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 Expert  722731

Expert in Copper Alloys: Continuous Casting Equipment, Consulting, and Supplies

Available for your Consulting and Expert Witness Needs

Ohio (OH)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
Expert has 40 years of experience in designing, building, installing, and operating continuous casting plants. His plants are in America, Europe and Asia. Most plants are for copper and copper alloys in the form of billet, tube, plate, coils, rod and other shapes. He has patents related to continuous casting and has granted licenses worldwide.

continuous casting equipment


continuous casting


copper alloy


journal bearing

Expert has developed spinodal copper alloys, copper anodes for semiconductor plating, and other commercial alloys. He has extensive data related to copper alloy properties and production.

copper alloy data


copper alloy mechanical property


copper alloy property

Expert has made and installed horizontal continuous casters for copper, brass, bronze, and cast iron.

horizontal continuous casting

Expert notes that many of the casting plants produce copper alloys for sleeve bearings and bearing cages. Expert is expert in the application of copper alloys to bearing applications.

metal bearing

As an adjunct to the continuous casting plants, Expert has built centrifugal casting equipment for copper alloys.

metal centrifugal casting

Expert has complete knowledge of the heat treatment of most copper alloys, and has developed special heat treatments for spinodal and alpha/beta brass alloys.

nonferrous metal heat treatment

Most of Expert's billet casting machines employ his unique and inexpensive mold designs. From small billets to 10" copper billets casting 12,000 lbs./hr, his mold designs have proved successful.

semi-continuous casting mold design


foundry machine

All of Expert's copper alloy continuous casting plants incorporate induction melters with features such as argon shield, refining, and degassing techniques. Each plant is equipped with induction furnaces built to his specification.

copper alloy melting

Expert pioneered in the continuous casting and heat treatment of aluminum bronze. Further to building continuous casting equipment for aluminum bronze, he has developed commercial heat treatments for the full spectrum of those alloys from 8% aluminum content (alpha alloys) for forming operations to 16% aluminum content (alpha/beta/gamma2 alloys) for wear applications.

aluminum bronze

Expert has consulted on manufacture of most wrought and cast brass alloys. He has developed grain refining materials for brass alloys.



leaded brass

Throughout his experience with copper alloys, Expert has consulted on many brass corrosion problems such as stress corrosion cracking, dezincification, dealuminization, and other problems related to brass and corrosive media.

brass corrosion


nonferrous metal melting

Expert holds patents for fine grain development in continuous cast copper alloys. Further, he has developed metal additives to grain refine cast alloys.

brass grain refinement

Expert has built several reclamation systems for metal slag (dross). The equipment can be either wet or dry systems. He also will buy and dispose of material to be reclaimed.

brass recycling

As well as producing every bronze alloy listed in the CDA, Expert has developed special bronzes for gears, sleeve bearings and other hardware—all now in commercial use. He developed spinodal bronzes to replace other copper sleeve bearing alloys used in heavy equipment.



wrought bronze

Expert has developed bronzes for specific applications such as 30% leaded bronze for fuel pump bearings, spinodal bronze for oil well drill bit bearings, and aluminum bronze and manganese bronze bearings for heavy equipment. He has built bearing test equipment for evaluation of sleeve bearing properties. Expert has developed and produced bronze sleeve bearings for many uses, including high-speed fuel pump and supercharger bearings to large heavy-duty bearings for off road equipment.

bronze bearing

Over 40 years, Expert has supervised and owned bronze casting foundries. He has worked with sand casting, chill casting, centrifugal casting, continuous casting and permanent mold casting. He is responsible for many developments in sand additives, mold materials, melting equipment and patterns.

bronze casting

Expert consults constantly on which materials to use with various corrosive media. He has many case histories related to alloy selection for corrosive environments.

bronze corrosion

All Expert's foundries and mills were fitted with reclamation equipment of his design. He has developed and sold several wet and dry systems for reclaiming metallics from foundry and mill residues.

bronze recycling

Expert has identified many causes and cures for casting defects. His metallographic examinations and conclusions have resulted in changes to eliminate casting defects such as shrinkage porosity, gas porosity, hot shortness, and other defects.

casting defect

Much of the copper alloy produced by Expert's plants require finishing and cleaning. He has developed both organic and inorganic cleaners, tailored to specific alloys.

copper alloy cleaning

Expert developed and produced a novel copper nickel alloy that successfully withstood seawater and turbulent corrosion. He has consulted on corrosion problems with several manufacturers of bearings, propellers and marine hardware.

copper alloy corrosion

Expert's development of copper alloys has been mainly on property improvement by grain refinement, heat treatment or composition variation. Most mills producing aluminum bronze and manganese bronze use his preferred compositions within specification. Also his patented grain refinement for continuous castings has improved the properties of several alloys used for gears and high-speed sleeve bearings.

copper alloy development

Expert's processing experience includes casting, drawing, machining, extrusion, rolling, and finishing of copper alloys. Most of his consulting work involves continuous casting, machining, drawing, and extrusion.

copper alloy processing

Expert has developed copper casting (99.9%+) for most founding methods. He has perfected melting schemes, deoxidizers, and degassers. He has been successful producing oxygen free continuous cast copper rod and tube.

copper casting

Expert's developments and patents have increased properties of copper alloys, well beyond their former typical features. Mechanical and chemical grain refinement as well as proprietary heat treatments have been applied to materials used for bearings, gears, bearing cages, and other hardware copper alloys. Several manufactures specify copper alloys made according to his criteria.

copper mechanical property

Copper and copper alloy melting information is part of Expert's operating history. He has information on melting all copper alloys, including melt treatments to yield optimum cast metal. He is experienced in all types of furnaces, basically concentrating on induction melting.

copper melting

Copper waste in the form of foundry residues or process scrap is dealt with in respect to Expert's reclamation operations. He has found many uses for copper waste, related to mixes for alloying.

copper waste

Expert has developed brass more resistant to dissolution of zinc because the castings or billets for wrought brass have been grain refined, providing thinner grain boundaries. After consulting on the problem for many years, he has convinced consumers to use corrosion inhibited brasses or other substitute copper alloys.


Expert has built and operated direct chill (DC) casters producing billets as large as 24" diameter. He has proprietary designs for molds superior to those supplied by other machine builders. He can supply complete plants--DC casters, water towers, pumps, heat treat furnaces, and laboratory equipment.

direct chill-casting

All of Expert's mills employ electric induction melters. He works closely with the largest furnace maker in the world when clients ask for melting equipment to be included in casting plant design. He is familiar with all aspects related to the melting process from refractories to molten metal treatment.

electric nonferrous-metal melting

Several years past, Expert developed a continuous cast copper alloy containing 30% lead that is now specified for most military and commercial aircraft fuel pump bearings. This alloy can only be produced using his patented die design. This development also has been adopted for the casting of high leaded supercharger bearings. The most important feature of these alloys is the very fine dispersion of lead particles throughout the metal matrix. Expert's fine grain, high-leaded continuous cast bronze bearings operate in 80,000 rpm exhaust-driven superchargers. He has worked with manufacturers, developing hydrodynamic bearing materials that must also operate at slow speeds without high wear. His bearing test equipment has been useful in evaluating high-speed hydrodynamic wear.

high-speed metal bearing


high-speed metal bearing technology

Expert's manufacturing experience affords complete case histories of metal failure analysis. He has worked with manufacturers and insurance companies, consulting on metal failure analysis. His findings have been the basis for fixing responsibility and cause for all types of metal failure.

nonferrous metal failure analysis

Expert has extensive knowledge regarding material selection for given applications. Manufacturers submit designs and operating parameters and he proposes and provides suitable material. Most applications involve copper alloys or steel.

metal material selection

Expert's operating experience has shown the correct heat treatment for copper alloys. He has discovered that many brasses can be strengthened by heat treatment, whereas the literature claims that is not possible. He is expert in developing required properties by heat treatment of aluminum bronzes, spinodal bronzes and other copper alloys.

nonferrous metal annealing

All of Expert's materials have been produced using the bearing design criteria contained in the CBI literature. Further, he has built and used bearing wear test machines to prove the value of various sleeve bearing materials. He developed and proof tested special spinodal bronzes to replace traditional materials.

bearing design

Although "copper" is a broad category, Expert has been involved in or has knowledge of most uses and production operations concerning copper. He has been on the ASTM committee for copper and copper alloys.


Expert has cast copper alloys by every means, including continuous casting, permanent mold casting, sand casting, centrifugal casting, rapid solidification casting, and zone refinement casting.

copper alloy casting

Expert has consulted on cases where he developed custom coatings for preventing corrosion. Also, with electric furnace makers, he has developed means to reduce corrosion in copper alloy components of water-cooled electric power supplies.

copper alloy corrosion inhibitor

Expert has manufactured many items in the traditional "gunmetal" alloy UNS C90500. He developed gear and bearing applications for this alloy.


Expert has developed and produced leaded tin bronzes for bearing, gear, and hardware applications. He has built several continuous casting plants for the manufacture of these alloys.

leaded-tin bronze

Expert has perfected the optimum composition for several manganese bronze alloys where it has been difficult to meet specified physical properties. He has built plants for casting manganese bronze. He has developed heat treatments for several manganese bronze alloys.

manganese bronze

He has assisted many foundries and mills, developing means to use residues and refine melts of nonferrous metals.

nonferrous metal refining

His experience related to tin bronzes covers the full spectrum from foundry operations, metallurgical properties, heat treatment and uses. He has built several casting plants for producing tin bronzes.

tin bronze

Using his patented continuous casting process, it is possible to produce bronze bearings for pumps and superchargers running at speeds in excess of 80,ooo rpm.

very high-speed metal bearing


cast alloy

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Detroit, Michigan;  Warren, Michigan;  Sterling Heights, Michigan;  Livonia, Michigan;  Dearborn, Michigan;  Westland, Michigan;  Columbus, Ohio;  Cleveland, Ohio;  Toledo, Ohio;  and Akron, Ohio.

Often requested
with this expert:

Foundry, Investment, Permanent Mold, Squeeze, Low Pressure,...
corrosion in plant,buildings, hvac, etc; Hi-Temp; surveys/...
Steel and Iron Casting Processes, Foundry Consulting,...
Metal Casting, Aluminum

Year   Degree   Subject   Institution  
1966   B.S.   Metallurgical Engineering   Case Institute Of Technology  

Work History:
Years   Employer   Department   Title   Responsibilities

1996 to 2004


Lakeside Industrial Products






Expert designs and sells continuous casting equipment, and consults for copper alloy application and manufacture.

1992 to 1996


Ampco Metals




Vice President Technology


He was responsible for developing copper alloy products and manufacture.

1984 to 1992






Vice President Manufacturing


Expert directed all sales and manufacturing operations.

1970 to 1992


Western Reserve Manufacturing






He was responsible for all sales and operations.

1960 to 1964


United States Steel Corporation


Steel Making Division




Expert was a foreman in the open hearth furnace division and in the rolling mill division.

Career Accomplishments:

Expert is a member of ASM.

Publications and Patents Summary

He has patents related to continuous casting of metals.

Consulting Services:
Selected Consulting Examples:
  • Expert consulted on, designed, and built continuous casting plants in the U.S., Mexico, France, Portugal, and China.
  • He researched and developed new copper alloys for BMP Industries, LLC.
  • Expert developed heat treatments for many copper alloys used in aerospace applications for Becotek Mfg.
  • He consulted on, developed, and patented a method of metal manufacture for the U.S. Navy.
  • Expert consulted on and developed manufacturing methods for aircraft fuel pump bearings at Sundstrand Corp.
Recent Client Requests:
  • Copper casting expert for consulting on Continuous strip casting of a lead free alloy for bearing production.
  • Bronze metallurgy expert for consulting on bronze composition, grain structure and processing.
  • Expert in bearing casting machines for consulting on cause and correction of casting defects.
  • Expert for consulting on Foundry.
  • Expert in comparison of lead lead bronze alloys.
  • Continuous copper expert for consulting on Info.
  • Expert in PTC Thermistor to assist with Gold Bonding and yield issues.
  • Expert in copper alloy forensic analysis for consulting on C87500 - si-bronze pump impeller failure.
  • Bronze bearing engineering expert for consulting on bronze sleeve bearing.
  • Expert in continuous cast molding for consulting on exporting molds to overseas market.
  • Copper tube technology expert for consulting on the cast-and-roll process used in manufacturing.
  • Expert for consulting on High power arc lamp power supply design consultation.
  • Expert in Copper continous casting and machining.
  • Copper Metallurgy expert needed for consulting on CDA 110 versus CDA 101.
  • Expert for copper, brass and zinc for consulting on downstream production.
  • Expert in bronze foundry for consulting on sand foundry Br-Ni-Al-C958000 and STD bronze C844.
  • Expert in copper corrosion reduction for consulting on copper corrosion inhibitor for brake fluid.
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 was an expert witness for Renault on accidents due to material failure.
Recent Litigation Client Requests:
  • Expert in PEX tubing for consulting on fitting failure due to dezincification.
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
1970 to 1970   Mexico   Expert designed, built, and installed continuous casting plant for copper billet in Monterrey.
1984 to 1984   France   He consulted on, designed, and built a continuous casting plant for Timco Vongy in Thonon.
1990 to 1990   Portugal   Expert designed, built, and installed copper anode continuous casters for Western Copper.

Market Research:
Expert developed sales programs for copper alloy products.

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:
Supplier and Vendor Location and Selection

He has extensive sources for copper alloy products.


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