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 Expert  722597

Expert in Steel and Iron Casting Processes, Foundry Consulting, Metallurgy, and NDT Non Destructive Testing

Available for your Consulting and Expert Witness Needs

Wisconsin (WI)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
Expert has extensive foundry experience with a strong emphasis in melting steel using both acid and basic processes. He developed metallurgical and operational melting procedures that optimized the acid and basic slags. He is very familiar with the use and abuse of oxygen to refine steel.

Expert has worked in research to develop new steel alloys for high hardness and toughness applications. He has also considerable expertise in analyzing microstructures and relating to process issues in heat treatment. He has developed metallurgical and process specifications for alloy steel including melting, refining, heat treatment and welding.

Expert has developed hundreds of weld procedures for steel castings and is familiar with ASTM A488 and ASME Sec IX for procedure qualifications. His procedures have been accepted by DOT, Military, Railroad, Mining and Oil and Gas market sectors.

Expert has developed metallurgical and foundry procedures for austenitic, ferritic, martensitic and duplex stainless steel castings. The procedures include melting in arc furnace and induction furnace, deoxidation, heat treatment and welding. He has developed these at a foundry during his 10 years in the metallurgical and quality departments and with many other foundries and OEM's during his more than 10 years of consulting.

The brinell hardness test is commonly used for assessing the hardness of ferrous castings. Expert has performed guage R&R and developed procedures for such testing.

Expert is very familiar with surface preparation after excavating a defect either by carbon arc or grinding. He has conducted numerous repair procedures for arc melting of steel by tungsten inert gas, flux cored or manual metal arc welding. He is familiar with the application and limitation of each process.

Expert has approximately 25 years of experience in research, manufacturing, development, management and testing of carbon steel, low alloy and stainless steel and manganese steel.

Expert has extensive experience analyzing casting defects determining root cause and implementing corrective actions. Over the last 10 years he has helped analyze processes in foundries to identify process or procedure issues to improve productivity, quality and safety.

Expert has developed casting specifications for engineers to ensure that the quality of the finished casting meets the customers' expectations. He has also been retained as an expert witness in litigation cases involving failed castings.

Expert is very familiar with all alloy steel castings including carbon, carbon manganese, manganese molybdenum, chromium molybdenum, nickel chromium molybdenum.

Expert has developed equipment and procedures to enhance the cleanliness of steel castings. One particular technology he helped develop was plasma refining of steel.

Expert has considerable experience in heat treatment including annealing, stress relieving, quench and tempering, normalizing, solution annealing, preheating and post heating.

Expert has considerable experience with first article casting requirements including foundry engineering, solidification modeling, and non-destructive testing procedures (radiography, ultrasonic, magnetic particle, liquid penetrant and visual). He is also familiar with destructive testing of castings both from a soundness and mechanical property assessment.

Expert has consulted with many iron foundries to improve the process for quality or productivity reasons.

Expert is very familiar with tensile, charpy and fracture toughness testing for steel castings. He has perfomed testing in very heavy sections and analyzed microstructures to correlate results. He is also familiar with hardness testing including rochwell, brinell and equotip.


acid slag


basic slag


electric ferrous-metal melting


ferrous metal melting


ferrous metallurgy


metal casting


steel foundry


steel melting


high-alloy steel


low-alloy steel


arc welding


wire welding


austenitic stainless steel


austenitic steel


martensitic stainless steel


metallurgical engineering


steel manufacturing


Brinell hardness test


carbon dioxide arc welding


flux-cored arc welding


repair welding procedure


shielded arc welding


carbon steel


Hadfield manganese steel


low-carbon steel


casting defect


casting process


steel casting defect


casting specification


casting technology


chromium-molybdenum steel


plain-carbon steel


clean steel


ferrous metal annealing


ferrous metal heat treatment


steel annealing


first article inspection


nondestructive test


ultrasonic testing


iron foundry


metal mechanical behavior


metal mechanical property




Rockwell hardness test

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Chicago, Illinois;  Rockford, Illinois;  Aurora, Illinois;  Naperville, Illinois;  Joliet, Illinois;  Elgin, Illinois;  Milwaukee, Wisconsin;  Madison, Wisconsin;  Green Bay, Wisconsin;  and Kenosha, Wisconsin.

Often requested
with this expert:

Manufacturing and Quality of Casting Methods, Problem...
Metallurgical Engineering, Materials Processing, Materials...
Minerals Preparation for Iron and Steel incl. DRI,...
Steel Foundry, Steel Manufacturing, Alloy Steel, Abrasion...

Year   Degree   Subject   Institution  
1982   B. Sc   Metallurgy   University of Strathclyde  

Work History:
Years   Employer   Title   Responsibilities

2000 to






He is president and founder of Expert's Firm a global metallurgical consulting company specializing in foundry processes and metal castings. Major activities are technical consulting to foundries and OEMs, foundry turnarounds, expert witness and training.

1997 to 2000


Process Metallurgy International, Inc


VP Technology


His duties included metallurgical consulting and R&D related to clean steel technology. Other responsibilties were marketing of cupola software, Electric Power Research Institute (EPRI) foundry engineering assessments and energy process audits.

1995 to 1997


Nupro Corporation


Metallurgical and Process Consultant


He was responsible for setting up a foundry consulting division. Other responsibilities included flux consultant for large integrated steel mills and minimills, and R&D for clean steel technologies. He was also involved in the development of a plasma aluminum low dross melter.

1985 to 1995


Maynard Steel Casting Company


Chief Metallurgist


He was responsible for all metallurgical processes and procedures including melting, heat treatment, welding and NDE/NDT for steels, stainless steels and austenitic manganese steels. He performed significant research and development in heavy section castings and is an authority in this field.

1983 to 1985


Steel Castings Research and Trade Association (SCRATA)


Technical Officer - Metallurgy and Quality


He conducted research on high alloy steel castings, non destructive techniques and performed failure analyses. He was the lead researcher on a steel casting cracking project.

Career Accomplishments:

He is a member of the American Foundry Society (AFS), the Iron and Steel Society (ISS), the American Society of Materials (ASM) and a former member of American Society of Testing and Materials (ASTM).


SNT-TC-1A Level III in Ultrasonic Testing (UT) and Magnetic Particle Testing (MT). Level II in liquid penetrant testing (PT).

Professional Appointments

Present chairman of national AFS steel division. Former member of Steel Founders Society of America (SFSA) Specifications Committee. Former Co-sponsor of ASTM A 609 Ultrasonic Testing of Steel Castings.


EPRI Innovators award. R&D 100 Award.

Publications and Patents Summary

He has more than 20 publications and given technical presentations at international conferences.

Selected Publications and Publishers  
 - SME  
 - Iron and Steel Society  
 - Engineered Casting Solutions  
 - Metal Casting Technology Center Industrial Symposium  

Government Experience:
Years   Agency   Role   Description
2004 to   DOT   Welding Engineer   He prepared welding procedure specifications (WPS) and qualifications (PQR) for steel foundry and DOT.
1992 to 1995   DOD   Welding engineer   He prepared and administered weld procedures for ballistic testing.
1992 to 1995   Corps of Engineers   Metallurgist   He designed alloy steels for high strength and excellent impact toughness.
1985 to 1997   DOC   Metallurgist   He performed research and development of casting processes to improve steel cleanliness.

Consulting Services:
Selected Consulting Examples:
  • He performed a quality and process audit of a large steel foundry and made recommendations to owners and implemented procedures to successfully turn-around the business.
  • He assessed all the plant activites at major gray iron and ductile iron foundries to improve quality, productivity and profitability.
  • He performed a due diligence assessment of the operations, equipment and processes for the buyer of a major steel foundry.
  • He modified the melting, pouring and melting processes to improve the quality in stainless steel castings and nickel based castings.
  • He developed specifications for an OEM for the successful production of large steel and gray iron castings.
Recent Client Requests:
  • Expert in Casting needed.
  • Expert in witness ductile iron casting for consulting on Witness of castings for Ductile Iron Pump Case.
  • Steel casting design expert for consulting on casting design to determine if correct and manufacturable.
  • Steel casting expert for consulting on replacing a large upper crosshead of a forging press.
  • Steel boiler expert for consulting on cupola liner structure failures.
  • Electric induction casting expert for consulting on Induction Casting Furnace and engergy usage reduction.
  • Iron foundry expert for consulting on iron foundry process improvement.
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:
He has been an expert witness in 3 litigations involving casting failures and foundry asbestos claims.
Recent Litigation Client Requests:
  • Steel industry expert for consulting on steel quality control in litigation.
  • Expert for consulting on Blast Furnace.
  • Expert steel alloys for consulting on patent dispute involving a hypodermic canola.
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:
Years   Country / Region   Summary
1997 to 1998   Spain   He performed research and development of microalloys for digger and dredge teeth castings for wear and impact properties. He was involved with the design of the alloys, the melting, pouring, molding and heat treatment of test blocks and castings. Some of the work was perfomed in Spain and some in America over the period.
1999 to 1999   Czech Republic   Audited and evaluated foundries for capabilities of producing large steel castings for OEM.
2004 to 2004   South. Korea   He audited a foundry to determine capability to produce crane castings for OEM in America.
2001 to 2001   Canada   He improved the process for making low and high alloy steel castings.
1996 to 1996   Switzerland   He presented the results of a cost benefit analysis study (CBA) made in the automotive industry concerning three different materials for engine blocks - gray iron, aluminum and compacted graphite iron.

Market Research:
He has experience for establishing a sales and marketing program related to foundry technical software.

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:

He has developed and presented training courses for the Cast Metals Institute (CMI)in: Direct Arc Melted Iron and Steel Casting Finishing and Cleaning Metallurgy of Cast Steel Induction Melting of Cast Steel.

Supplier and Vendor Location and Selection

He has evaluated foundries capabilities to produce castings for OEM companies and recommended foundries to casting buyers.

Other Skills and Services

He has performed numerous failure analyses on many types of casting components including oil related, trucking, mining, cement, defense, railroad and automotive. He has experience with simulation softwares for steelcastings.


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