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 Expert  725855

Expert in Aluminum Die Casting Operations, Metal Cleanliness & Die Lube Dillution and Application

Available for your Consulting and Expert Witness Needs

Tennessee (TN)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
Expert has more than 26 years experience working in aluminum die casting. Expert spent 20 years working for Doehlar Jarvis, working in their die cast department, where he manually ran the die cast machines, gaining the skills and knowledge necessary for producing fine quality aluminum castings. He has developed skills such as solder removal from dies, increasing the machines operational availibility, reducing cracks in castings, reducing porosity in castings and proper die lube application. Expert worked as a service technician where he set the dies and adjusted pressures and perameters ensuring that the die cast machines were ready for production runs. Also at Doehlar Jarvis, Expert spent 10 years working in their Quality Assurance department as a lab technician. In this capacidy he assisted the die cast department by metal testing, such as chemistry analysis, utilizing a spectometer for alloys such as 383, A383, 380, 356, and 319, grain size analysis, density testing, hardness testing and porosity analysis utilizing a fluoroscope machine. Expert has also performed sand test on foundry sands, such as PH determination, ADV {acid demand value}, grain fines and LOI {loss on ignition} to determine resin levels. He also monitored die lube dillution ratios via an evaporation test. Expert worked with metallurgists to lower scap rates by reducing porosity in aluminum die castings, reducing oxides in metal by a k-mold test. Expert has experience in metal cleanliness such as oxide removal and furnace cleaning.

Expert has spent another 6 years working for a Japaneese die cast company, as a Quality Assurance Associate, at this company Expert has done full layouts of aluminum die castings by reading blueprints and ensuring all dimensions are correct with the use of an optical scope, coordinate measuring machine, height gauges and a contour machine. Expert has performed CPK studies to verify the casting machines capability for production runs. Also Expert has worked with machining departments to verify tool changes and adjustments for a smooth machined surface of aluminum die castings.

Expert has experience in maintaining Quality certifications such as QS9000 and TS16949. Expert has experience in the calibration of spectrometer's, mixing of metals to achieve the proper alloy, degassing of molten metals, sedimentation testing of castings, impregnation of castings, surface testing of machined surfaces. Expert achieved a level 2 fluorocope certification and recieved a kaizen award in 2006.


metal chemical analysis


coordinate measuring machine




aluminum die casting


die casting


metal testing


quality assurance


aluminum solder


die casting lubricant


die castings


die lubricant


die-casting die

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Knoxville, Tennessee;  Johnson City, Tennessee;  Asheville, North Carolina;  and Greenville, South Carolina.

Often requested
with this expert:

Metal Casting, Aluminum
Die Casting Machinery, Die Cast Trim Presses, Die Casting...
Aluminium, Magnesium, and Zinc High Pressure Die Casting
Manufacturing and Quality of Casting Methods, Problem...

Year   Subject   Institution  
2005   Diecast Opperation/QA Inspection   Doehlar Jarvis  

Work History:
Years   Employer   Department   Title   Responsibilities

2006 to 2012


Kawasaki TN.


Quality Assurance


Quality Assurance Associate


Expert has done final Inspection of castings, used a cmm to verify dimensions, used a spectrometer to analize alloys, used an optical scope to verify dimensions,

1986 to 2006


Doehlar Jarvis


Quality Control


Lab Technician


Expert operated diecast machines for ten years, worked in a testing lab for ten years, adjusted pressures parameters, set up die cast machines and troubleshot problems. Tested alloy metals for chemistry content, grain refinement, hydrogen content, oxides ect. Used a Flouroscope machine to monitor porosity in castings. Helped to solve many porosity problems.

Career Accomplishments:

Level 2 Flouroscope certificate, 2006 kaizen award continual improvement


2006 Kaizen award

Publications and Patents Summary

Just finished writing a book about "The Aluminum Die Cast Process" and in the process of having it published.

Consulting Services:
Selected Consulting Examples:
  • A diecast engineer who was new at his company came to him often for advice on diecast problems or issues, because he new the expert had operated a diecast machine for many years. The expert offered advice on porosity reduction.
  • He advised his plant to install a filter in holding furnace to prevent oxides from being poured into castings.
  • He suggested self-analysis of all incoming sows or ingots, never trust vender samples when buying metal.
  • He gave advice to a company on how to melt scrap AC2B metal and pour it into ingot molds and sell it as certified AC2B metal instead of selling it for scrap.
  • He introduced density testing to a plant to check for porosity in castings. He also offered advice on doing k-mold tests on molten metal to check for oxides. He done a test on the dilution of die lube. This was a three month study in wich data was colected, graphed and submitted to the compay. This test proved that improper die lube ratio's caused dies too solder more and need to be polished more often. The company was pleased with the results.
Recent Client Requests:
  • O-ring expert for consulting on Concentric O-ring Seals in Diesel between Aluminum / Plastic.
  • Expert in intota for consulting on Aluminum Die Cast process.
  • Casting expert firms for consulting on Die-Cast Supply Plant Qualification resource sought.
  • Expert in surface finishing consult for consulting on Aluminum die cast consumer product.
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:
  • Expert in 721787 for consulting on Low Pressure Die Casting Machine.
  • Expert in ISO expert witness On Aluminum Casting Technologies.
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:
Machines should opperate efficiently and profitably.

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:

Achieved level 2 flouroscope certificate, spc training, blueprint reading, GD&T

Supplier and Vendor Location and Selection

Prior experience: Contacts, coworkers, known suppliers, known products that work.

Other Skills and Services

Strive to boost employee morale and rapid continual improvement of the company.


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