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 Expert  107990

Expert in Thermal Spray Technology and Coatings/Thermal Plasma Processes

Available for your Consulting and Expert Witness Needs

Pennsylvania (PA)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness

Summary of Expertise: Listed with other top experts in: 
Expert has worked with HVOF combustion spray processes for the last six years. He has hands-on experience with the Jet Kote (TM) and JP-5000 systems, and he has also worked with samples from the CDS (R) and TopGun (R) systems, spraying metallic (80/20 NiCr), carbide (WC/Co; Cr3C2/NiCr), and ceramic (Al2O3, Al2O3/TiO2) corrosion and wear-resistant materials. Expert has experience in the HVOF spraying of polymeric and polymer/ceramic nanocomposite coatings. One of his current research areas is in residual stress in HVOF sprayed coatings. He developed a simple non-destructive test to measure relative residual stress. Currently, Expert is conducting research to correlate work with X-ray stress measurements and key process parameters such as particle velocity, measured by laser stroboscopy.

high velocity oxy-fuel spray coating process

Employing his electrical engineering background and plasma device research experience, Expert has designed, developed, and operated several laboratory and industrial scale transferred-arc DC furnace systems used for melting metals or for extractive metallurgy (smelting). He has designed and built plasma reactors and furnaces, DC plasma power supplies, and associated electrical control systems. One of his major contributions, stemming from his PhD research work, has been in the area of multiple arc systems, which permit stable operation and coalescence of multiple free-burning arcs or gas-stabilized plasma torches operated from either single or multiple power supplies. Some systems based on these principles have been developed for commercial use. Expert's most recent work on plasma melting was the cold hearth transferred-arc melting of reactive metals, such as Ti and Ti6Al/4V, as an alternative to electron beam melting/refining.

plasma melting

In recent years, Expert's background in thermal plasma devices and technology has been directed in the area of plasma processing of materials. He has focused on plasma sprayed metallic, composite, or ceramic coatings for protecting surfaces against the harmful effects of wear, corrosion, or thermal degradation. He is experienced in the plasma spray forming of structural deposits and refractory metals; reactive plasma spray synthesis of advance materials; and RF induction-coupled plasma (ICP) treatment of materials. In the latter case, Expert led a two-year program that developed a novel RF plasma-driven process which successfully demonstrated the feasibility of such a process for converting selected hazardous military wastes to potentially usable materials. This work was subsequently scaled up by an industry partner to a full-scale, 600 kW level. This research has led to new, ongoing, research on the plasma recycling of polymeric waste.

plasma processing


plasma spray


plasma spraying


plasma surface treatment


plasma torch

Expert's expertise in plasma and HVOF technology has enabled him to extend his knowledge to all the major thermal spray processes. These processes include APS, VPS, shrouded plasma, reactive plasma synthesis, HOVF, wire-arc, and conventional flame spray. He has a broad knowledge of the coating applications these processes are used for. Additionally, he has a thorough understanding of the key process/structure/property concepts important in thermally sprayed coatings. This includes the key coating characterization and testing procedures: metallography, optical microscopy, X-ray diffraction, etc. Expert is currently Director of the Center for the Plasma Processing of Materials (CPPM), one of the world's leading university-based thermal spray/plasma processing research centers. The CPPM conducts fundamental and applied R&D on thermal spray coatings and plasma processing of materials. Expert has established a program of "services" that provides technical assistance to small- and medium-sized companies.

thermal spray coating process


thermal spray technology


thermal spraying carrier gas

Expert has worked with twin wire-arc spraying of metallic materials for a number of years, and is familiar with spraying of materials including Al, Zn, NiCr and some cored wires. His primary expertise is with the Tafa 9000 series equipment.

electric-arc spraying

Expert's lab and research has involved LPPS® or VPS for more than a decade, including the deposition and spray forming of reactive and refractory materials such as Ti, W, Ta, Re, NiTi, and related alloys.

low-pressure plasma spraying

Expert is recognized as an extremely capable writer, editor, and proofreader.

technical writing

Expert has over 10 years experience in the thermal spray field as a researcher and as an educator. His studies of electric arc and plasma technology provide a strong background in this technology area. He is currently Vice President of ASM International's Thermal Spray Society and has been a member of the TSS Board for several years.

thermal spray coating material

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: New York, New York;  Yonkers, New York;  Newark, New Jersey;  Jersey City, New Jersey;  Paterson, New Jersey;  Elizabeth, New Jersey;  Trenton, New Jersey;  Philadelphia, Pennsylvania;  Allentown, Pennsylvania;  and Baltimore, Maryland.

Often requested
with this expert:

Non-Stick Coatings, Thermal Spray Coatings
Tribology, Wear, Coatings, Materials Selection, Materials...
Corrosion and Metallurgical Failure Analysis
Polymer Coatings, Adhesives Development, Polymer...

Year   Degree   Subject   Institution  
1985   PhD   Electronic and Electrical Engineering   Loughborough University  
1978   MSc   Electroheat and Industrial Process Heating   Loughborough University  
1977   BSc (Hons)   Electronic and Electrical Engineering   Loughborough University  

Work History:
Years   Employer   Department   Title   Responsibilities

2009 to


(Undisclosed University)


Materials Science & Engineering


Teaching Professor


Expert is also the Associate Department Head of the MSE department and Undergraduate Program faculty advisor.

2002 to 2009


Expert's University, Center for the Plasma Processing of Materials (CPPM)


Materials Science and Engineering


Auxiliary Professor


Expert was Associate Director of the Drexel Plasma Institute (DPI).

1980 to 2004







Plasma device design for steel melting.

1996 to 2002


Expert's University, Center for the Plasma Processing of Materials (CPPM)


Materials Science and Engineering


Research Professor


CPPM Director, 1997-2010. Plasma treatment/destruction of waste.

1992 to 1996


Expert's University, Center for the Plasma Processing of Materials (CPPM)


Materials Engineering


Research Assistant Professor


Thermal spray projects in CPPM.

1989 to 1992


Expert's University, Center for the Plasma Processing of Materials (CPPM)


Materials Engineering


Research Associate


Thermal spray and plasma melting projects in CPPM.

1985 to 1989


University of Minnesota


Mineral Resources Research Center


Post Doctoral Fellow


Plasma smelting and in-flight plasma treatment of metallic and ceramic materials at power levels up to ~1 MW.

Career Accomplishments:

Expert is a member of the IEE (UK), a Chartered Engineer (C. Eng.), a Fellow of ASM International (2003), a Fellow of Alpha Sigma Mu (2009) and a member of IEEE, TMS, ACers and AIST. He was Vice-President (2002-04)/President (2004-06)/Immediate Past-President (2006-08) of ASM International's Thermal Spray Society (TSS) , and served as s Trustee of ASM International (2009-12).

Professional Appointments

He has served as a proposal reviewer for NSF, a member of the editorial board of Plasma Chem. and Plasma Processes (1999-2010), and the Journal of Thermal Spray Technology (JTST).


Expert received the Instructor of Merit Award, ASM International (2000). He is a Fellow of ASM International (2003) and Alpha Sigma Mu (2009). He received the College of Engineering Outstanding Auxiliary Faculty award in 2007, the Harold M. Myers Award for Outstanding Service to the University in 2009, and was the Philadelphia Liberty Bell Chapter of ASM International's Delaware Valley Materials Person of the Year in 2007. He was recipient of the 2010 Albert Sauveur Award & Lecture, 2012 Eisenman Award & Lecture and 2015 Meritorious Service Award from the Philadelphia Liberty Bell Chapter of ASM International.

Publications and Patents Summary

He co-holds three patents, more than 90 publications, and has given more than 90 presentations at national and international conferences and meetings.

Selected Publications and Publishers  
 - European Congress on Thermal Plasma Processes  
 - Welding Journal, American Welding Society  
 - International Materials Reviews  
 - International Symposium on Plasma Chemistry, International Union of Pure and Applied Chemistry  
 - Proc. IEE  

Government Experience:
Years   Agency   Role   Description
1990 to   NSF   Reviewer   Expert has served as a proposal reviewer for NSF and has served on several SBIR panel reviews in the area of coating and waste technologies.

Consulting Services:
Recent Client Requests:
  • Non-stick coating expert for consulting on abrasive resistant coating.
  • Expert in intota for consulting on Metco Sprabronze AA with 405NS Bond.
  • Powder flux expert for coating soldered preforms.
  • Expert in polyurethane processing for consulting on covering rolls and other shapes to provide an extremely tough long wearing surface.
  • Expert in MSS for consulting on the hi-production (quick-dry) drying of an exterior wood product.
  • Carbide expert for consulting on tungsten carbide failure.
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:
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.

Language Skills:
Foreign Language   Description
French   Expert can read French at "O-level."

Additional Skills and Services:

Expert was co-instructor of ASM International's three-day thermal spray technology course for ~10 years, teaching in Germany, Singapore, Japan, Canada, France, and the USA.

Supplier and Vendor Location and Selection

He has experience locating vendors of thermal spray coating technology and thermal plasma technology.

Other Skills and Services

Academic Course Assessment and ABET.


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