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Metallurgy and Materials Selection and Failure Analysis Expert

Technical Consultant #2364


Expertise

  • Physical metallurgy, corrosion science and wear of materials.
  • Failure analysis - mechanical fracture, corrosion (wear of metals), ceramics and polymers.
  • Selection and specification of a wide range of metallic alloys and materials to meet process or product requirements: Carbon, alloy, stainless and tool steels,copper, nickel, cobalt and titanium alloys and nonmetallic materials.
  • Corrosion in aqueous, high temperature, molten polymer, molten salt and many other chemical environments in a wide range of process equipment.
  • Solutions for abrasive and adhesive wear problems through selection of alloys, nonmetallic materials, surface engineering and the use of hard materials such as carbides and powder metallurgy tool steels.
  • Equipment condition evaluation and inspection.
  • Specification and evaluation of electrolytic and electroless coatings, such as chromium and nickel.
  • Materials engineering for high hazard plant operations containing corrosive materials at high temperature and pressure.
  • Metallurgy and materials research and development, applied materials engineering consulting, plant operations and maintenance, plant equipment inspection-evaluation and technical management
  • Metallurgy and materials engineering training.

Expert Witness Experience

  • Completed metallic process equipment failure analysis investigations and expert witness documentation for plant site failures.

Experience

Undisclosed Company, Principal Consultant, Present

  • Providing an array of services to clients in metallurgy, materials engineering technology and industrial applications; identifying problems and supplying definition and implementation of durable solutions.

DuPont Company, Wilmington, DE, 1998 - 2016

Principal and Senior Materials Consultant and Materials Engineering Technology Leader

  • Defined equipment procurement specifications for crucial corrosion and wear resistance criteria for polymer compounding equipment that resulted in year over year savings of $1.5 million.
  • Solved key equipment corrosion issue and specified alternative materials of construction for polymer processing equipment that delivered $1 million annual savings in reduced maintenance costs and improved product quality.
  • Developed a successful materials fabrication, high temperature corrosion and wear solution for a novel equipment design that resulted in $10 million annual savings from increased process uptime and capacity and reduced maintenance costs.
  • Completed equipment failure analysis and expert witness documentation to DuPont Legal Advisors for oil release issue.
  • Recognized many times at the corporate level for technical excellence and leadership.
  • Engineering Excellence Award Honorable Mention -"Improvement of Capacity and Uptime in Fluoropolymer Production."
  • Engineering Excellence Award Nomination - "Large Compounding Extruder Facility Commercialization."
  • Engineering Excellence Award Nomination - "Advantage Additive® Corrosion Solution."
  • Chief Science Officer Accomplishment Award - "Recognition for Outstanding Dedication and Extraordinary Effort in Maintaining Physical Failure Analysis Capability for DuPont.

Technical and Professional Positions - DuPont, 1977 - 1998

  • Technology Manager - Research and Engineering Technology
  • Research Manager - Central Research and Development Department
  • Sr. Supervisor and Research and Development Site Head - Titanium Technologies
  • Planning Manager - Engineering Research and Development
  • Sr. Supervisor/Supervisor Materials - Engineering Research and Development
  • Senior Research Engineer - Engineering Research and Development
  • Research Engineer - Engineering Research and Development

Responsibilities

  • Managed engineering, research and development and plant technical groups in different businesses. Responsibilities included technical program definition, results, budget, administrative and personnel accountability of exempt and nonexempt employees.
  • Key contributor and co-leader of the technical team that identified the root cause and implemented a solution to a critical process reactor cracking issue. This result saved product sales in excess of $50 million and insured safe plant operation.
  • Engineering Excellence Award - "Resolution of a Reactor Cracking Problem."
  • Key contributor and co-leader of a technical process development team that developed an environmentally-friendly process for acidic by-product destruction that was patented and sold to another company.
  • Defined and conducted applied materials research programs directed at solving important business manufacturing equipment issues and enabling product development or improvement.
  • Provided the metallurgy expertise for the development of a palladium-nickel alloy electroplating process to replace costly pure gold coating used for electronic and communications connector products. The commercialized process delivered a large competitive cost advantage and significant value when the business was later sold.
  • Electronic Connector Study Group - Best Session Paper, "Creep Corrosion over Gold, Palladium and Tin-Lead Electroplate."

Honors & Publications


Credentials

  • Elected Fellow of ASM International for significant contributions in applied metallurgy and materials engineering that enabled solutions to complex equipment and process problems
  • Six Sigma Green Belt Certification
  • DuPont Management and Leadership Courses

Academic and Professional Affiliations

  • Fellow (FASM), Life Member and National Education Chairperson - ASM International, Metals Park, OH
  • ASM International - Brandywine Valley Chapter: Chapter Chairperson, Program Chairperson, lecturer for educational courses, Executive Committee
  • Previous DuPont Company Representative and MTI Director
  • Drexel University, Industrial Advisory Committee of the Department of Materials Science and Engineering College of Engineering, College of Engineering Alumni Advisory Council

Awards

  • Electron Microscopy Society of America Presidential Fellowship
  • Electronic Connector Study Group - Best Session Paper

Publications and Patents

  • Author and Co-Author of numerous peer reviewed scientific journals, (educational literature for conferences and symposia) and Text Books
  • U. S. Patent - Electrochemical Cell, Distribution

Education

  • Ph.D. Materials Engineering, Massachusetts Institute of Technology, Cambridge, MA
  • B.S. Metallurgical Engineering, Drexel University, Philadelphia, PA
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