Metallurgical Engineer
Materials, Processes, and Physical/Nondestructive Testing
PROFESSIONAL SUMMARY
Accomplished Metallurgical Engineer with track record of expert work with metals, ceramics, polymers, and manufacturing processes. Experienced with high & low volume product lines and manufacturing cell environments. Engineering focus balanced with strong business acumen. Superb problem solver with investigative style yet highly results-oriented. Project leader who can multi-task. Executes research leading to new patents. Technical resource for cross-functional teams.
EDUCATION
Cleveland State University, Cleveland, OH 1980
Bachelor of Metallurgical Engineering
TECHNOLOGY EXPERTISE:
Metals
Non-Ferrous Alloys - Aluminum, Beryllium, Magnesium, Titanium, NiTi, Copper, and Zinc
Electrical Contact Alloys - Gold, Silver, Platinum, and Palladium
Hard and Soft Magnetic Alloys – Nickel, Cobalt, Iron, and Rare Earths
High Temperature Alloys - Nickel, Cobalt, Molybdenum, Refractory Metals
Ferrous Alloys - Alloy, Tool, and Stainless
Ceramics
Carbides, Oxides, and Nitrides, Glasses
Polymers
Thermoplastics/Thermosets, Fluoroelastomers, and Silicones
Engineering Processes
Heat Treating, Casting, Forging, Powder Metallurgy, Welding, Brazing, Soldering Finishes and Coatings - Electrodeposited Metals, Electropolishing, Passivation, and Anodizing
Physical / Non-Destructive Testing
Metallography – Optical Metallography, Scanning Electronic Microscopy (SEM) with EDX .
Non-Destructive Testing - Radiographic, Magnetic Particle, and Fluorescent Penetrant,
Physical Testing - Hardness – Rockwell, Superficial Rockwell, and Microhardness Testing, Plane Strain Fracture Toughness, Rotary Beam Fatigue, Tensile, Stress Rupture, Creep, Charpy/Izod Impact, FTIR, DSC, DTMA
SPECIFIC STRENGTHS
• Effectively managing process and budget for lab upgrades.
• Researching improvements for product development.
• Authoring laboratory procedures.
• Managing testing laboratories.
• FDA protocols.
• Problem solving.
• MIL Specs, ISO, ASTM, AMS, and SAE specifications.
• Conducting Supplier Audits
• DFM, FMEA, and Six Sigma.
• Preforming Failure Analysis Investigations
• Mentoring engineers and technicians.
• Read and speak French fluently.
• Presentations and training.
• Computer literate.
• Quality compliance.
SAMPLE SUCCESSES
• While with Norman Noble, use laboratory techniques to determine process variations that contribute to products that fail to meeting customer requirements or internal quality objectives.
• Elements – Twin Cities, use failure analysis to troubleshoot customer’s manufacturing processes and suggest improvements and/or alternative processes to improve product robustness or improve yield.
• While with Boston Scientific, eliminated inefficient/ineffective laser cutting and cleaning processes, thus reducing undesirable mechanical and structural properties.
• While with Memry Corporation, reduced failure analysis investigations from 3-10 business days down to 1-3 days.
• While with SciMed Life, transferred all department technology to Belgium location in only 9 months, with 92% yield on one product line and 95% yield on second.
• While with SciMed developed improved slotting process reducing slotting time for 250 tubes from 8 hours to 1 hour and improved brazing process to reduce time from one hour to 15 minutes per lot of 50 assemblies.
EXPERIENCE
Norman Noble, Inc. Highland Heights, OH 2011-2013
Contract manufacturer of medical device, aerospace, and automotive components
Corporate Metallurgist
• Perform in-depth failure analysis using SEM/EDAX on components to determine possible root causes of failure.
• Interfacing with customers to provide materials & process recommendations to improve product reliability, reduce costs, and improve manufacturability.
• Provide expertise in Nitinol testing – Bend & Free Recovery and Differential Scanning Calorimetry to determine the shape set temperatures to achieve the proper transformation temperatures.
• Train technicians in laboratory procedures - optical microscopy, SEM techniques, and Nitinol testing.
• Conduct internal process and system audits.
Elements - Twin City Testing, St. Paul, MN 2010 – 2011
Metallurgical and materials testing laboratory that services the automotive, aerospace, medical device, metalworking, and heavy equipment industries.
Senior Metallurgical Failure Analysis Engineer
• Perform in-depth failure analysis on mechanical, electrical, and electronic components.
• Interfacing with customers to provide materials & process recommendations to improve product reliability, reduce costs, and improve manufacturability.
• Provide materials characterization and independent process verification testing.
• Train technicians in metallographic procedures - sample preparation, optical microscopy, and SEM techniques.
• Setting work direction for technicians as needed to meet project deliverables.
Kostur Consulting, Golden Valley, MN 2007 - 2010
Advise growing companies in materials/process selection, failure analysis problem solving.
Metallurgical Engineering Consultant
• Perform in-depth failure analysis and materials characterization studies.
• Provide materials and process expertise to manufacturing engineering, process development, and quality assurance.
• Develop NiTi Passivation process.
• Develop mechanical testing and corrosion test methodologies.
• Conduct presentations to update management on project status.
• Interfacing regularly with customers, R&D, Manufacturing, Process Development, Quality, Regulatory, Marketing, and Sales personnel.
• Setting work direction for technicians as needed to meet project deliverables.
• Provide work direction to technicians for competitive product testing and analysis.
Boston Scientific/SciMed, Minneapolis, MN 2000 – 2007
Design and manufacturer of less-invasive medical devices.
Research and development in angioplasty guidewires.
Principal R & D Engineer
• Implemented cost and labor savings in the manufacturing of guidewires through materials and process improvements.
• Managed specific equipment and manufacturing processes to produce guidewires on site.
• Developed in-vitro and in-vivo testing protocols as part of team with Quality Assurance Engineers, Clinical Specialists, and vendors.
• Selected to teach metallurgy, Nitinol, metallography, and laboratory safety to a group of 25 engineers on an ongoing basis.
• Meet with physicians to get feedback on new product designs and to listen to input for new product features.
Memry Corporation, Menlo Park, CA 1997 – 2000
Manufacturer of metals with shape memory and superelastic properties.
Managed metallographic and physical testing labor...
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