WKU News

Faculty in Western Kentucky University’s School of Engineering & Applied Sciences, housed within the WKU Ogden College of Science & Engineering, are examining what happens to metal when it is cut with high-energy manufacturing processes such as industrial lasers. 

Led by Dr. Ben Dinan, Assistant Professor of Mechanical Engineering at WKU, the team is investigating the "heat-affected zone" (HAZ) created during laser cutting. While laser tools produce precise cuts, the rapid heating and cooling change the metal's internal structure and mechanical properties near the cut. Understanding these changes enables engineers to design safer, more reliable, and longer-lasting components for everything from automobiles and heavy equipment to bridges, pipelines, and energy infrastructure.

Their research has already revealed unexpected findings, including that the heat-affected zone does not develop uniformly throughout the thickness of the material, showing significant differences between the top and bottom surfaces. Additionally, discussions with other researchers while presenting at the The Minerals, Metals & Materials Society (TMS) 2026 Annual Meeting led the team to modify their hardness mapping strategy, significantly reducing sampling requirements and accelerating the project.

Caleb Matthews, a senior pursuing a Mechanical Engineering major and Systems Engineering and Mathematics minors from Hardyville, joined the lab after applying for a posted undergraduate research position through Handshake. He participates in nearly every stage of the research process, including sample preparation, metallography, microscopy, hardness testing, data collection, and analysis. 

"The most challenging part of the project was facing failures," Matthews said. "Times when things didn’t work out, or when we realized we just had to change our entire approach. Getting samples made, prepped, and even analyzed just to start over from scratch was rough.” 

Dr. Dinan highlighted that undergraduate students are involved from beginning to end, helping design experiments, analyze data, and communicate their findings. 

"Caleb has become an integral member of the research team," said Dr. Dinan. "Our students are not simply observing research; they are making important contributions while gaining experiences that prepare them for graduate school and industry careers."

The team's first manuscript from this research has been accepted for publication in the Association for Iron & Steel Technology Steel Properties & Applications Conference Proceedings. Following his previous presentations at the WKU Student Scholar Showcase and the TMS Annual Meeting, Caleb will present the team’s research this fall at the TMS Fall Meeting at Material Science & Technology in Pittsburgh as the team expands the research to additional steel alloys.