Select optimal material after thorough review of Physical, Mechanical, Component Elements, Electrical, Thermal, Chemical, Optical, Processing and Descriptive properties. (Material: Metals & Alloys. Polymers, Carbon/Carbon Composites and other Non-metallic materials).
– Assure / qualify application of material to fabricate Mechanical & Structural parts, Propulsion & Thermal components,
Electronics parts, Printed Wiring Boards, etc.
Identify MIL/FED/Industry specification for the procurement of the material. Establish private specification if required.
Establish applicable engineering notes and approve engineering drawing.
– Select Non-Destructive Testing (Ultrasonic, Radiographic X / Gamma Rays, Dye Penetrant, Eddy Current, Magnetic Particle, etc.) for the Material / Part
to optimize quality.
Review and approve production process(es).
Certify first production part.
Operation Excellence Methodologies to optimize Product Quality and Return on Investment by applying Cost & Schedule Savings ideas, Lean Thinking, Six Sigma Capabilities, Statistical Problem solving, etc.
Train Materials and Process engineering college graduates in understanding requirements and applications.
Process Engineering
Identify MIL/FED/Industry specification for the processes. Establish private process specifications if required.
Qualification / Application of Additive Manufacturing (3D Printing) process for printing metallic and non-metallic parts.
Qualification / Application of Metallurgical processes for Metal Joining (Welding, Solid State Bonding, Brazing, and Soldering) and other joining processes (Mechanical Fastening, Epoxy Bonding, etc.).
Qualification / Application of other Processes, Raw Material melting / Forging / Rolling / Casting, Heat Treating, Materials Testing, Non-destructive Testing, Chemical Processes (Anodize, Conversion, Passivation, Etching, Plating / Coating), Polymers Processing, Carbon-Carbon Composite Processing, etc.
Qualification / Application of Space Radiation Shielding process using refractory metals & alloys.
For the new or suspect design, if required, evaluate accelerated 4X Life testing of components based on Coffin-Manson / Weibull models.
Failure Investigation & Analysis
Investigate Corrosion / Material Degradation Failures of parts and components and provide recommendations. Perform Corrosion Analysis.
Investigate failures of Mechanical / Structural, Propulsion, Thermal, Electronics parts and components (Material: Metals & Alloys. Polymers, Carbon/Carbon Composites and other Non-metallic materials).
– Establish Failure Investigation and Analysis Plan.
– Systematic failure Analysis using Non-destructive Testing and Material / Metallurgical characterization devices (SEM/EDS, FTIR, Auger, GC-MS, XRF/XRS/XPS, Metallography/Optical Microscopy, etc. as applicable).
– Find Root Cause and provide Corrective Actions.
Fracture Mechanics
Review application and engineering drawing of the part.
Assure Single Point Failure of the system if applicable.
Establish Fracture Control Plan.
Review Static & Dynamic Stress Analysis (Finite Element Analysis). Identify high stress concentration area with cyclic and sustained tensile loads.
Identify initial flaw size (undetected based on applicable efficient non-destructive testing).
Perform damage tolerance analysis using NASA FLAGRO (NASGRO) software to predict safe life of the part (4X operational Life).
Electronics
Review and approve Materials & Processes of the Electronic parts.
Review and approve Semiconductor materials and processing.
Review and approve fabrication of Printed Wiring Boards and Printed Board Assemblies.
– Review and approve Materials & Processes of PWBs based on IPC-6011, IPC-6012, IPC-A-600, etc.
– Review and approve processing of Printed Board Assemblies based on IPC J-STD-001 S/A, IPC-A-610, IPC/JEDEC J- STD-033, ANSI/ESD S-20.20, NASA-STD-8739, MIL-STD-883, MIL-STD-750, MIL-PRF-31032 /1 or /2 or MIL-PRF-55110 and Cable and Wire Harness Assemblies based on IPC/WHMA-A-620-S, MIL-W-5088, etc.
– Qualify fabrication houses.
– For degraded or failed assembly perform failure analysis to find toot cause and provide corrective actions.
