Expert in Aluminum/Materials Joining and Product Manufacturing
Expert ID: 108185 Pennsylvania, USA
Expert has expertise in forming and machining aluminum product forms. He has assisted clients regarding the effects of alloy and temper on forming and machining response and in cost-effective selection of aluminum product forms and fabrication processes. His knowledge of component fabrication includes sheet metal forming processes (stamping, blanking, stretch forming, hydroforming, bending roll forming, magneform, tool design, and grid stain analysis) as well as metal removal processes (turning, milling, cutting, and chemical milling).
Expert has extensive experience integrating design, prototyping, performance evaluation, and manufacturing process aspects of aluminum-based products. Areas in which he has provided assistance include new product ideation; design for functionality and manufacturability; project/venture value analysis; rapid and cost effective prototyping; product form, alloy and temper selection; manufacturing process selection; and invention and development of manufacturing processes.
Having a broad knowledge of new product and manufacturing process development, Expert's has provided designs for automotive, transportation, aerospace, and machinery industries. He was the principal developer of processes for the manufacture of aluminum automotive heat exchangers; these include radiators, heater cores, engine oil coolers, air change coolers, A/C condensers & evaporators, and cold plates. He was also the principal developer of fluxless brazing and soldering processes.
Applying his knowledge of aluminum to the automotive industry, Expert has developed autobody stuctures. He designed monocoque and space frames fabricated from multi product forms, sheet, extrusions, and castings. Assembly methods with which he is familiar include resistance spot welding, weld bonding, mechanical fasteners, gas metal arc welding, MIAB welding, and magneform. He is experienced with the common infrastructure (steel & aluminum) assembly concept based on resistance spot welding. In addition to his expertise in autobody structure, Expert has designed integral and modular blocks with thermal sprayed bore coatings for use in engine blocks. Lastly, he has developed cast brake rotors with thermal sprayed wear surfaces.
Expert has interfaced with clients in the development and prototyping of various products, including bowling pins; bicycles/motorcycles; cooking utensils; residential air conditioning and refrigeration components; and boats/personal water crafts. He adapted, refined, or invented the required assembly and manufacturing processes for these products.
Expert may consult nationally and internationally, and is also local to the following cities: Pittsburgh, Pennsylvania - Youngstown, Ohio - Canton, Ohio
|Year: 1963||Degree: B.S.M.E.||Subject: Mechanical Engineering||Institution: University of Pittsburgh|
|Years: 1996 to Present||Employer: Undisclosed||Title: Independent Consultant||Department:||Responsibilities:|
|Years: 1966 to 1996||Employer: Aluminum Company of America (ALCOA)||Title: Technical Consultant||Department:||Responsibilities:|
|Years: 1963 to 1966||Employer: Westinghouse Electric Corporation - Bettis Atomic||Title: Design Engineer||Department:||Responsibilities:|
|Years||Country / Region||Summary|
|Years: to Present||Country / Region: United Kingdom||Summary: Expert was the Alcoa corporate contact with TWI (British Welding Institute).|
|Years: to Present||Country / Region: Japan||Summary: He was the principal technical contact with Kobe Aluminum (Alcoa joint venture partner) on all joining technology issues.|
|Years: to Present||Country / Region: Europe||Summary: Expert has extensive experience working in Europe, specifically Germany, England, and Sweden. In Europe, he had major responsibility for the assembly of aluminum prototype cars at a major auto manufacturer.|
|Associations / Societies|
|Expert is a member of many professional societies, including Sigma Xi, Society of Automotive Engineers, Society of Manufacturing Engineers, American Welding Society, and the American Society for Metals.|
|Licenses / Certifications|
|He is a Registered Professional Engineer with a Pennsylvania license.
|Expert served on the Board of Trustees for the Edison Welding Institute.|
|Awards / Recognition|
|He is the recipient of the Arthur Vining Davis award for "Development of Aluminum Automotive Spaceframe" and was elected a Fellow of ASM International.|
|Publications and Patents Summary|
|Expert has thirteen U.S. patents in the areas of aluminum joining, surface treatment, and product developments.|
Fields of Expertise
aluminum fusion welding, aluminum welding, aluminum brazing, soldering, aluminum alloy, aluminum forming, aluminum machining, aluminum product, aluminum product design, fluxless aluminum brazing, fluxless soldering, aluminum alloy welding, gas-metal arc aluminum welding, thermal spray technology, aluminum bicycle, consumer product, bicycling, aluminum fastening, capacitor discharge welder, silver brazing, sheet metal forming, copper brazing, corrosion-resistant aluminum coating, aluminum strength, anodized aluminum, thermal spray coating material, fluxless vacuum aluminum brazing, zinc aluminum solder, extruded aluminum heat sink, gas-tungsten arc aluminum welding, aluminum brazing filler alloy, aluminum welding filler alloy, aluminum plating process, aluminum torch brazing, aluminum torch welding, aluminum tack welding, aluminum butt welding, aluminum dip soldering, aluminum forge welding, aluminum density, aluminum metallurgy, extruded aluminum product, aluminum etching, aluminum heat treatment, aluminum application, aluminum sheet formability evaluation, aluminum cutting, aluminum forming process design, aluminum sawing, aluminum flanging, aluminum solder, thermal spray coating process, roll forming, aluminum