Metallurgist, Materials Scientist, Process Expert Consultant Resume
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Resume of DBI, Ph.D. Consultant
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  • Aeronautics
  • Automotive
  • Defense
  • Manufacturing
  • Metallurgy

This expert has a Ph.D. and M.S. in Metallurgical Engineering from the Georgia Institute of Technology in Atlanta, GA.

This expert received a Bachelor of Materials Engineering from Georgia Institute of Technology in Atlanta, GA.

Metallurgist, Materials Scientist, Process Expert Consultant Resume
 

This expert specializes in metallurgical engineering for the aerospace industry, advanced manufacturing, problem solving and design, and material processing. Further expertise includes robotics and cnc programming, metal matrix composites, high strength, and corrosion resistant alloys.

Specialization includes aging kinetics modeling, microstructural characteristics optimization, robust SPC techniques, and crack incubation time and crack extension in creep-brittle materials. Other specialties include testing of creep-brittle materials, material processing and mechanical testing.

Additional experience and specialization includes aerospace, aging aircraft, and aircraft structure and design. Other related experience includes aluminum, aluminum alloys, aluminum extrusions, and alloy development. Furthermore, this expert specializes in materials development, process engineer, process improvement, and process optimization. Other areas of emphasis are residual stress reduction, research and development, creep deformation, and creep crack growth. This expert also has a background in elevated temperature properties, fracture mechanics, time dependent fracture mechanics (TDFM), mechanics of materials, and failure analysis.

This associate offers expertise specific to material selection, materials testing, corrosion, and friction stir welding. Other specific areas include design allowables development, specification development, heat treatment, quality systems, quality inspection, and statistical process control.

This associate has served as a professor of engineering and is highly regarded in areas including problem solving, manufacturing, robotics, MIL-HDBK-5 Data, MMPDS Data, AS9100, ISO9000, AS9000, AMS 2770, AMS 2772, SAE, Society of Automotive Engineers, composite manufacturing, C-130 and F-22 aircraft, airframe improvement, and P-3 Orion.

This expert has conducted numerous studies in areas including alloy development for aging aircraft, improved high strength extrusion alloys for upper wing and fuselage applications, development and implementation of drop-in-replacement alloys, and creep crack growth incubation in aluminum alloys. Other studies have entailed corrosion and aging, transient crack growth behavior in aluminum alloys, creep crack growth behavior of aluminum alloys, and experimental analysis and numerical analysis. Elevated temperature crack growth of aluminum alloys, creep behavior of aluminum alloys, and creep crack growth behavior of aluminum alloys are other studies this expert has conducted.

Consultant, Kevin Kennedy Associates Inc.

Providing project management, aerospace industry metallurgical engineering, metallurgy, materials engineering, process engineering, failure analysis, forensic engineering, consulting and related expertise to a wide variety of clients.

 

Visiting Assistant Professor, Miami University, Oxford, OH

Full-time faculty member, Manufacturing and Mechanical Engineering Department; instruction in Advanced Manufacturing, Problem Solving and Design; expertise in metallurgy, material processing, robotics and CNC programming; Designing and leading Advanced Manufacturing projects and laboratory exercises; Creating positive learning environment with relevant industry knowledge and focus; Faculty advisor to local chapter of the Society of Automotive Engineers (SAE).

 

Manager, Quality and Metallurgy, Universal Alloy Corporation, Canton, GA

Expertise in the extrusion of high-quality, hard aluminum alloys for the aerospace industry and supply of extrusions to all major aerospace companies, including Boeing, Lockheed Martin and Airbus.

 

New Airframe Development

Company leader, Boeing Sonic Cruiser program. Identified industry concerns and proposed solutions. Launched study to minimize residual stress in extrusions and improve producibility. Spearheaded company metal matrix composites initiatives on the Airbus A380 program. Worked with Lockheed Martin to develop Friction Stir Welding for aerospace applications. Represented company on the Society of Automotive Engineers Aerospace Materials Committee. Directed the Research & Development efforts for aluminum 7249-T76511 and 7249-T7X511. Worked with customer engineering to develop high strength, corrosion resistant alloys. Participated in programs focused on Alloy Development for Aging Aircraft. Coordinated material testing efforts at the Air Force Research Laboratory at Wright-Patterson AFB. Developed new heat treatment for 7249 optimized for both strength and corrosion resistance. Authored industry specification for 7249-T76511 and led efforts to have data published in MIL-HDBK-5.

 

Graduate Research/Teaching Assistant, Georgia Institute of Technology, Atlanta, GA

Conducted research sponsored by the NASA Langley Research Center as part of the High Speed Research Program (formerly the High Speed Civil Transport). Investigated and characterized creep and creep crack growth behaviors of two candidate aluminum alloys and evaluated the influence of alloy chemistry on the creep behavior. Studied the creep and creep crack growth behavior of aluminum alloys 2519-T87 and C415-T8. Developed new model for the transient crack growth behavior of creep-brittle materials. Proposed new theory of crack incubation time and crack extension in creep-brittle materials. Discovered new crack growth mechanisms for creep-brittle materials. Presented research at the National Symposium on Fracture and Fatigue and other major conferences. Published research in Engineering Fracture Mechanics and other major journals. Organized ASTM round-robin testing of creep-brittle materials. Substituted for professors in Materials Science (Mechanics of Materials and Fracture Mechanics). Assisted professors in classes ranging from Introduction to Materials to Composite Manufacturing. Taught lab classes focusing on material processing and mechanical testing. Devised laboratory projects and authored procedures.

 

Process Optimization

Performed studies to model aging kinetics under the influence of changing press parameters. Reduced thermal rework by more than 20% by utilizing press parameters that optimize kinetics. Designed experiments to identify the key factors influencing growth of the recrystallized layer. Introduced new die design concepts to optimize microstructural characteristics and features. Developed and implemented Statistical Process Controls within key plant departments. Reduced flow time through quality department by more than 25% by using robust SPC techniques. Determined corrective action for process deviations and authorized customer shipments. Addressed quality, design and material issues by traveling to customer sites and facilities.

 

Senior Materials and Processes Engineer, Aging Aircraft Programs, Lockheed Martin Aeronautics Company, Marietta, GA

Lead metallurgist to the P-3C Service Life Extension Program. Developed and performed material characterization tests at the Naval Air Systems. Designed and directed test plans on site at the national test lab in Holland. Proposed corrosion resistant material substitutions for the C-130, C-5 and C-141 airframes. Created corrosion sensitivity matrix to assist material selection for aeronautical applications. Worked with the U.S. Air Force Corrosion Office on corrosion prevention for aging airframes. Authored and managed test plans performed at the Air Force Research Lab. Collaborated with the Naval Air Systems on service life extension programs. Led the Lockheed Martin effort to develop and characterize aluminum 7249-T76511. Wrote proposals and statements of work to characterize candidate materials for aging airframes. Authored numerous company-confidential, classified research reports on material development efforts. Presented declassified materials development work at AeroMat and other conferences.

 

Process Improvement

Directed aluminum heat treatment and assigned corrective action for process deviations. Interfaced with design and stress engineers to optimize material selection. Authored and revised material and process specifications. Represented company at industry meetings on common process and material initiatives.

 

Graduate Research/Teaching Assistan, Georgia Institute of Technology, Atlanta, GA

Conducted research sponsored by the NASA Langley Research Center as part of the High Speed Research Program (formerly the High Speed Civil Transport). Investigated and characterized creep and creep crack growth behaviors of two candidate aluminum alloys and evaluated the influence of alloy chemistry on the creep behavior. Studied the creep and creep crack growth behavior of aluminum alloys 2519-T87 and C415-T8. Developed new model for the transient crack growth behavior of creep-brittle materials. Proposed new theory of crack incubation time and crack extension in creep-brittle materials. Discovered new crack growth mechanisms for creep-brittle materials. Presented research at the National Symposium on Fracture and Fatigue and other major conferences. Published research in Engineering Fracture Mechanics and other major journals. Organized ASTM round-robin testing of creep-brittle materials. Substituted for professors in Materials Science (Mechanics of Materials and Fracture Mechanics). Assisted professors in classes ranging from Introduction to Materials to Composite Manufacturing. Taught lab classes focusing on material processing and mechanical testing. Devised laboratory projects and authored procedures.

Quality Metallurgy Report
Continuous Improvement Report
A Thermal Model of Friction Stir Welding in Aluminum Alloys

This expert is the author of numerous publications related to alloy development for aging aircraft, improved high strength extrusion alloys for upper wing and fuselage applications, development and implementation of drop-in-replacement alloys, creep

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