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 Expert  108185

Expert in Aluminum/Materials Joining and Product Manufacturing

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 extensive knowledge and experience in most processes and methods for joining aluminum, having numerous technical publications, presentations, and patents in the area. He consults with clients on process and equipment selection as well as troubleshooting existing operations. Fusion joining processes in which he is familiar include GMAW, GTAW, electron beam, laser, torch, and resistance spot. He is knowledgeable of many brazing and soldering applications such as flux furnace, dip (salt bath), controlled atmosphere flux (CAB), fluxless vacuum and inert gas brazing, and flux and fluxless ultrasonic soldering. In the area of solid state joining, Expert is familiar with cold pressure, resistance butt, induction, friction, friction stir, and magnetic impelled arc butt (MIAB) welding, as well as diffusion bonding. He has worked with mechanical fasteners including clinches, rivets, and threaded fasteners. His experience in aluminum adhesive bonding extends to pretreatments, thermosets, thermoplastics, and anerobics.

aluminum fusion welding


aluminum welding


aluminum brazing



Expert has expertise in forming and machining aluminum product forms. He has assisted clients regarding the effects of alloy and temper on forming and machining response and in cost-effective selection of aluminum product forms and fabrication processes. His knowledge of component fabrication includes sheet metal forming processes (stamping, blanking, stretch forming, hydroforming, bending roll forming, magneform, tool design, and grid stain analysis) as well as metal removal processes (turning, milling, cutting, and chemical milling).

aluminum alloy


aluminum forming


aluminum machining

Expert has extensive experience integrating design, prototyping, performance evaluation, and manufacturing process aspects of aluminum-based products. Areas in which he has provided assistance include new product ideation; design for functionality and manufacturability; project/venture value analysis; rapid and cost effective prototyping; product form, alloy and temper selection; manufacturing process selection; and invention and development of manufacturing processes.

aluminum product


aluminum product design

Having a broad knowledge of new product and manufacturing process development, Expert's has provided designs for automotive, transportation, aerospace, and machinery industries. He was the principal developer of processes for the manufacture of aluminum automotive heat exchangers; these include radiators, heater cores, engine oil coolers, air change coolers, A/C condensers & evaporators, and cold plates. He was also the principal developer of fluxless brazing and soldering processes.

fluxless aluminum brazing


fluxless soldering

Applying his knowledge of aluminum to the automotive industry, Expert has developed autobody stuctures. He designed monocoque and space frames fabricated from multi product forms, sheet, extrusions, and castings. Assembly methods with which he is familiar include resistance spot welding, weld bonding, mechanical fasteners, gas metal arc welding, MIAB welding, and magneform. He is experienced with the common infrastructure (steel & aluminum) assembly concept based on resistance spot welding. In addition to his expertise in autobody structure, Expert has designed integral and modular blocks with thermal sprayed bore coatings for use in engine blocks. Lastly, he has developed cast brake rotors with thermal sprayed wear surfaces.

aluminum alloy welding


gas-metal arc aluminum welding


thermal spray technology

Expert has interfaced with clients in the development and prototyping of various products, including bowling pins; bicycles/motorcycles; cooking utensils; residential air conditioning and refrigeration components; and boats/personal water crafts. He adapted, refined, or invented the required assembly and manufacturing processes for these products.

aluminum bicycle


consumer product

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Pittsburgh, Pennsylvania;  Youngstown, Ohio;  and Canton, Ohio.

Often requested
with this expert:

Aluminum Alloys
Welding Engineering, Process Development, Welding...
Metal Casting, Aluminum
Resistance Welding, Laser Welding, Arc Welding, Ultrasonic...

Year   Degree   Subject   Institution  
1963   B.S.M.E.   Mechanical Engineering   University of Pittsburgh  

Work History:
Years   Employer   Title  

1996 to



Independent Consultant


1966 to 1996


Aluminum Company of America (ALCOA)


Technical Consultant


1963 to 1966


Westinghouse Electric Corporation - Bettis Atomic


Design Engineer


Career Accomplishments:

Expert is a member of many professional societies, including Sigma Xi, Society of Automotive Engineers, Society of Manufacturing Engineers, American Welding Society, and the American Society for Metals.


He is a Registered Professional Engineer with a Pennsylvania license.

Professional Appointments

Expert served on the Board of Trustees for the Edison Welding Institute (1989-96).


He is the recipient of the Arthur Vining Davis award for "Development of Aluminum Automotive Spaceframe" and was elected a Fellow of ASM International.

Publications and Patents Summary

Expert has thirteen U.S. patents in the areas of aluminum joining, surface treatment, and product developments.

Selected Publications and Publishers  
 - International Body Engineers Conference and Proceedings  
 - Society of Automotive Engineers. SAE paper  
 - Manufacturing Review  
 - American Society of Testing and Materials Special Technical Publication  
 - Welding Journal  

Consulting Services:
Recent Client Requests:
  • Expert for consulting on Alunimun Fintube Brazing.
  • PET molding expert for consulting on Help develop braze process for assembly of small cutting tools.
  • Expert in photochemical etching of miniature aluminum parts, anodization, vendor search and process qualification needed for consulting.
  • Welding expert to recommend welding procedures for aluminum bus in a high voltage substation..
  • Metallurgy expert for consulting on root cause determination for sorter monorail wear.
  • Aluminum expert for consulting on fluxless brazing of aluminum.
  • Expert for consulting on Alloy selection for.
  • Expert furnace brazing for consulting on Furnace Brazing.
  • Expert for consulting on Al-alloy selection and laser micro-welding.
  • Expert in Aluminum Alloy Properties to assist with materials and process questions.
  • Alcoa metallurgy expert for consulting on Aluminum forming & heat treat.
  • Expert for consulting on Aluminum and Copper joining processes.
  • Aluminum welding expert for consulting on 5083 to 6061 flange welding.
  • Aluminum welding expert for consulting on Aluminum Sheetmetal Warping during Weld.
  • Machine shop with expert services for consulting on Sheet Metal Shop.
  • Expert in aluminum brazing & weld issues for an aerospace oil cooler.
  • Aluminum brazing expert for consulting on aluminum brazing.
  • Expert in aerospace rated rivets for consulting on determining what are the proper tools and methods of installation.
  • Aluminum welding expert for consulting on Oil Heated Rotational Molds.
  • Expert in aluminum for consulting on polished or anodized sheets.
  • Aluminum welding expert expert for consulting on t,y, and k aluminum welding.
  • Expert in aluminum welding to assist withWelding 5"x5"x1.5" 6061-T6 plate into 0.2" thick aluminum tube process validation.
  • Welding process expert for consulting on AL TIG welding.
  • Aluminum welder expert for consulting on aluminum welding--porosity issues.
  • Metal welding expert for consulting on machine frames and tubing.
  • Expert in zinc soldering for consulting on soldering to aluminum-doped zinc oxide.
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:
Recent Litigation Client Requests:
  • Commercial trailer design expert witness for consulting on Commercial Trailer Design.
  • Expert in brazing wire design for litigation.
  • Expert in Possible testifying retention (108383) by Plaintiffs' Counsel.
  • Expert satley north carolina dr. aluminum for consulting on expert witness for plaintiff in federal court i Ga.
  • Expert in aerospace applications for consulting on hermetic dissimilar metal electrical connectors.
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.

International Experience:
Country / Region   Summary
United Kingdom   Expert was the Alcoa corporate contact with TWI (British Welding Institute).
Japan   He was the principal technical contact with Kobe Aluminum (Alcoa joint venture partner) on all joining technology issues.
Europe   Expert has extensive experience working in Europe, specifically Germany, England, and Sweden. In Europe, he had major responsibility for the assembly of aluminum prototype cars at a major auto manufacturer.

Additional Skills and Services:
Supplier and Vendor Location and Selection

Expert has experience providing vendors of: aluminum joining, welding, brazing, and heat treating; equipment forming, stamping, blanking, bending, and tooling.


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