Metallurgy and Materials Selection and Failure Analysis Expert

Technical Consultant #2364

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.

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

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."

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

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

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