SHENGLI LIU

**** *** **, *** *

Monroe, WI *****

608-***-****(h)

acrxph@r.postjobfree.com

WORK EXPERIENCES

Metallurgist, Jan. 2012 Sept. 2015

Grede LLC (former Citation Corp), Browntown WI. Manufacturer of diverse large gray and ductile castings, including train brake rotors, large air compressor housings, heavy track structure components, powertrain housings, flywheels, flywheel housings and etc. for Caterpillar, Cummins, John Deere, Waukesha Engine, Trane, Ingersoll Rand and Agco, and ISO 90001 certified.

Investigate into root cause of product and/or process failures, and determine appropriate product disposition and/or process improvements.

Conduct failure analysis and customer return analysis, including defect characterization, root cause analysis and corrective actions. Typical defects include sand, slag, shrink, porosity, stress cracks, filter failure, hard or soft castings, low elongation, poor nodularity.

Prepare internal or external reports detailing causes and corrective actions based on data analysis and investigation results.

In charge of an internal metallurgical lab, responsible for the chemical analysis, molding sand and core sand analysis, spectrometer and C/S determinator operation, training, calibration, and maintenance, troubleshooting, with excellent records on 5S and safety.

Participated in development of FMEA/PPAP, formulation of quality control policies and procedures.

Responsible for sampling systems, procedures, and statistical techniques; design or specify inspection and testing mechanisms and equipment.

Prepare material certificates for customers.

Sr. Engineer/Supplier Quality Engineer, July. 2002 Dec. 2011

Slinger Manufacturing, Slinger WI. Manufacturer and distributor of engine components (cylinder liners and pistons) and providing technical support, quality programs and supply chain service to automotive OEM’s, such as Ford, GM and Chrysler, Nemak, Castek and small engine OEM’s, such as Briggs & Stratton, Kohler, Kawasaki, Harley Davidson, Honda PE, Waukesha Engine.

Responsible for customer RFQ analysis and define internal manufacturing processes, prints and material specs and quality programs for the internal cast iron foundry and external suppliers (the internal foundry is ISO 9001 certified, the external suppliers are TS16949 certified) .

Successfully conducted 10 high volume production launches (from 0.5 million up to 5 million each) of automotive cylinder liners and pistons, valuable launch experience gained.

Developed numerous PPAP plans and on-site audited the PPAP processes.

Reviewed and critiqued numerous PFMEA’s and control plans, to make them more effective and robust. As a result, we achieved 0 PPM from our customers.

Supervising the internal lab staff, and responsible for all testing procedures, and equipment. The internal lab conducts chemical analysis, macro/microstructure evaluation, and hardness testing, surface finish testing, nondestructive testing such as magnetic particle and eddy current testing.

Responsible for materials specification, production processes and quality programs involved in cylinder liner production.

Coordinating with outside labs on the procedures and techniques for nondestructive testing of engine components, including ultrasonic testing, radiographic examination, magnetic particle and eddy current testing.

Conducted failure analysis and troubleshooting on engine component failures and customer returns for establishing effective corrective actions.

Developed a nondestructive detecting process for cast iron microstructure based on eddy current principle.

Developed a new bonding mechanism to improve the bonding strength between liner and block, coauthored a patent. As a result, emission due to bore distortion will be minimized and heat transfer through liner-block interface improved. Developed production process and equipment accordingly.

Senior Project Engineer, Jan. 1997-Oct .2001

CTS Corp., Manufacturer of electronic components and subsystems for automotive and electronic OEM’s, such as Ford, GM and Chrysler, and Motorola.

Developed a new type of automotive sensors (based on functional coatings made with polymer), that could be applied to the automotive powertrain and drivetrain systems (such as throttle body position sensors, EGR sensors, drive-by-wire pedal sensors, steering/torque sensors, transmission sensors, seat occupancy sensors, with a significant improvement in durability, reliability and safety, awarded with 3 patents. One paper published in the proceedings of IEEE Holm Electrical Contacts. )

Key member in the product design group, participated in designing position sensors, EGR sensors, pedal sensors, transmission sensors, in-cylinder pressure sensors with focus on material performance.

Conducted failure analysis and troubleshooting of customer returned electronic components or assemblies.

Developed and designed unique gold-gold-interconnect bonding fixtures for bonding surface-acoustic-wave chips to singulated ceramic packages, easy to assemble/disassemble and to pick/place.

Established a tribology testing program, designed and constructed custom POD (Pin-On-Disk) testers, characterized mechanical wear and electrical contact performance and identified major factors in the contactor/polymer coating/lube system.

Designed and constructed surface scanner capable of testing surface roughness and contact resistance spontaneously in 2-D and 3-D modes with sub-micron resolution.

Metallurgist & Dept. Supervisor, Jan. 1993-Dec. 1996

Helwig Carbon Products Inc. Leading manufacturer of electrical contacts and motor brushes.

Established an electrical contact testing lab, enabled to characterize contact performances under application conditions, helped product developments and improvements.

Developed state-of-the-art net shape production processes based on powder metallurgy principle, significantly reduced labor cost, improved production capacity and quality.

Developed various electric contact material formulations, including copper/carbon, silver/carbon, polymer/carbon composite materials.

PROFESSIONAL AFFILIATION

AFS, ASM

EDUCATION

Ph.D.: Metallurgical Engineering, (Minor: Mechanical Engineering), May 1993.

University of Wisconsin Madison, Department of Materials Science and Eng.

M.S.: Metallurgical Engineering, Aug. 1989.

University of Wisconsin Madison, Department of Materials Science and Eng.

B.S.: Materials Engineering, Dec. 1976.

Inner Mongolia Polytech University, Department of Materials Eng.

PUBLICATION

Available upon request.

Contact this candidate