Expert Details

Expert in Adhesives, Coatings, Materials and Process Chemistry

Expert ID: 730533 Illinois, USA

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Expert is a professional chemist with 35+ years experience in academics, commercial, aerospace, electronics, and automotive-related industries. A hands-on consultant on various aspects of engineering materials, their applications and processing, with extensive experience in materials and process engineering, product research and development, validation testing, and laboratory management.

Selected areas of expertise:

 Materials and Process Issues and Failures
 Validation of Alternate Materials & Processes

 Adhesive Bonding of Dissimilar Materials
 Adhesive Bonding in Miniature Electronic Devices

 Metal-to-Metal & Film-to-Metal Laminates & Processes
 Variability Reductions in Products & Processes

 Applications Development, Testing, and Validation
 Materials & Process Specifications

 Product & Process Failure Modes & Effects Analysis (FMEA)
 Document Review & Technical Writing


Selected areas of industry experience:

Expert was Process Engineering Manager employed by a manufacturer and worldwide supplier of coated metals and adhesively-bonded metallic laminates and composites for brake noise control and sealing/gasket applications. Responsibilities including:

Held responsibility for bringing materials-oriented approaches to optimizing processing parameters to improve product quality control, FMEA, product performance characteristics, variability reduction, and cost reduction. Supervised testing laboratory for manufacturing operations.

Expert was Director of Product Development employed by a manufacturer and supplier of coated metals and adhesively-bonded metallic laminates and composites for automotive, electronics, appliances, and other markets. Responsibilities including:

Oversaw product development projects, including consumer and industrial, electrical and electronic, and automotive applications. Held responsibility for new product development, product improvements, qualification of alternative raw materials, transitioning new materials from laboratory to production, FMEA and corrective actions, and support to manufacturing, purchasing, sales and marketing.

Expert was Engineering Laboratory Manager employed by a major defense company – aircraft and missiles – for design, prototyping, testing, and manufacturing of engineering components and systems. Responsibilities including:

Lead multi-disciplinary staff of 50+ scientists, engineers, and technicians. Held accountability for professional development of staff members, managing department budget, capital equipment purchases, and maintenance of 21,000 square foot facility. Involved in materials science group specializing in the development of materials for very high temperature applications and fabrication and testing of prototype, fiber-reinforced, composite components.

Adhesive Bonding of Sub-miniature Electronic Devices to Dissimilar Materials - A Case Study.

At issue in the 26-week project summarized here were adhesive bonds used to attach sub-miniature electronic microphones to plastic fixtures that allow the assembly to be incorporated into application-specific packaging. Specifically, the microphone cases are made of stainless steel and the mounting fixtures are glass-filled Nylon. These devices are in actual service for many years and are continuously exposed to high humidity and a temperature of ~95 °F. The specific goal of the project was to identify alternative adhesives that would significantly enhance bond strengths and would be less susceptible to humidity. The result would be longer service life in current applications and development of new applications.
Optimizing Cure Process for Special Silicone-based Pressure Sensitive Adhesive - A Case Study.

In the process optimization study at hand, six distinct tasks led to successful production of commercial material involving a partially cured adhesive that did not exhibit oozing during stamping into shims, storage prior to use by the customer, or during bonding operations at the customer. The tasks:

 Laboratory-scale testing to establish time/temperature profiles to yield the non-oozing adhesive.
 Establish concentration of un-reacted cure agent using Differential Scanning Calorimetry (DSC).
 Production-scale trials to validate the time/temperature profile for the non-oozing adhesive.
 Establish concentration of un-reacted cure agent in production material using DSC.
 Experimentally record the time/temperature profile through the entire sequence of solvent removal, increasing temperature, and cure reaction.
 Complete documentation of processing parameters and control methods.

This case study is one aspect of “Materials for Noise and Vibration Control: What Causes Product Variability?” published by the Society of Automotive Engineers as Paper #2006-01-3226, October 2006.
VEHICLE BRAKE NOISE SHIMS: A TUTORIAL FOR CONTINUOUS PRODUCT IMPROVEMENTS - A Case Study.

Expected performance for these layered assemblies of polymer-based coatings and supporting substrates is based on two factors: (1) the composition, quality, and durability of each coating; and (2) the composition, quality, and durability of each material-to-material interface.

This is the second of two papers about this type of material for noise and vibration control. The objective is to provide readers with an overview of issues affecting design/development of products for controlling vehicle brake noise. Taking the format of a tutorial, it is intended for anyone involved in their design, manufacture, or use. It provides basic information and numerous references that will support evaluating potential failure modes and their effects in relation to choices of materials and provides an appendix with generic root causes.

Unwanted performance variations in materials for noise and vibration control can be minimized. The viscoelastic damping materials discussed in this paper is multi-layered combinations of various chemical coatings and supporting substrates. In designing and producing these products, there are many opportunities to affect the physical and chemical properties of the interfaces and coatings, for better or worse.

Initially, this requires a detailed understanding of the application-specific requirements for the engineering component made from these materials. Based on these requirements, appropriate selections of raw materials – polymers, additives, metal substrate, paints, adhesives, etc. – can be decided as part of the design/development of new products. The product design phase must consider manufacturing processes capable of converting the raw materials into products with consistency.

Expert may consult nationally and internationally, and is also local to the following cities: Chicago, Illinois - Rockford, Illinois - Aurora, Illinois - Naperville, Illinois - Joliet, Illinois - Elgin, Illinois - South Bend, Indiana - Gary, Indiana - Milwaukee, Wisconsin - Kenosha, Wisconsin

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Education

Year Degree Subject Institution
Year: 1972 Degree: PhD Subject: Chemistry Institution: Missouri University of Science and Technology (formerly Univ. of Missouri - Rolla)
Year: 1968 Degree: MS Subject: Chemistry Institution: Tennessee Technological University
Year: 1966 Degree: BS Subject: Chemistry Institution: Tennessee Technological University

Work History

Years Employer Title Department Responsibilities
Years: 2005 to Present Employer: Undisclosed Title: Materials & Process Chemistry Consultant Department: Responsibilities: MATERIALS & PROCESS CHEMISTRY CONSULTANT, Chicago, Illinois 2005 – Present

Expert is a professional chemist with 40+ years experience in academics, commercial, aerospace, electronics, and automotive-related industries. A hands-on consultant on various aspects of engineering materials, their applications and processing, with extensive experience in materials and process engineering, product research and development, validation testing, and laboratory management.
Years: 2004 to 2005 Employer: Wolverine Advanced Materials Title: Process Engineering Manager Department: Responsibilities: Process Engineering Manager employed by a manufacturer and worldwide supplier of coated metals and metallic laminates and composites for brake noise control and sealing/gasket applications. Responsibilities including:

Held responsibility for bringing materials-oriented approaches to optimizing processing parameters to improve product quality control, FMEA, product performance characteristics, variability reduction, and cost reduction. Supervised testing laboratory for manufacturing operations.
Years: 1993 to 2004 Employer: Material Sciences Corporation Title: Director of Product Development Department: Responsibilities: Director of Product Development employed by a manufacturer and supplier of coated metals and metallic laminates and composites for automotive, electronics, appliances, and other markets. Responsibilities including:

Oversaw product development projects, including consumer and industrial, electrical and electronic, and automotive applications. Held responsibility for new product development, product improvements, qualification of alternative raw materials, transitioning new materials from laboratory to production, FMEA and corrective actions, and support to manufacturing, purchasing, sales and marketing.
Years: 1982 to 1993 Employer: Lockheed Missiles and Space (Dallas, TX) Title: Engineering Laboratory Manager Department: Responsibilities: Engineering Laboratory Manager employed by a major defense company – aircraft and missiles – for design, prototyping, testing, and manufacturing of engineering components and systems. Responsibilities including:

Lead multi-disciplinary staff of 50+ scientists, engineers, and technicians. Held accountability for professional development of staff members, managing department budget, capital equipment purchases, and maintenance of 21,000 square foot facility. Involved in materials science group specializing in the development of materials for very high temperature applications and fabrication and testing of prototype, fiber-reinforced, composite components.

Career Accomplishments

Associations / Societies
American Chemical Society
Materials Research Society
SAE International, Inc.
Sigma Xi, The Scientific Research Society
The Adhesion Society
Publications and Patents Summary
Expert has a total of 14 publications in professional journals, 26 presentations at professional meetings, and one patent.

Additional Experience

Expert Witness Experience
Expert has been retained on personal injury cases and a class action suit involving commercial signage. He generally does not accept ligtigation support projects.
Vendor Selection
Extensive experience in selecting and validating materials for new and existing applications, selecting and validating alternatives to discontinued materials, selecting and qualification of vendors for custom mixing of adhesives and coatings.
Other Relevant Experience
Expert has considerable experience in the following areas of materials and processing in laboratory-scale work, prototyping, and full-scale production:
Product Development, Production Planning, Quality Assurance, Process Improvements, Failure Analysis, Failure Modes, Formulation Chemistry, Technical Documentation, Laboratory Equipment, Performance Testing, Adhesive Bonding, Zero Defects, Test Equipment, Product and Process FMEA.

Fields of Expertise

acrylate coating material, acrylic adhesive material, acrylic coating material, adhesive material, adhesive material film, adhesive tape-coating material, automotive brake material, automotive coating material, automotive material, chemical conversion coating material, chemical-resistant coating material, chromate conversion coating material, clear coating material, coating inspection, coating material analysis, coating material characterization, coating material failure, coating material failure analysis, coating material quality assurance, corrosion-resistant material, electronic product development, adhesion technology, two-part adhesive, ethylene-vinyl acetate hot-melt adhesive, aqueous adhesive, silver adhesive, heat-activated adhesive, plasticizer-resistant adhesive, cold seal adhesive, solvent adhesive, adhesion loss, urethane adhesive, radiation-curable pressure-sensitive adhesive, ultraviolet-curable pressure-sensitive adhesive, adhesive curing, glass bonding, solventless adhesive, silver epoxy, diffusion bonding, thermally conductive adhesive material, steel adhesive, conductive adhesive bonding, epoxy bonding, adhesion science, polyurethane adhesive, polyethylene terephthalate adhesive, metal adhesive, pressure-sensitive tape, laminating adhesive, removable adhesive, water-activated adhesive, metal bonding, plastic adhesive, adhesion testing, aerospace coating material, methacrylate adhesive, solvent bonding, adhesion promoter, adhesive applicator equipment, adhesive application process, polymer adhesive, water-based adhesive industrial application, adhesive application, water-based adhesive, electronic component-to-substrate adhesive bonding, material product development, dental adhesive, pressure-sensitive adhesive, electrically conductive adhesive, adhesive failure analysis, adhesive selection, adhesion, polymer bonding, silicone adhesive, ultraviolet-curable adhesive, adhesive failure, soda glue silicate cement, wire bonding, 1,1-dichloroethylene, 1,1,1-trichloroethane, acrylic resin, medical adhesive, phenolic adhesive, thermosetting adhesive, thermoplastic adhesive, rubber adhesive, plastic pressure bonding, air-sensitive material handling, hot-melt adhesive, epoxy adhesive, electrical adhesive, electrical tape, cyanoacrylate adhesive, automotive plastic, automotive alloy, automotive composite, automotive adhesive, adhesive testing, adhesion theory, acrylate, absorbent material

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