Expert Details

Expert in Metallurgical Engineering, Failure Analysis, Heat Treatment, Supplier Development and Coatings

Expert ID: 726080 New Hampshire, USA

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He has performed over 500 failure analysis of components which fractured due to fatigue. This has included both low cycle and high cycle fatigue failures due to mechanical, thermal mechanical and environmentally enhanced fatigue.

He has specified and developed various heat treatments for ferrous alloys to include annealing, normalising, harden & tempering, nitriding, carburizing and stress relief treatments.

He has performed over 1200 failure analysis of engineering components. He has experience with fatigue, creep rupture, hydrogen embrittlement, tensile overload, corrosion, erosion and stress-corrosion cracking.

He has extensive experience selecting materials for a wide range of applications.

He has extensive understanding of mechanical properties of both ferrous and non-ferrous alloys at ambient and elevated temperature, in both benign and aggressive environments.

He has a through understanding of metallurgical engineering, processing effects on mechanical behavior and environmental effects on material properties.

Many of his failure analysis have involved components fabricated from aluminum, titanium, nickel and cobalt based alloys.

He has extensive experience with low alloy steel, carbon steel, austenitic stainless steel and martensitic stainless steel. Processing, heat treatment, mechanical behavior and welding are just some of the areas of expertise.

He has performed over 500 failure analysis of steel components ranging from carbon steel to austenitic and martensitic stainless steel.

He has 26 years experience in the mechanical behavior, testing, failure analysis and manufacturing processes related to ferrous and nonferrous alloys include all structural steels, stainless steels, nickel-base alloys, aluminum-base alloys and titanium-base alloys.

He performed a failure analysis of US Coast Guard turbocharger. Developed surface modification technology to improve solid particle erosion resistance. Impellers useful life has been extended 10 fold.In response to the loss of heavy forging capability in the US, Expert developed heavy forging suppliers in Germany, Austria, France and Japan to provide these critical components for OEM's. He performed the failure analysis of a gas turbine disk which had fractured aboard a commercial airline resulting in rupture of the fuselage and loss of life of two passengers. He performed failure analysis of a Rene 41 blisk used in the auxillary power unit for the space shuttle. Took part in 3 years of investigation as part of NASA's "back to space" effort after the Challenger accident. He performed failure analysis of a newly designed jet engine during development testing and identified significant manufacturing problems with the new braze materials used in the low pressure stator assemblies. Recommended processing changes and NDT to identify if the conditions were present in manufactured components. All recommendations were implemented and project moved forward.

Expert may consult nationally and internationally, and is also local to the following cities: Boston, Massachusetts - Worcester, Massachusetts - Lowell, Massachusetts - Cambridge, Massachusetts - Brockton, Massachusetts - New Bedford, Massachusetts - Fall River, Massachusetts - Lynn, Massachusetts - Manchester, New Hampshire - Providence, Rhode Island

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Education

Year Degree Subject Institution
Year: 1983 Degree: B.S. Subject: Metallurgy and Materials Engineering Institution: Lehigh University
Year: 1987 Degree: M.S. Subject: Metallurgy and Materials Science Institution: Rensselaer Polytechnic Institute

Work History

Years Employer Title Department Responsibilities
Years: 2008 to 2009 Employer: Rotating Machinery Services, Inc. Title: Senior Project Manager Department: N/A Responsibilities: Expert was responsible for all technical and commercial aspects of contract execution for company’s gas turbine, steam turbine and axial compressor overhaul rerate and upgrade contracts. He was also responsible for providing authoritative technical expertise in materials and weld engineering in the design, analysis, manufacture and application of the company’s product.
Years: 2002 to 2008 Employer: Westinghouse Electric Title: Technical Engineering Lead, Materials and Welding Group Department: Nuclear Manufacturing Responsibilities: His responsibilities included directing, planning and reviewing all materials and weld engineering activities during proposal stage and manufacturing execution of Control Element Drive Mechanisms, Reactor Coolant Pumps and Reactor Vessel Internals. Responsible for supporting divisions interests with technical presentations to customers and attendance at industry forums.
Years: 1996 to 2002 Employer: Dresser-Rand Title: Manager, Advanced Engineering and Development Department: Steam Turbine, Motor and Generator Division Responsibilities: He was responsible for recommending and implementing technological research and development to advance technical capabilities and enhance product offerings for new products and aftermarket. Product lines included steam and gas turbines, hot and warm gas expanders. Department consisted of core technical disciplines relevant to turbomachinery design: aerodynamics, rotordynamics, stress and vibration and materials science.

Years: 1989 to 1996 Employer: Dresser-Rand Title: Chief Metallurgist Department: Steam Turbine, Motor and Generator Division Responsibilities: His responsibilities included leading the materials group and providing authoritative technical expertise, leadership and direction in the design, analysis, manufacture and application of the company’s products, i.e., steam turbines and gas expanders.

Years: 1986 to 1989 Employer: Sundstrand Aviation Title: Sr. Materials Engineer Department: Materials Department Responsibilities: He was accountable for selecting materials/processes for new products during design development as well as support of product in field. Product lines included: Space Shuttle APU’s, Missile System HPU’s, Undersea Propulsion Systems, Ram Air Turbines and Mechanical Actuation Systems.
Years: to Present Employer: Undisclosed Title: Materials Engineer Department: Materials Engineering Research Laboratory Responsibilities: He was primarily responsible for failure analysis of commercial/military fleet and experimental gas turbine engine hardware.

Government Experience

Years Agency Role Description
Years: 2008 to 2009 Agency: US Coast Guard Role: Consultant Description: He performed failure analysis of a USCG turbocharger and selected coating scheme to eliminate future erosion damage to impeller vanes. Developed and qualified supplier.
Years: 1998 to 2000 Agency: US Navy Role: OEM Program Manager Description: He was responsible for directing and managing all commercial and design aspects of a proposal for the main turbine-generators for the new CVX designed aircraft carriers.
Years: 1988 to 1988 Agency: US Air Force Role: OEM Failure Analyst Description: He performed an expedited failure analysis of a critical component on the B-1B bomber averting grounding of fleet.
Years: 1987 to 1989 Agency: NASA Role: OEM Failure Analyst Description: He was the OEM's materials expert working with NASA and related government agencies to insure space shuttle reliability in the "back to space effort" after the Challenger accident.

International Experience

Years Country / Region Summary
Years: 1995 to 1998 Country / Region: China Summary: He was responsible for materials engineering technology transfer as related to manufacture of steam turbines as part of joint venture. Responsible for supplier development of large turbine forgings.
Years: 1994 to 1994 Country / Region: Germany Summary: He was responsible for developing supplier of solid A286 rotor forgings for gas expanders.
Years: 1992 to 1994 Country / Region: Japan Summary: He developed and qualified supplier to produce differentially heat treated steam turbine rotors.
Years: 2007 to 2007 Country / Region: France Summary: He developed and qualified supplier of thick 300 series stainless plate for ASME Section III nuclear vessel applications.

Career Accomplishments

Associations / Societies
American Society for Testing and Materials (ASTM)
American Society of Mechanical Engineers (ASME)
Amerian Society of Metals (ASM Intl.)
Publications and Patents Summary
10 Technical Publications

Additional Experience

Expert Witness Experience
Expert has been an expert witness/consultant in litigation representing manufacturers, end users and insurnace companies.
Training / Seminars
Expert provides seminars on failure analysis, material selection, material specifications and ASME Section III usage.
Vendor Selection
Expert has vast experience with supplier development and supplier qualification of ferrous and non-ferrous forgings, castings, bar and thick plate in North America, Italy, Germany, Austria, England, France, Japan, China and Tiawan.
Marketing Experience
Expert has intimate knowledge of the turbomachinery industry. OEM's weaknesses/strengths, technology push-market pull and international growth outlook.
Other Relevant Experience
Expert has extensive experience with design, operation and failure modes of steam turbines, gas turbines and gas expanders.

Fields of Expertise

fatigue failure, ferrous metal heat treatment, metal failure analysis, metal material selection, metal mechanical property, metallurgical engineering, nonferrous metal failure analysis, steel, steel failure analysis, alloy steel, aluminum alloy, aluminum material selection, austenitic steel, carbon steel, failure analysis, fatigue limit, fatigue measurement, fatigue resistance, fatigue strength, fatigue testing, heat-affected zone, heat-resistant steel, iron alloy, iron metallurgy, metal alloy, metal creep, metal failure, metal mechanics, metal property, metal testing, metallurgical aging, metallurgical testing, metallurgy, nickel alloy, nonferrous alloy, nonferrous metal, rotating-beam fatigue testing, stainless steel failure analysis, steel mechanical property, titanium alloy, weldability, welding failure analysis, welding, airframe fatigue, product failure, ASME Section IX Code Welding, weld overlay, welding equipment, metal replacement material, 9310 alloy, welding engineering, 52100 steel, ferrous metallurgy, grain size, fatigue property, nonferrous metal heat treatment, ferrous metal annealing, nonferrous metal annealing, galvanic protection, American Petroleum Institute, distortion control, aircraft engine failure analysis, coating selection, aluminum alloy selection, weld metal, welded joint design, microstructure analysis, wire welding, Edison Welding Institute, metal product manufacturing facility, hot working, cold working, American Iron and Steel Institute, welding quality, metal protective coating material, welding testing, corrosion fatigue, nonferrous metal corrosion, age hardening stainless steel, nonferrous metal welding, cold-rolled steel, nonferrous metallurgy, aluminum casting failure analysis, metal bonding, chromium steel, chromium-molybdenum steel, weldment corrosion resistance, incoming steel inspection, metal nondestructive testing, repair welding procedure, metal deformation, iron heat treatment, ferrous metal, ferrous metal casting, metal mechanical behavior, filler alloy selection, cast nickel alloy, metallic element, corrosion failure analysis, fatigue crack growth, metal alloy research management, dissimilar material welding, welded joint, materials selection, welding application, pressure vessel welding application, iron alloy corrosion, ferrous metal corrosion, nonferrous metal casting, metal welding, cobalt alloy, ferrous structural component, automatic welding, welding standard, weldment, specific material welding, welding code, weld, vacuum welding, stainless steel, metal physical property, grain boundary, fusion welding, fatigue, metal embrittlement, cobalt, metal case hardening, carburizing, carbonitriding, austenitic stainless steel, arc welding, aluminum corrosion, aluminum

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