David Farrell

Mechanical Systems, Process Review, Fatigue, Repair and Reliabilty / Quality Engineer

**** ***** ******* *** - *****, OK

acrvz1@r.postjobfree.com - 918-***-****

Have over 20 years of experience in Following Industries

1) Aircraft

2) Oil and Gas

3) Process Manufacturing

WORK EXPERIENCE

Sr Engineer

Lufthansia-BizJet June 2015 to Present

Duties: Performed primary structural drawing review - 2D and Solid Works and Stress analysis on interior fuselage aircraft structure, including floor beams, stringers and frames. Composite panels material and process - installation and machining analysis and monument analysis along with Vendor checking. Quality and Reliability testing of latches. Helped with innovative new light pallets for interior attachment structure. Analysis includes some systems analysis, support on quality, cost cutting and member of the MRB board. Review with DER on static loads. Hours estimation for analysis. Changed design based on analysis and helped with methods and checking some work of less experienced stress engineers. Helped with Quality and Lean initiatives. FEMAP, LISA, FEM models and Solid Works CAD, Excell and MS Office Products.

Contract Consultant Fatigue and Reliability Quality Engineer

Sargent Fletcher - May 2013 to August 2013

Duties: Performed Various Fatigue and Reliability (MTBF) analysis on an advanced fuel plumbing system for Kerosene that must be used as both ground based and also used deployed off the rear of aircraft - in flight. System used a drum reel,High pressurized hose systems. Design was for both on ground and off ground. Engineering work included forced vibration with and without fuel pressure present, failure modes with bearings, and high pressure pipe system external loads and internal pressure. Flexure Joint analysis and reliability analysis was modeled with Bearing and fit issues for the equipment. ANSYS workbench and Caesar software was used along with hand models to check brackets and support structure. Pipe checks included both ASME methods and more rigorous imposed criteria to meet FAA requirements for both on and off aircraft on the ground. Successfully Set up fatigue analysis modal High cylce method using (Shigley methodology) and FEM models. Helped with contact bearing and material analysis, Vendor and supplier issues. Changed design based on analysis and helped while supervising the work of other engineers involved in the project.

Engineering Nacelle Quality Stress Specialist

NORDAM, NTR Division - Tulsa, OK - October 2011 to February 2013

Completed all assigned stress reports as acting Lead MRB signature stress engineer. Staff Lead Engineer duties including leading and direction of the mid, Jr and Sr level engineers on a new Nacelle concept with GE.

Helped with mass properties and MRB actions with Jr Engineers, held meetings with Sr and Lead engineers located overseas, and corrected reports on static stress analysis of Nacelle structures

and repairs of plumbing systems attached to nacelle or engine. Successfully solved many problems concerning

attachment of systems pipes to cowl and nacelles. Analysis included Hammer, Fatigue, Shock and vibration

modal analysis. Performed and wrote new fatigue analysis on Aluminum perforated inlet nacelle OML skin. Sinusoidal and Random Vibration fatigue. Some analysis used Nastran to develope Eigen Values. Corrected errors and helped repair several delivered Nacelle systems as acting MRB lead stress engineer.

Contract Engineeer/ Analyst- Boeing Dallas

Volt Technical - Dallas, TX - September 2010 to September 2011

Continue work from previous contract which involved testing and production level layout work to evolve into final product to install on the aircraft. Fatigue and Damage tolerance and residual strength analysis, assistance with Reliability engineering to determine failure modes and complex mechanical load paths. Static stress Report analysis and final sizing. This contract involved completion to production level engineeering with MRB support. Aspects of the design was very similar to landing gear but much more complicated due to all the systems, and complex fittings . Retained on the engineering staff as a contract engineer until final project was completed with all analysis reports due and blessed. Work involved was with a large sperical bearing hydraulically actuated system which was attached to go thru the skin into interior primary structure such as floor beams etc. System was military in nature. Reports included Fatigue and Static Stress reports. Derivation of stress intensity factors was also needed for Dadt analysis. Learned and used software such as Ceasar for Lug Dadt analysis as well as Nastran and Patran for the basic load paths. Retained until the CDR was completed with Final report for acceptance by both civilian (FAA) as well as meeting the military Statement of Work for the contract. Helped with the stress criteria as it unfolded in the design details.

Contract Systems Engineer, and Reliability Structural Testing Consultant

Advantage Resourcing - Dallas, TX - August 2009 to January 2010

Prototype Engineer Boeing Dallas

Modification of a Boeing B737 aircraft for military purpose. Layout to intial stage design which was designed

and built for a full scale wind tunnel test. Supported all phases of this design concept to build a prototype

aircraft. Supported the shop personel as well as doing the stress reports and test reports. Finished for PDR

level and was retained for 2nd new contract.

Contract Reliability and Structural Engineer Level 5

Spirit Aerosystems, Tulsa - March 2008 to August 2009

Wyatt and Associates

Worked as a Sr. level lead Stress Engineer and Systems Test Plan Engineer, then MRB engineer for first G650

Wing to be tested. Tested Componants including Flaps . Worked on Reliabilty report (MTBF) with failure modes and help narrow and isolate the issue of Flap Skew testing . Was used as the Liason Quality Engineer for designing tooling and test fixtures including the support floor hydraulics for some specialty equipment and whiffle tree. This involved close work with inspectors and mechanics on the shop floor. Wrote and co-authored strain gage test plan. Software used was Caesar, Nastran and Patran, and various FEM and hand solutions based in Excel.

Structures Stress FATIGUE Group Engineer, Tinker AFB

The Boeing Company - May 2007 to March 2008

Contract MRB Stress Engineer: VOLT Technical Group

Wrote Dispositions and reports to support the repairs on primary

Aircraft structure; some grounded AOG. Worked skins, Wings and Spars and substructure for the KC135

aircraft. Trained on REDARS, and pulling loads from old Boeing reports. Used current Boeing stress analysis

methods including Boeing analysis IAS, SA, to document reports and analysis. Completed several large repairs

(many discrepancies) on wings skin, production breaks and stringers. Fatigue and static analysis.

Consultant Engineer (Sr. Contract Engineer)

Lockheed Martin - Fort Worth, TX - January 2006 to March 2007

JSF Subsystems Stress

Analysis of Weapons Bay area. Analysis included Lockheed methods for shock and vibration fatigue for

plumbing mounting systems in JSF. Hydraulic line analysis. Extensive linear Pipe modeling of hydraulic, PAO,

electrical cables and Fuel lines for 2ndary Bracket analysis. ANSYS. Fatigue analysis required by Air Force.

Contract Composites Stress Engineer (Sr.) Composites Structures

Northrop Grumman Corporation - El Segundo, CA - January 2003 to January 2006

El Segundo, CA

Contract Composites Stress Engineer (Sr.) Composites Structures:

(Worked here previously) JUCAV project.

Preliminary Sized and designed Weapon Bay Doors

- using Patran and Nastran and hand methods. Worked to initially

Establish the design criteria. JSF methods. Strong use of Patran, Nastran nonlinear, ANSYS

Engineer level 3

Lockheed - Fort Worth, TX - February 2001 to December 2003

Duties: Worked in JSF program on systems issues with mechanical parts subject to failure such as Landing gear, engine mounts, primary structure and LO skin based failures analysis. Issues such as deflection, stress and cyclic failure. Joined test group and performed Testing and FEM correlation. Received training on Stress Check and Ideas, Catia Stress, Nastran linear analysis and some training with ProMechanica. Training on Lockheed methods and memos. Re-training on ANSYS nonlinear, Stress Check and devised own software based on hand methods.

Stress Contract Engineer Civil Aircraft work

VOUGHT - Grand Prairie, TX - January 2001 to February 2001

MRB stress group for the

GIV and GV Composite Gr/Ep honeycomb Engine Nacelles - Duties: Hot

/ cold areas. Metallic and composite sections checked for Static Stress

Strength Stability and Yielding analysis.

Sr. Materials Review Board Engineer- repair

DALFORT AEROSPACE - Dallas, TX - April 2000 to January 2001

Wrote ECN's and reports kept on file for the FAA to check. Worked closely with SW Airline chief of structures

and Enginering and was invited to attend SW Airlines engineering meetings. Devised new bulkhead repair on

B737, which was copied by Boeing Seattle. Proposed DER candidate while repairing SW airlines thru Atlanta

FAA Office. COSMOS FEM training and usage for engine tooling project and other projects where reverse

engineering was required to maintain static strength and equivalent fatigue resistance.

Contract Engineer, External Loads, Stress Engineer

SIKORSKY HELICOPTOR COMPANY - Stratford, CT - August 1998 to April 2000

Duties involved modification of existing helicoptors and maintaining static strength or revising loads and

redesign if needed. Made stress reports of primary structure (MRB) on Assembly, and supported both loads

and stress groups. Worked on several interior projects including a new hatch, and EFAM Wing attachments

to fuselage.

Contract Engineer

The Boeing Company - Wichita, KS - March 1996 to August 1998

Duties: Boeing Fatigue and Static analysis of interior fuselage structure in the Boeing 747SF aircraft, skin,

floor beams, stringer Splices & frames. Boeing modified passenger to combi type cargo aircraft. Mostly interior

cargo attachment analysis to floor beam structure and stringers. One project included cutting upper deck

beams and putting in tension ties. Cutting holes in Fuselage and put in a Northrop Cargo plug. Seat track

attachment analysis and redesign for heavier pallet loads. Prepared final report and structural substantiation

of floor structure drawings and frame attachment at FS 1000. Used Boeing Fatigue methodology in reports.

Worked with liaison shop crew later, was retained to do MRB

engineering to review and size to completion several MRB and ECN type

problems and projects. Learned/Refresh coursework on the following

Software: ELFINI, NASTRAN, SASSI, IDEAS, PATRAN.

Contract Fatigue and Reliability and Stress Loads Engineer

ASSOCIATED AIR CENTER - Dallas, TX - February 1995 to February 1996

Contract then became Direct

Completed several Boeing B737, B757 Interior Modification projects doing stress and drawing support.

Performed External loads analysis on Antenna installations. Attached Galleys, and Detmer Seats, hung PATs

aux fuel tanks off the floor beams for extended range. Modified Avionics racks and added racks where none

existed. Fixed and repaired corroded Bearing Straps around the doors. Wrote all required reports including 1)

Static Ultimate Strength, 2) Fatigue 3) Dadt 4) Inspectability report required by the FAA for 8110 or for repair

station work or for new STC. Projects concerning B727, B747-200 and Boeing 737-500 aircraft. Produced

Damage tolerance analysis for FAA certification on antennae

installations. Left to go to the Boeing Company after DER at Boeing suggested it.

Contract Stress Engineer (Mid level Engineer)

Gulfstream - Savannah, GA - 1993 to 1995

Completed the Strength Stress analysis report on the frames and fuselage. Static Strength final report analysis.

Some MRB Work on the GIV and some interior work on seat tracks.

Contract Stress Engineer Static Stress Analysis on the Japanese FSX

General Dynamics/Lockheed - Fort Worth, TX - 1992 to 1993

Fort Worth, TX

Contract Stress Engineer Static Stress Analysis on the Japanese FSX

Fighter, Composite Ventral Fins and attachment region. Fins mounted on

Doors. Completed Sizing and Report. Review drawings Some course grid

NASTRAN FEM analysis. Final Stress Report.

Engineer

Dee Howard Company - San Antonio, TX - 1990 to 1992

Analysis of interior modifications made to large and narrow body aircraft. Galley, beds, chairs and bulkhead

installations. Recoded a software program that finds the blowout pressure on the bulkheads as required by

FAA when adding bulkheads. Chair and table attachments, overhead bin analysis to stringers and frames.

Seat track attachments analysis and frame buckling, floor beam analysis and skin analysis for antennae or

for repairs as needed. Testing apparatus work and systems issues analysis . Some Fatigue cracking analysis. Material analysis and exposure to testing for building block componant allowables.

Software was Cosmos . Most work was hand analysis and was based on Static Strength and Fatigue.

Jr Engineer Reliabilty and Logistics Analyst

Northrop B2 Division - Los Angeles, CA - 1988 to 1990

Complex Reliability and Cost analysis for supply and maintenance issues using math models and large data files software such as FOCUS, for FRACAS database. Later was trained on Fatigue and strength analysis - was transfered to Fatigue analysis and Reliability. Worked with customer who was the Air Force. Exposure to Dormant useage reliability analysis, completed reports. Some work with APU systems attachment to airframe. NASTRAN, NCASA, NCAD (Wire Frame), CADAM (Section Properties) and CATIA., SAS, FOCUS, others.

Technician NUS Haliburton

Stack Sampler Engineering Technician

Designed testing apparatus and built it in shop, used it 20 floors high on Chevron and Shintech Smoke Stacks.

Prior to College Graduation - Houston, TX - 1981 to 1983

Co-Op Engineer part time.

Shlumberger / Grumman of Houston - Houston, TX - 1980 to 1981

Solved Problems on the manufacturing line and helped with Quality control issues. Assembly line Oil drilling

platform and Deep drill bit assemblys. F14A Tomcat componants.

EDUCATION

BSME

Arizona State University

August 1987

Chemical Engineering

University of Oklahoma 1983-1984 did not finsh, transferred credits to ASU.

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