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 Expert  108383

Expert in Aluminum Alloys

Available for your Consulting and Expert Witness Needs

North Carolina (NC)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
In his 35 year career with Alcoa, Expert has worked on the metallurgy and heat treatment of representatives of all the wrought alloy systems designated by the Aluminum Association as well as the 3XX casting alloys. He is an expert regarding the effects of alloying and processing on the microstructure, properties, and performance of these materials. He is internationally recognized as an expert on the heat-treatable alloys and has worked extensively on the alloys used in the aerospace industry.

aluminum alloy

Expert directed the development of high-strength alloys at Alcoa for much of his career. He either developed or directed the development of almost every modern alloy used today on aircraft. He also had a hand in developing many of the alloys used in the automotive industry. In his early years, Expert did research on alloys that are used in the packaging and construction industries.

aluminum alloy development

Expert is particularly knowledgeable of the properties of aluminum alloy products used in the transportation industries. These include strength, fracture toughness, fatigue strength, resistance to the growth of fatigue cracks, resistance to stress-corrosion cracking and exfoliation corrosion, and formability. He has published papers summarizing his own work and that of others regarding metallurgical factors that influence these properties.

aluminum alloy property


aluminum alloy selection

Widely recognized for his expertise in this area, Expert has been the chief author of ASM Handbooks on the heat treatment of aluminum. He is particularly expert in the processes of quenching and aging (precipitation heat treatment). Expert developed Quench Factor analysis, a method of modeling effects of quench path on strength, corrosion resistance, and fracture toughness of aluminum alloy products. He also developed a model that allows one to predict the strength and electrical conductivity of 7XXX products as a function of chemical composition, aging time, and aging temperature. He is co-patent holder of the T77 temper for 7XXX alloys and recently solved the problem of intergranular corrosion of 7150-W extrusions by recommending a modification to the quench practice.

aluminum heat treatment


quench factor analysis

Expert is an expert in the physical metallurgy of aluminum and its alloys. He teaches physical metallurgy to Alcoa metallurgists, and he has taught the physical metallurgy of aluminum at courses sponsored by ASM and at Purdue University. He recently authored an article in volume 20 of the ASM Handbook Materials Selection and Design, which showed how composition, processing, and metallurgical structure affect the properties of aluminum alloy products. In addition, he was the chief consultant to Alcoa's fabricating divisions on metallurgy problems.

aluminum metallurgy

Expert has in-depth knowledge of factors affecting strength. He delivered a keynote address at the Fourth International Conference on the Metallurgy of Aluminum Alloys that dealt with the metallurgical factors affecting the strength of aluminum alloy products. These factors include chemical composition, microstructural features such as precipitates, degree of recrystallization, grain size, and crystallographic texture, plus processing variables such as quenching, aging, and cold work.

aluminum strength

As Chief Extrusion Metallurgist at Alcoa's Lafayette for two years, Expert developed expertise in effects of such factors as chemical composition, preheat and reheat practices, extrusion temperature, reduction ratio, and others on the ease of extruding and on the resultant properties of the extruded products.

extruded aluminum product


aluminum extruding

In his roles in the Alloy Technology Division and later as Chief Scientist, Expert directed the alloy development of high-strength aluminum alloys for many years at the Alcoa Technical Center. During his tenure, most of the high-strength alloys used in the transportation industry were developed. Several of the alloys won R&D 100 awards, which recognized them as being among the most significant developments.

Expert has also developed commercial personal computer software for education in materials science, which includes simulation of electron and X-ray diffraction patterns, interactive graphical programs to help explain stereographic projection, pole figures, and crystalline orientation distribution function. More than half the metallurgy and materials science departments in the US and Canada use these programs.


metal alloy research management


cast alloy

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Raleigh, North Carolina;  Greensboro, North Carolina;  Durham, North Carolina;  Winston Salem, North Carolina;  Fayetteville, North Carolina;  Cary, North Carolina;  High Point, North Carolina;  Greenville, North Carolina;  Concord, North Carolina;  and Lynchburg, Virginia.

Often requested
with this expert:

Aluminum/ Materials Joining and Product Manufacturing
Metal Casting, Aluminum
Aluminum Extrusion Industry- Turn Around Jobs, New Plant/...
Welding Engineering, Process Development, Welding...

Year   Degree   Subject   Institution  
1988   PhD   Materials Engineering   Drexel University  
1966   MS   Metallurgical Engineering   University of Pittsburgh  
1962   BS   Metallurgical Engineering   University of Pittsburgh  

Work History:
Years   Employer   Department   Title   Responsibilities

1998 to


(Undisclosed Consulting Company)





Expert is a consultant on aluminum allloy selection and heat treatment, and an expert witness on failures of aluminum alloy products.

1981 to 1998




Technical Center


Chief Scientist - Aluminum Alloys


Expert served as director of R&D for alloy and heat treatment development. He also acted as a consultant to plants for various problems.

1979 to 1981


Alcoa's Lafayette Works



Chief Extrusion Metallurgist


Expert was in charge of all metallurgy and quality control for commercial and aerospace extrusions.

1963 to 1979


Alcoa Technical Center



Engineer/Senior Engineer/Group Leader/Section Head


Expert worked on development of alloys and heat treatments.

1979 to 1981


Purdue University



Adjunct Professor


Expert taught the course "Physical Metallurgy of Aluminum Alloys".

Career Accomplishments:

Expert is a Fellow of ASM International, a member of TMS of AIME and past president of Structural Materials Committee, and a member and past president of Alcoa Chapter of Sigma Xi.

Professional Appointments

In 1996 Expert was named a Distinguished Alumnus of the University of Pittsburgh, Department of Materials Science and Engineering. He has served on committees to evaluate the metallurgy and materials sciences departments at Georgia Institute of Technology, Purdue University, and the University of Pittsburgh, and was recently named to the NASA Aeronautics and Space Technology Advisory Committee.


Expert has won several awards, including the Expert Douglas Gold Medal from AIME, the Edgar C. Bain Award from ASM International, and the Francis C. Frary, A. V. Davis, and Creativity Awards from Alcoa. He is also a four-time winner of R&D 100 Award.

Publications and Patents Summary

Expert has published over 80 papers, book chapters, and articles in technical encyclopedias, and has eight patents on aluminum alloys and heat treatments.

Selected Publications and Publishers  
 - Advanced Materials and Processes  
 - Proc. ICAA5, Aluminum Alloys--Their Physical and Mechanical Properties  
 - Progress in Astronautics and Aeronautics  
 - Proc. International Conference on Computer-Assisted Materials, Design and Process Simulation  
 - Journal of Physics  

Government Experience:
Years   Agency   Role   Description
1995 to 1998   NASA   Committee Member   Advised NASA on aluminum materials and processes

Consulting Services:
Selected Consulting Examples:
  • Expert often consults with R&D personnel at Alcoa Technical Center on the development of new alloys and processes.
  • Expert consults with several Alcoa operating divisions on technical problems in manufacture of aluminum alloy products.
  • Expert consults with Alcoa's and outside attorneys on patent matters.
  • Expert has acted an an expert witness for an aluminum extrusion company regarding a law suit involving failure of aluminum extruded tube.
  • Expert frequently advises TelTech clients on aluminum alloy selection, properties, and problems.
Recent Client Requests:
  • Expert in Metal for Aerospace.
  • Expert for consulting on Course Grain Extrusion Analysis.
  • Expert on 7050 aluminium alloy for consulting on 7050 alloy.
  • Aluminium forging expert for consulting on Aluminium aerospace alloy forging.
  • Alcoa metallurgy expert for consulting on Aluminum forming & heat treat.
  • Expert in Blistering in Heat Treat of 7075 0.040" gage extrusion.
  • Expert in Aluminum Alloy Properties to assist with materials and process questions.
  • Aluminum extruded expert for consulting on small light weight tubing.
  • Expert in aluminum for consulting on production of smooth & crack-free aluminum anodes.
  • Expert in Ul failure for consulting on electrical conductivity of aluminum lug.
  • Expert in aluminum for consulting on the physical/mechanical aspects of product fabrication and limiting corrosion.
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
Expert has been deposed several times regarding Alcoa patents, and has served as the chief witness in an Alcoa suit vs. Reynolds on patent matter. He has also served as an expert witness in a case involving an aluminum product failure.
Recent Litigation Client Requests:
  • Expert in Possible testifying retention (108383) by Plaintiffs' Counsel.
  • Expert in metal fracture analysis for consulting on alloy wheel and rim fracture.
  • Aluminum die casting expert needed for consulting regarding the cause of a aluminum alloy 380 failure.
  • Stretch wrap packaging expert for consulting on using stretch wrap for aluminum extrusion returns to manufacturer.
  • Expert in ISO expert witness On Aluminum Casting Technologies.
  • Expert satley north carolina dr. aluminum for consulting on expert witness for plaintiff in federal court i Ga.
Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

Market Research:
As sole owner of Scientific Software Services, Dr. Satley has developed software for education in Materials Science and marketed the programs around the world.

Click the green button above to contact Expert for a free initial screening call regarding your marketing research, industry research, and company research needs.  For research needs involving multiple experts or secondary research, a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:

Expert has delivered a lecture on the Physical Metallurgy of Aluminum Alloys to Alcoa metallurgists, graduate students at Purdue University, and to metallurgists at an ASM International Sponsored Course. He also has developed a seminar on the Heat Treatment of Aluminum Alloys sponsored by TMS of AIME (Feb 2001).


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