Expert Details

Expert in Steel and Iron Casting Processes, Foundry Consulting, Metallurgy, and NDT Non Destructive Testing

Expert ID: 722597 Wisconsin, USA

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Expert has extensive foundry experience with a strong emphasis in melting steel using both acid and basic processes. He developed metallurgical and operational melting procedures that optimized the acid and basic slags. He is very familiar with the use and abuse of oxygen to refine steel.

Expert has worked in research to develop new steel alloys for high hardness and toughness applications. He has also considerable expertise in analyzing microstructures and relating to process issues in heat treatment. He has developed metallurgical and process specifications for alloy steel including melting, refining, heat treatment and welding.

Expert has developed hundreds of weld procedures for steel castings and is familiar with ASTM A488 and ASME Sec IX for procedure qualifications. His procedures have been accepted by DOT, Military, Railroad, Mining and Oil and Gas market sectors.

Expert has developed metallurgical and foundry procedures for austenitic, ferritic, martensitic and duplex stainless steel castings. The procedures include melting in arc furnace and induction furnace, deoxidation, heat treatment and welding. He has developed these at a foundry during his 10 years in the metallurgical and quality departments and with many other foundries and OEM's during his more than 10 years of consulting.

The brinell hardness test is commonly used for assessing the hardness of ferrous castings. Expert has performed guage R&R and developed procedures for such testing.

Expert is very familiar with surface preparation after excavating a defect either by carbon arc or grinding. He has conducted numerous repair procedures for arc melting of steel by tungsten inert gas, flux cored or manual metal arc welding. He is familiar with the application and limitation of each process.

Expert has approximately 25 years of experience in research, manufacturing, development, management and testing of carbon steel, low alloy and stainless steel and manganese steel.

Expert has extensive experience analyzing casting defects determining root cause and implementing corrective actions. Over the last 10 years he has helped analyze processes in foundries to identify process or procedure issues to improve productivity, quality and safety.

Expert has developed casting specifications for engineers to ensure that the quality of the finished casting meets the customers’ expectations. He has also been retained as an expert witness in litigation cases involving failed castings.

Expert is very familiar with all alloy steel castings including carbon, carbon manganese, manganese molybdenum, chromium molybdenum, nickel chromium molybdenum.

Expert has developed equipment and procedures to enhance the cleanliness of steel castings. One particular technology he helped develop was plasma refining of steel.

Expert has considerable experience in heat treatment including annealing, stress relieving, quench and tempering, normalizing, solution annealing, preheating and post heating.

Expert has considerable experience with first article casting requirements including foundry engineering, solidification modeling, and non-destructive testing procedures (radiography, ultrasonic, magnetic particle, liquid penetrant and visual). He is also familiar with destructive testing of castings both from a soundness and mechanical property assessment.

Expert has consulted with many iron foundries to improve the process for quality or productivity reasons.

Expert is very familiar with tensile, charpy and fracture toughness testing for steel castings. He has perfomed testing in very heavy sections and analyzed microstructures to correlate results. He is also familiar with hardness testing including rochwell, brinell and equotip.

He performed a quality and process audit of a large steel foundry and made recommendations to owners and implemented procedures to successfully turn-around the business.He assessed all the plant activites at major gray iron and ductile iron foundries to improve quality, productivity and profitability.He performed a due diligence assessment of the operations, equipment and processes for the buyer of a major steel foundry.He modified the melting, pouring and melting processes to improve the quality in stainless steel castings and nickel based castings.He developed specifications for an OEM for the successful production of large steel and gray iron castings.

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 - Milwaukee, Wisconsin - Madison, Wisconsin - Green Bay, Wisconsin - Kenosha, Wisconsin

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Education

Year Degree Subject Institution
Year: 1982 Degree: B. Sc Subject: Metallurgy Institution: University of Strathclyde

Work History

Years Employer Title Department Responsibilities
Years: 2000 to Present Employer: Undisclosed Title: President Department: Responsibilities: He is president and founder of a global metallurgical consulting company specializing in foundry processes and metal castings. Major activities are technical consulting to foundries and OEMs, foundry turnarounds, expert witness and training.
Years: 1997 to 2000 Employer: Process Metallurgy International, Inc Title: VP Technology Department: Responsibilities: His duties included metallurgical consulting and R&D related to clean steel technology. Other responsibilties were marketing of cupola software, Electric Power Research Institute (EPRI) foundry engineering assessments and energy process audits.
Years: 1995 to 1997 Employer: Nupro Corporation Title: Metallurgical and Process Consultant Department: Responsibilities: He was responsible for setting up a foundry consulting division. Other responsibilities included flux consultant for large integrated steel mills and minimills, and R&D for clean steel technologies. He was also involved in the development of a plasma aluminum low dross melter.
Years: 1985 to 1995 Employer: Maynard Steel Casting Company Title: Chief Metallurgist Department: Responsibilities: He was responsible for all metallurgical processes and procedures including melting, heat treatment, welding and NDE/NDT for steels, stainless steels and austenitic manganese steels. He performed significant research and development in heavy section castings and is an authority in this field.
Years: 1983 to 1985 Employer: Steel Castings Research and Trade Association (SCRATA) Title: Technical Officer - Metallurgy and Quality Department: Responsibilities: He conducted research on high alloy steel castings, non destructive techniques and performed failure analyses. He was the lead researcher on a steel casting cracking project.

Government Experience

Years Agency Role Description
Years: 2004 to Present Agency: DOT Role: Welding Engineer Description: He prepared welding procedure specifications (WPS) and qualifications (PQR) for steel foundry and DOT.
Years: 1992 to 1995 Agency: DOD Role: Welding engineer Description: He prepared and administered weld procedures for ballistic testing.
Years: 1992 to 1995 Agency: Corps of Engineers Role: Metallurgist Description: He designed alloy steels for high strength and excellent impact toughness.
Years: 1985 to 1997 Agency: DOC Role: Metallurgist Description: He performed research and development of casting processes to improve steel cleanliness.

International Experience

Years Country / Region Summary
Years: 1997 to 1998 Country / Region: Spain Summary: He performed research and development of microalloys for digger and dredge teeth castings for wear and impact properties. He was involved with the design of the alloys, the melting, pouring, molding and heat treatment of test blocks and castings. Some of the work was perfomed in Spain and some in America over the period.
Years: 1999 to 1999 Country / Region: Czech Republic Summary: Audited and evaluated foundries for capabilities of producing large steel castings for OEM.
Years: 2004 to 2004 Country / Region: South. Korea Summary: He audited a foundry to determine capability to produce crane castings for OEM in America.
Years: 2001 to 2001 Country / Region: Canada Summary: He improved the process for making low and high alloy steel castings.
Years: 1996 to 1996 Country / Region: Switzerland Summary: He presented the results of a cost benefit analysis study (CBA) made in the automotive industry concerning three different materials for engine blocks - gray iron, aluminum and compacted graphite iron.

Career Accomplishments

Associations / Societies
He is a member of the American Foundry Society (AFS), the Iron and Steel Society (ISS), the American Society of Materials (ASM) and a former member of American Society of Testing and Materials (ASTM).
Licenses / Certifications
SNT-TC-1A Level III in Ultrasonic Testing (UT) and Magnetic Particle Testing (MT). Level II in liquid penetrant testing (PT).
Professional Appointments
Present chairman of national AFS steel division. Former member of Steel Founders Society of America (SFSA) Specifications Committee. Former Co-sponsor of ASTM A 609 Ultrasonic Testing of Steel Castings.
Awards / Recognition
EPRI Innovators award.
R&D 100 Award.
Publications and Patents Summary
He has more than 20 publications and given technical presentations at international conferences.

Additional Experience

Expert Witness Experience
He has been an expert witness in 3 litigations involving casting failures and foundry asbestos claims.
Training / Seminars
He has developed and presented training courses for the Cast Metals Institute (CMI)in:
Direct Arc Melted Iron and Steel
Casting Finishing and Cleaning
Metallurgy of Cast Steel
Induction Melting of Cast Steel.
Vendor Selection
He has evaluated foundries capabilities to produce castings for OEM companies and recommended foundries to casting buyers.
Marketing Experience
He has experience for establishing a sales and marketing program related to foundry technical software.
Other Relevant Experience
He has performed numerous failure analyses on many types of casting components including oil related, trucking, mining, cement, defense, railroad and automotive. He has experience with simulation softwares for steelcastings.

Fields of Expertise

acid slag, basic slag, electric ferrous-metal melting, ferrous metal melting, ferrous metallurgy, metal casting, steel foundry, steel melting, high-alloy steel, low-alloy steel, arc welding, wire welding, austenitic stainless steel, austenitic steel, martensitic stainless steel, metallurgical engineering, steel manufacturing, Brinell hardness test, carbon dioxide arc welding, flux-cored arc welding, repair welding procedure, shielded arc welding, carbon steel, Hadfield manganese steel, low-carbon steel, casting defect, casting process, steel casting defect, casting specification, casting technology, chromium-molybdenum steel, plain-carbon steel, clean steel, ferrous metal annealing, ferrous metal heat treatment, steel annealing, first article inspection, nondestructive test, ultrasonic testing, iron foundry, metal mechanical behavior, metal mechanical property, microstructure, Rockwell hardness test, steel casting, welding, foundry tech, foundry machine, heat-affected zone, inspector training, ultrasonic test, metal property, immersion testing, bend test, American Society for Testing and Materials E981, qualification testing, distortion control, fatigue failure, ferrotitanium, ferrosilicon, ferroselenium, ferromanganese, ferrochromium, slag, master alloy, casting porosity, quality evaluation, metal product manufacturing facility, American Iron and Steel Institute, welding quality control, stainless steel 316, carbon arc, base metal (welding), bare-metal arc welding, iron recovery, shielded metal arc welding, steel property, foundry, steel machining, material property test, secondary operation, alloy steel, chromium steel, metal-related quality improvement, metal-related quality control, capability study, metal heat treatment quality control, heat-resistant alloy welding, iron heat treatment, electric steel melting, electric iron melting, ferrous metal casting, filler alloy selection, metal material selection, quality standard, gage R&R test procedure, chromium alloy, quality improvement, quality assurance, burn-in, due-diligence investigation, surface-wave test, metal casting (artifact), thickness measurement, cast metal, mechanical test, metal welding, pulse-echo method, ferrous structural component, quality, pig iron, specific material welding, ultrasonics standard, stress cracking, steel, stainless steel, quality control, quality auditing, metal physical property, iron melting, inert gas-shielded arc welding, heat-resistant steel, ferromolybdenum, failure analysis, box annealing, baking

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