Expert Details

Expert in Composite Materials

Expert ID: 108445 Delaware, USA

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Expert has had extensive experience in cost/performance trade studies for the selection of composite materials. These materials use graphite, aramid, glass, and polyolefin fibers with epoxy, vinyl ester, and other thermosetting resins. Expert has knowledge of the structural capabilities, limitations, and processing requirements for composite material systems. He feels that this is essential for determining the product design and life cycle cost. He uses control or modification of the processing parameters to improve performance and reduce variability. Expert has six patents pending in this area. He uses micromechanical methods (Halpin-Tsai and MIL HDBK 17) to predict material properties where required.

Expert has successfully designed over 150 composite pressure vessels. This has required the integration of materials knowledge, processing options, and structural analysis. The principal design tools that he uses are netting and laminate theory, which he has used to develop computer codes for the rapid evaluation of proposed designs. He has designed many sandwich laminate structures to reduce cost and weight using foam and honeycomb cores with graphite, aramid, and glass fiber skins. He has several patents pending which relate to composite structures design. Expert also has successfully designed hundreds of fiber-reinforced plastic (FRP) tanks, piping, stacks, and other custom products primarily for the chemical process industry where corrosion resistance and cost are driving factors.

Expert has used finite element analysis to verify design capability of over 200 models. This has involved the use of TEXGAP, NASTRAN, and PATRAN-ABAQUS programs. In a supervisory position, Expert has been responsible for interpreting, evaluating, and determining the validity of FE analyses. He has often used micromechanics theory for material property input. He has also used laminate theory for plate and shell structures to predict resin crazing and to validate FE analysis.

Expert has been responsible for the filament winding of hundreds of composite pressure vessels using both prepreg and wet winding materials. He has used fibers consisting of graphite, aramid, glass, and polyolefin. He has used resins which include UV cure epoxy, 250 and 350 degrees F epoxy, and other thermoset resins. Expert has written computer programs for pattern generation and translators to integrate the design codes. He has evaluated fiber path stability and fiber and resin stresses with specialized computer codes. He has five patents pending which are related to composites processing and filament winding.

Expert has been involved with many failure analyses of composite structures. These analyses have involved reviewing the design and manufacturing history using laminate, FE, and/or microscopic analyses. Along with this, he has used his knowledge of the capabilities and limitation of many composite material systems. He was heavily involved with redesign efforts for the IR+D programs for other aerospace divisions. He has performed load transfer analyses for patches and repairs to damaged structures. Expert has written many design and analysis computer programs for laminated beams, plates, and shells. These include micromechanics, shear deformation effects, linear and large deformations, and elastic stability calculations.

Expert managed the design/analysis and composites manufacturing groups for a major aerospace company. He has approximately 15 patents directly related to composite pressure vessels. He has also written computer codes for cylindrical, dome and attachment design/analysis. Expert is also knowledgeable of ASME Section X. He was responsible for the successful design and testing of over 200 composite pressure vessels.

Expert has experience with tanks (both cylindrical and rectangular) for the chemical processing industry and with design of storage vessels for high pressure fluids including vessels with thermoplastic and metal liners. He is knowledgeable in and an active participant with ASME RTP-1, ASME Section X, and ANSI/ASME B31.3 FRP Pipe committees.



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Projects ranged from structural design and analysis over a wide range of applications; failure analysis; manufacturing processing (such as filament winding, resin transfer molding, hand lay up, and spray up); materials selection; expert witness testimony in product liability cases; and expert witness testimony in patent dispute cases.

Expert may consult nationally and internationally, and is also local to the following cities: Philadelphia, Pennsylvania - Allentown, Pennsylvania - Reading, Pennsylvania - Bethlehem, Pennsylvania - Lancaster, Pennsylvania - Trenton, New Jersey - Camden, New Jersey - Wilmington, Delaware - Baltimore, Maryland - Alexandria, Virginia

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Education

Year Degree Subject Institution
Year: 1985 Degree: M.M.A.E. Subject: Mechanical and Aerospace Engineering Institution: University of Delaware
Year: 1982 Degree: B.M.E. Subject: Mechanical Engineering Institution: University of Delaware

Work History

Years Employer Title Department Responsibilities
Years: 1991 to Present Employer: Undisclosed Title: Engineering Consultant Department: Owner and Principal Engineer Responsibilities: Expert is an engineering consultant (and has been since 1991) involved with structural design and analysis and expert witness testimony with a specialty in laminated and composite materials. With 18 years’ experience in advanced composites and FRP (fiber reinforced plastics), his background spans the marketplace for composites applications. He has assisted hundreds of satisfied clients through the years. These projects ranged from structural design and analysis over a wide range of applications; failure analysis; manufacturing processing (such as filament winding, resin transfer molding, hand lay up, and spray up); materials selection; expert witness testimony in product liability cases; and expert witness testimony in patent dispute cases.
Years: 1992 to 2003 Employer: Composites USA Title: Manager Department: Engineering and QA Responsibilities: He was accountable for the design and analysis of fiberglass (FRP) composite structures for the chemical process industry and other structural applications. These products include tanks, pipe, duct, stacks, process vessels, and scrubbers as well as many custom applications. He was responsible for specification writing, sales, marketing, and process development for new applications. He programmed cost estimating spreadsheets that were linked to engineering calculations that led to cost-competitive proposals that increased gross sales and profits. He also provided engineering calculations that allowed Composites USA to quote on projects that were previously not bid.
Years: 1985 to 1992 Employer: Thiokol Corporation Title: Manager Department: Advanced Technology, Elkton, MD Responsibilities: Expert was responsible for the output of the Analytical and Composites Groups. The design, analysis, and manufacturing of composite structures were integrated within this department which included designers, engineering analysts, chemists, process engineers, and technicians. Composites design and manufacturing, and thermal, structural, dynamics, and mass properties analyses were provided to support division and corporate programs. He managed three corporate IR&D programs relating to advanced materials and structures that focused on improving performance while reducing costs and lead times. He developed and demonstrated a number of innovative design and manufacturing features to meet specific project requirements on both the division and corporate levels.

Career Accomplishments

Associations / Societies
Expert is a member of the ASME, ASTM, AIAA, SAMPE, and NACE. He is a former member of the AIAA Technical Subcommittee on Structures.
Licenses / Certifications
He is a Professional Engineer in eight states: Delaware, Pennsylvania, Illinois, Maryland, New York, Virginia, Arizona, and New Jersey.
Professional Appointments
Expert was elected to ASME RTP-1 Design and Fabrication and Section X subcommittees. He is an active contributor with regards to elastic instability, micro-mechanics, and failure theories. He has been a member of the ANSI B31.3 / ASME FRP pipe design committee.
Awards / Recognition
He is listed in "Who's Who in Science and Engineering."
Publications and Patents Summary
Expert has 21 patent disclosures relating to composite designs and fabrication techniques. 14 patents have been issued with the others subject to DOC export regulations.

Additional Experience

Expert Witness Experience
Expert has served as an expert witness in product liability and patent dispute cases.
Marketing Experience
At Composites USA he was responsible for specification writing, sales, marketing, and process development for new applications. He programmed cost estimating spreadsheets that were linked to engineering calculations that led to cost competitive proposals that increased the gross sales and profits. He provided engineering calculations that allowed Composites USA to quote on projects that were previously not bid.

Fields of Expertise

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