinle, F. E. Critchfield, J. M. Castro and C. W. Macosko, “Kinetics and Conversion Monitoring in a RIM Thermoplastic Polyurethane Systems,” Appl. Polym. Sci., 25, 2327, (1980).

  49. J. M. Castro, C. W. Macosko, F. E. Critchfield, E. C. Steinle and L. P. Tackett, “Reaction Injection Molding: Filling of a Rectangular Mold,” J. Elast. Plastics, 12, 3 (1980).

  50. Lopez-Serrano, J. M. Castro, C. W. Macosko and M. Tirrel, “Recursive Approach to Copolymerization Statistics,” Polymer, 21, 263 (1980).

  51. Chuckaphum Aramphoghum and Jose M Castro, "Microfluidics and rheology of carbon black suspensions for In-Mold Coating applications: some insight into the slip flow phenomena", Accepted for Publication in the Journal of Computer-Aided Materials Design (2006).

  52. Chuckaphum Aramphoghum and Jose M Castro, “Microfluidics and rheology of carbon black suspensions for In-Mold Coating applications: some insights into the slip flow phenomena”, Accepted for Publication in the Journal of Computer-Aided Materials Design (2006).

  53. Mike Rabinovich, Kate Olsavsky, Mauricio Cabrera Rios and Jose M Castro, “Sheet Molding Compound (SMC) Characterization using spiral flow”, Accepted for Publication in Journal of Applied Polymer Science (2006).

  54. Carlos E Castro, Mauricio Cabrera Rios, Blaine Lilly and Jose M. Castro, Multiple Criteria Optimization with Variability Considerations in Injection Holding, Accepted for Publication in Polymer Engineering and Science (2006).

  55. Mauricio Cabrera Rios and Jose M. Castro, “Study o fan economical way of using Carbon fibers in Sheet Holding Compound (SMC) Compression Molding for Automotive Applications, Accepted for Publication in Polymer Composites (2006).

  56. Mauricio Cabrera Rios and Jose M. Castro, “ The Balance between Durability, Reliability, and Affordability in Structural Composites Manufacturing”, Accepted for Publication in Polymer Composites (2006).

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CHAPTERS IN EDITED BOOKS

  1. J. M. Castro and R. M. Griffith, “SMC/RTM/SRIM Press Molding,” Handbook on Composites Engineering, edited by P. K. Mallick, Marcel-Decker Publishers (1996).

  2. J. M. Castro, “Reactive Liquid Composite Molding,” a chapter in the book, Innovations in Polymer Processing: Molding, edited by J. Stevenson, Hanser Publishers (1996).

  3. J. M. Castro and R. M.Griffith, “In Mold Coating,” a chapter in the book, Sheet Molding Compound Materials: Science and Technology, edited by H. Kia (1993).     

  4. J. M. Castro and C. C. Lee, “Model Simplification,” a chapter in the book, Fundamentals of Computer Modeling for Polymer Processing, edited by E. C. Bernhardt and C. L. Tucker, Hanser Publishers (1989).

  5. E. G. Melby and J. M. Castro, “Glass Reinforced Thermosetting Polyester Molding: Materials and Processing,” a chapter in the book, Comprehensive Polymer Press (1988).

  6. J. M. Castro and J. A. Romagnoli, “Analysis of the Reaction Injection Molding (RIM) Process,” Chapter 2 of the book, Developments in Plastics Technology 2, edited by A. Whelan and J. L. Craft (1985).

  7. J. M. Castro and C. W. Macosko “Reaction Injection Molding” Encyclopedia of Materials Science and Engineering, Michael Beuer, editor in chief (1986).

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SERVICE TO THE DEPARTMENT

Service to the Department

  • Lead the college wide task force in Manufacturing that got the Graduate Interdisciplinary program in Manufacturing approved

  • PI with Prof Lee of Chemical Engineering of a winning academic enrichment proposal that provided a faculty for our department.

  • Chair of the search committee in charge of manufacturing faculty hiring

  • Member of the College wide committee developing the master of engineering practice (MEP)

  • Chair of the committee to develop manufacturing option for ISE curriculum

  • Graduate Studies Chair starting in October 1, 03.

Graduate Students Advised

    PhD graduated
    Lisa Abrams graduated Wi 01
    Mauricio Cabrera Rios graduated Spring 02
    Xu Chen graduatED Wi 03

    PhD Students current
    Konstantin Zuyev anticipated graduation Spring 04
    Chuckaphun Aramphoqphun anticipated graduation Winter 04
    Narayan Bhagatula anticipated graduation Spring 05

    MS Students
    Graduated    : Kartick Hariharam, Sunneel Vadlimudi, Ranjeet Hogade, Deng Huang, Lynnette Dehnke, Bart Lacount and Konstantin Zuyev, Sarah Boyland, Permadi
    Current: Mike Rabinovich, Athirad Jantharawong, Candy Toha, Rachmat Mulyana and Andrea Jones

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