PROFESSIONAL EXPERIENCE:

Confidential

Advanced Manufacturing Process Engineer

Responsibilities:

• Led in the Ceramic matrix - composites (CMCs) with Carbon fiber - reinforcement, formulation, impregnation of carbon fibers with bindingpolymer (thermoset resin) composites, curing, heat treating from induction furnace and chemical vapor deposition (CVD) of the porous Carbon with carbon for densification purposes.
• Managed process optimization to maximize production efficiency while meeting customer product requirements,
• Performed tasks related to continuous process improvement and established program on carbon re-enforcement formulation, processing and manufacture by Chemical Vapor deposition (CVD) pyrolysis means. Formulation, Molding and curing of Carbon reinforced fiber impregnated with polymer materials.
• Induction Heat Treatment, Chemical vapor of carbon on the molded graphitic carbon matrixes and final Heat Treatment
• Initiated program for Associates on carbon composites processing, Vacuum furnace Pyrometry Temperature uniformmance and System Accuracy Test (SAT) for the carbon Friction materials Group.
• Pitch based carbon fiber, phenolic resin fibers (polymer) were impregnated into the carbon - re enforced carbon and re-baked in order to carbonize the pitch resin impregnated and thermally cured.

Confidential, White Hall, MI

Advanced Propulsion Engineer

Responsibilities:

• Responsible in reviewing the metallurgical integrity, Aluminum casting, and cost performance of the Lost wax investment casting processes of super alloys,
• Led in aspects of product write ups, repairs and overhauls and disposition for repairs
• Occasionally applied NDT, and sophisticated testing laboratory instrument for the quality validation of the repaired and overhauled component assemblies.
• Have used SCADA (supervisory control and data acquisition) software program for process control, the gathering of data in real timefrom remote locations in order to control processing equipment
• Designed allowable, and control of the outgassing (sublimation) polymer- nickel species/thermal vacuum stability with statistical data analysis of results, as required.
• The casting operation involved production of alloyed parts having *Single crystalline structure, *directionally solidified (DSSC) and Equiax nickel super alloy investment castings structures with advanced configurations. Did assessed damage mechanisms in the vacuum furnaces, root causes of the Pressure rises and fluctuations, abnormal corrosion and reduction reactions, heaters, flares, burners, refractory, graphite insulation coatings, sublimation of CO2, Ni co- polymer binders, solidification and desorption and fall back on critical processed. Monitored and provided hands on support in the investment casting operations of different metal parts, design of the invested reusable wax pattern surrounded, with a refractory material. The reusable wax patterns required extreme care for they are not strong enough to withstand forces encountered during the mold making. *Initiated in the facility equipment installation, preventive maintenance, participated in repairs, and provided needed technical . s: Identified and resolved Ferrous and non ferrous, Ti, aluminum melting, pouring and casting related issues: Inspecting of casting defects, Pouring, fluxing, dew point, humidity, porosity inclusions, gating and Mold and design issues, Heat Treating, recrystallization and annealing Heat Treat, braze issues.

Confidential, Forest OH

Short Consulting Contract: Sr. Metallurgical Project Engineer

Responsibilities:

• Reviewed and Directed Projects, supervised coating processes, standardization of process documentation, material flow, process metrics and monitoring.
• Led in aspects of product write ups, repairs and overhauls and disposition for repairs
• Occasionally applied NDT, and sophisticated testing laboratory instrument for the quality validation of the repaired and overhauled component assemblies
• Performed the duties of Polymer Additive Engineer, Provided technical directions in Welding, Coating, Brazing, Heat Treatment, testing of Aluminum plate Heat Exchangers.
• Handled issues which arose as new products transition from prototyping to full production,
• Managed projects, reviewed, developed standard work instruction, reworked procedures, submitted proposals, equipment specifications, and fixtures for all forms of Heat treatment, coating, and Brazing.
• Provided technical guidance in Vacuum Furnace and Molten salt bath Brazing of Steels, Aluminum, Heat Treating, welding electro cleaning, supervision in the design and manufacture of the Aluminum Heat Exchangers (HVAC) Systems.
• s: Resolved the occurred (a) aluminide (cladding (Alclad) thermally processing problems and the thermally oxidation (discoloration) reaction issues on the thermally process Heat Exchanger component assemblies. Also resolved the outgassing problem associated with improper formulation of the filler metal used in joining parts from vacuum furnace. The sublimed bye product gases evolved at elevated eutectic processing temperature was responsible in corroding, irreversible destruction fixtures, processed parts and the hot walls of the CVD furnace internal structures, blocking off the diffusion pump valves. It often causes the Vacuum pressure fluctuations or drops, system shut off and delayed production for months. The sublimed reaction gasses would crystalize forming solid film deposit clusters on the furnace heating elements, and chamber walls. As the toxic growth crystallites increases in thickness atomic layer by layer, they would fall back by capillary action on the thermally processed components and fixtures, physically destroying the parts placed in the vacuum chamber. The sublimation and its reversal reaction was mitigated by (1) re-designing the in situ water- base polymeric compound paste to enhance viscosity and prompt dryness before it was introduced into the furnace chamber for thermal processing. The innovation process enhanced brazes joint quality, increased throughput, vacuum life cycle and overall profitability for the company.

Confidential, Rural Hall, NC

Chief Metallurgist

Responsibilities:

• Directed operations, managed, production schedule, releases, deliveries, product quality assurance and assured manufacturing analysis attained peak efficiency. Encouraged and mentored subordinates and championed manufacturing improvement.
• Empowered to define, identified new opportunities to impact business and operations goals positively and encouraged the application of Six Sigma tools.
• Directed and coordinated forging plant operations (provided of interpretation of furnace chart, time versus, ramp rate, homogenization Isothermal temperatures and cooing rate to assure parts were properly treated for coining and uniform forging in 3D crystal grain planes of orientation.
• Provided direct supervision of the forging shop, Quality testing of the turbine component assemblies, Machining, laboratory and made recommendation for improvements or reworks.
• Investment cast aluminum, provided and directed the vacuum furnace operations and repairs, metal-forging processes, Heat Treatment and property evaluation processes using metrology devices.The materials forged and stamped
• Led in aspects of product write ups, repairs and overhauls and disposition for repairs
• Performed High Temperature vacuum Heat Treating, brazing, and Investment Casting of turbine blades and vanes of either the Single Crystal nickel based, Super-alloy either CMXS3, CMSX-6, MSX10, IN713, Rene80, X40, IN requiring directional Solidification cooling approach to achieve the needed orientation of grain structure without evidence of Creep presence.
• Super alloys, Aluminum and steel forgings, Materials selection and wax model design support for investment casting of single crystal turbine blades. The West German Company was acquired by Elwood forging company in 2012 and then was shut down.

Confidential, Greenbelt, MD

Aerospace Engineer Technical Manager

Responsibilities:

• Championed in the selection, formulation and manufacture of composites using a combination of either Metals, ceramics, cement, and or polymers.
• Managed and supervised the manufacturing of Critical Spacecraft Propulsion Projects, including coatings.
• Managed and steered costs and expenditure, kept engineering works and internal research spends under control
• Managed the RO/ and DI water purification system and interfaced with Vendors.
• Responsible the delivery of all engineering works, following budget and guaranteeing technical performance
• Led cross-discipline teams, managed performance and developed teams
• Supported the commercial teams with technical expertise
• Analyzed, managed and averted all technical risks for engineering works
• Performed the duties of a Chemical Plating Engineer, Soldering, supervised and directed all the plating-projects
• Developed budgets and performed other Managerial functions and responsible for leading, managing and held weekly meeting to resolve manufacturing issues and enforced continuous improvement.
• Selected to be a member of the Confidential ’S SBIR/STTR (Small Business Innovation Review) program Nominated by 17 Confidential Chiefs to be recognized by their head boss (the Confidential ’S Center Director at Goddard) for financial for the plating shop work, well done in the Agency.
• : In less than 5 months of hire, was nominated as a Confidential Ambassador to Industries, *Selected to provide support in the design and development of Lithium and Ni-Cd secondary rechargeable batteries for Spacecraft exploratory flight missions. *Provided value added support and worked collaboratively with cross functional groups within Confidential . *Was ed and monetary price for Enforcing Health and environmental (EH&S) regulatory requirement in the NAS’A Plating shop. I left Confidential shortly, due to down sizing reason.

Confidential, Norwich, NY

Advanced Specialist

Responsibilities:

• Led in the manufacture of critical aircraft components such as Socket assemblies, compressors, Igniters, Leads, Harnesses Thermal Systems with additive manufacturing for legacy heat exchangers, fluid conveyance systems, Airframe Conveyance systems, flexible joints, etc.
• Managed composites project: Alloying and formulation of Metal matrix- composites (MMCs) containing Al2SiO3 and polymer additive constituent parts - assembled in a graphite fixture with Fe-Ni metal terminals in a metallized aluminum cylinder and fused from vacuum furnace of high temperature, low pressure for aircraft sensing systems development.
• Managerial and Demonstrated process experience in surface finishing testing and failure Analysis, Solder and Braze alloying paste formulation, pick and place, solder Reflow, Pin in Paste Soldering, Reflection in voids / Acid bleed, Water Spots reduction and reliability, surface preparation and Cleaning Systems, soldering and conformal coating.
• Led in the metal polymer binding (resin) additive, coating, repairs, Soldering, Heat Treating and Welding of Turbines air foils, Blades, diffuser, actuators, compressors, Engine Igniters, Rotor Shafts and Hubs.
• Provided technical support and in fixture design and Welding (Flux Cored Arc, Stick, MIG, TIG, procedures on Aluminum, Steel, Stainless Steel, Titanium Nickel alloys, and various types of metals, NDT and with ASME codes, application.

Confidential

Advanced Materials Engineer

Responsibilities:

• Performed the duties of a chemical Plating Engineer, trained subordinates and support QA measurements and plating, Stamping, welding, Die casting of aluminum, Brazing, Heat Treating processes.
• Defined process manufacturing parameters and controls which included but not limited to automation after product launch, scrap reductions, process optimization, etc.
• Applied knowledge of TS16949 in the parts design, development, production quality validation
• Provided hands on, manufacturing Engineering responsibilities- coatings, plating, Heat treating, furnace design and repairs, automation, Testing, Product reviews, re-engineering, sustaining, provided needed support to production personnel on the work floor and used knowledge of 6 Sigma tools to troubleshoot, implemented continuous improvement and lean manufacturing, for profit.
• Led in aspects of product write ups, repairs and overhauls and disposition for repairs
• Occasionally applied NDT, and sophisticated testing laboratory instrument for the quality validation.
• Defined, identified defects and provided mitigation that prevented failure recurrence, led in the product preparation for manufacturing, measurement, materials selection, machine performance and tooling.
• s: Led and supported efforts in Metal casting, coating, Maintenance Department, new product development, R&D, with variety of material tasks classifications, planning and processing, evaluation of out gassing materials (sublimation) on the vacuum furnace walls, tensile and stress testing,. *Applied FMEA, a Gauge R&R, ISO/TS16949 and PPAP standards. *Supported and Team work in the development and implementation of manufacturing processes on product development assuring component quality produced was maintained at a Cpk of 2 or better. I left Denso in good standing for a PhD studies at the University of Tennessee at Knoxville, at the end of my contract completion.

Confidential, Jonesboro, Arkansas

Metallurgical Manager

Responsibilities:

• Reviewed and corrected work instructions, Liaised with design Engineers, Tooling, Prototyping, Testing and Manufacturing personnel
• Provided corporate on product design, Welding, Heat Treatment and Electroplating
• Worked with sites to ensure sound environmental management practices including C02 emission reductions.,
• Contributed to the overall design of process flow-sheets, plant layouts, material handling systems, manpower requirements, equipment repairs, procurement and material utilization.
• Advised management about metallurgical operations (thermal coating, barrel plating, Rack electroplating and standard work practices that maximize operational efficiencies, reduction of overall manufacturing redundancies,
• Worked with site management to improve plant-operating performance; reduce waste and delays; promote cost reductions; and achieve a high level of operating efficiency.
• Evaluated current, potential processing methods and recommended improvement to enhance quality compliance of product, lean manufacturing, increase throughput and profitability.
• Monitored and analyzed key metallurgical performance indicators of process operations and recommend corrective actions to the operations team.
• Developed, mentored and reviewed metallurgical activities working with the operations team and external consultants.,
• Reviewed and advised management in developing and maintaining Metallurgical accounting, reconciled procedures and coordinated the shipment of finished products to customers; on time.
• Actively involved in plant decision-making process by way of reviewing and monitoring process-operating parameters on a continuous basis.,
• Led in aspects of product write ups, repairs and overhauls and disposition for repairs
• Provided technical input to all project evaluations e.g. capital expenditure proposals and/or - Provided technical advice and solutions to operations on Heat Treating, Welding, QA Testing, metal cast part, fixture design, and/or corporate management to address environmental risks and emerging compliance issues.
• Liaised with key stakeholders to ensure they are kept well informed of site activities and to enable concerns and issues to be addressed promptly.
• Performed other duties as required including but not limited to metal forming, stamping, Cast parts possessing single crystalline structure, *directionally solidified (DSSC) and Equiax nickel super alloy investment castings structures with advanced configurations.

Confidential, Colorado Springs, CO

Aerospace Battery Development Project Engineer

Responsibilities:

• Formulation of polymer composites with nickel powder composites for use in developing battery electrodes ( Anode and Cathode).
• Execution of battery development projects from laboratory scale through pilot trials.
• Assessed, selected and incorporated strategic materials, additive polymer binders for the Battery electrode formulations, Cell design configurations, and other cell parameters with DOE methodology.
• Coordinated, executed product development trials (manufacturing of Secondary Rechargeable Battery electrode) project and collaborated testing with Sandia National Laboratory in New Mexico, the nation's premier science and engineering lab for national security and technology innovation as well as with Dow Chemical company who supplied the polymer resins; used.
• Summarization and presentation of respective test results, with conclusions, and recommendations.
• Prepared material reviewed and updated specifications, along with other engineering documents, including cost estimates.
• Supported all product phases, R&D, including development, validation, and pilot production.
• The company shut down its operations permanently and moved out of the State of Colorado.