Failure Analysis of Crane Track-Pads
- Analysis of failure
- Characterization of defect
- Assessment of casting operations
- Manufacturing recommendations to reduce risk of future failures
Light Rail Bogie Frame Production
- Observation of manufacturing
- Recommendations to improve casting quality and delivery
- Assessment of residual stresses caused by welding and cold straightening
Casting and Extrusion Process Improvement of Lead Alloys
- Developing process changes to reduce potential of cracking
- Plating anode development project
Investment Casting Project
- Optimization of technology and process for ductile iron
- Cost-benefit of metal comparisons ductile iron, malleable iron, steel
Cost Benefit Analysis of Different Casting Technologies
- Comparison of green sand automatic molding, no-bake, gas-hardened and shell casting for ductile iron
Process and Quality Optimization of Pump Castings
- Project included, duplex stainless steel, austenitic stainless, ductile iron, grey iron and bronze
Development of Electric Arc Melting Process for Stainless Steel
Technical Specialist for OEM and integrated foundry, in China. Major projects included:
- Hydroelectric Turbine Components: Development of casting parameters to produce CA-6NM martensitic stainless steel Runner Band and Crown and Blade for large Francis Turbine. Included chemistry formulation, gating, pouring, welding and heat-treatment.
- Three River Gorge: Process improvement to eliminate scrap of very large and critical screw castings for the Ship Lift at this dam
- Steam Turbine Casings: Involved with gating and risering of these very large castings >50 tonne. Project also included weld repair and inspection procedure improvement. Castings were Cr-Mo steel
- EAF Melting and LMF Refining Furnace: Development of Procedures
- Development of Road Map to produce ASTM A352 Grade LCC Mooring Support Castings
- Defect Analysis and new procedures to produce Cross Member for Forging Press
Liquid Ring Compressor: Rotor Casting Failure and Troubleshooting
- Process audit of foundry and Recommendation of Changes and Testing to improve Quality
Melting and Vacuum Casting of Cu-Si Alloys to be used in Solar Grade Silicon Refining
Large Steel Castings for Crane for Nuclear Power Station. Troubleshooting into Cracked Castings Protocol:
- Foundry process analysis
- Metallurgical Investigation to Characterize Defect
- Root Cause Analysis
- Salvage and NDE and Destructive Testing Procedure Development
- Implementation of Process Changes to produce Successful Castings
Process Audit of potential Steel Casting Suppliers in USA, Asia and Europe for large Construction and Mining OEM
- All foundry processes were examined for technology and controls to ensure that potential suppliers had capability to produce large critical steel castings with low risk to OEM
- Following the process review of the foundries, a Gap Analysis was performed
Casting Consultant for Space Frame Connector Castings
- Tooling Design to Produce new concept castings for Construction Industry
Metallurgical and Casting Training for Major Power Generating Turbine Company
- Focus was on Hydroelectric Turbines and castings used in Fabrication of Francis, Kaplan and Pelton Turbines
Casting Consultant for a large Military Garrison
- Projects included developing procedures for problem castings for Military vehicles both Sand and Investment Castings
- Process audit of all foundry operations and recommendations for Improvement
- Developed a data-base framework with foundry metrics
Casting Consultant for Large Forging Press Manufacturer
- Development of Foundry Engineering Methodology for large Platen Casting
Foundry Specializing in Impeller Castings
- Process Improvement and Metallurgical Expertise to Produce High Quality Austenitic, and Duplex Stainless Steel Castings
Cracked Casting for Oil and Gas Components
- Root Cause Analysis and Corrective Action Performed for next Castings
High Visibility Government Project
- Project Manager for Casting, Concept to Shipment
Development of Procedures for Magnetic Particle Testing and Ultrasonic Testing
- Also included was training Ultrasonic Inspectors
Foundry Metallurgist and Technical Director
- On-Going Foundry Metallurgical and Technical Support
Heat Treatment Metallurgist
- On-Going Metallurgist for Heat Treating Company
- Heat Treatments Solution Anneal, Quench Temper, Normalize, Anneal, Stress Relieve, Age
Welding Metallurgist
- On-Going Metallurgist for Fabricating Company
- Development of Weld Procedures meeting AWS, ASME and ASTM Welding Codes
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