Engineer Process

SUMMARY OF QUALIFICATION:

. **+ years experience in Materials, Manufacturing, Failure Analysis and

New Product Development.

. Hand-on experience on new product development, manufacturing process

development/improvement, quality assurance, statistical process

control (SPC) and data analysis; lean/six sigma; 8D process and root

cause analysis; Shainin Red X problem solving.

. Comprehensive understanding on metallurgy, fracture/fatigue failure of

materials, diverse experience on various mechanical/materials

testing/analysis tools and equipments, data gathering and analysis.

. Excellent interpersonal, communication and problem-solving skills.

PROFESSIONAL EXPERIENCE:

Senior Project Engineer 5/2012-

present

Senior Process Engineer 12/2010-

4/2012

Tosoh SMD, Grove City, Ohio

Manage new product development (NPD) projects, develop/refine

fabrication/bonding process for sputtering targets of Al, Ti, Cu, Ni, Ag,

W, etc, drive manufacturing process continuous improvement based on SPC and

process capability analysis, non-conformance investigation, root cause

analysis and corrective action implementation, and provide technical

support for purchasing, quality control, sales and customers.

. Lead NPD projects, including feasibility design, prototype

development, product launch, etc.

. Investigate metallurgy and texture of new products, audit incoming

material quality, and drive cost saving.

. Developed a new Ti-CuZn Near Net Shape HIP process, annual cost saving

about $0.5 million.

. Reduced the scrap rate from 30% to zero for Ag and Ni7V fabrication.

. Addressed the non-conformance in Cu Forte bonding, developed new

procedure and new spec. per SPC.

. Solved the Al Zip bonding unparallel pressing issue, developed a NDT

method to check the on-hold/recalled products and implemented the

corrective actions including the FMEA and control plan.

Research Associate Professor 6/2008-

11/2010

Research Associate

6/2004-5/2008

Research Assistant 9/2001-

5/2004

Department of Mechanical Engineering, University of South Carolina

Organized and managed concurrent multiple projects, developed and optimized

new friction stir welding process, researched on the fracture/failure

behavior of thin sheet materials and heterogeneous joints in projects

sponsored by NASA, US Air force, US Navy and GM etc., conducted

metallurgical, failure investigation and root cause analyses using finite

element simulation and test tools (SEM, XRD, EDS, Optical, etc.),

interfaced with sponsors/customers, furnished proposals, reports and

publications to secure continuous funding, mentored research assistants.

. Developed a new metal welding (friction stir welding) process for

aerospace applications (2xxx, 5xxx, 6xxx and 7xxx series Al),

optimized joint properties through root cause analysis and process

improvement. Enhanced weld efficiency for Al alloys from 75% to 95%

(along with increased ductility) through optimizing pre-weld heat

treatment, welding and post-weld heat treatment.

. Reviewed and developed various test plans (tension, bending, torsion,

dynamic impact loading, fatigue, mixed mode fracture and fracture

toughness, digital image correlation, etc.) for new materials,

heterogeneous joints, thin sheet aluminum alloys, steels and plastics

based on ASTM, customers' or other standards. Developed experimental

procedures, designed loading fixtures and investigated the fracture

and failure behavior of these materials or components under various

loading, conducted failure analysis.

. Performed failure and stress analysis of plastics and metallic sheets

under bending and mixed mode loading by finite element simulation

(using ANSYS and in-house software CRACK3D).

. Demonstrated the feasibility of new friction extrusion process for

making wires at low cost and optimize the die geometry and process

parameters by performing DOE and statistical analyses.

. Designed and implemented the slow tensile frame for stress corrosion

tests, including mechanical parts and LABVIEW control/data acquisition

software.

. Conducted materials characterization and failure analysis and

fractographic analyses on failed specimens.

Senior Process Engineer and Vice-director

12/1999-8/2001

Process Engineer 4/1992-

11/1999

Institute of Friction Welding, Xi'an, China

Managed the research team and on-going projects, led and participated in

over 20 research and industrial projects on process development and

control, materials analysis and testing, welding and heat treatment, etc.

. Worked closely with manufacturing lines of many companies in

aerospace, oil drilling, military, automotive and geological

exploration on friction welding product development, from engineering

design (in mechanical parts, electronic parts and control systems),

feasible studies, prototypes, process analysis, quality control, to

turn-key full productions.

. Led projects on property optimization of friction welded petroleum

well drilling pipes with post-weld induction heat treatment.

. Guided the upgrading of friction welding control system from old relay

array to PLC and/or industrial computer control system, developed

control circuits and data acquisition software, enabling monitoring

and analyzing welding quality and process reliability and increasing

sales by 50%.

. Developed test plans for various materials and components (steel,

aluminum alloys, ceramics, polymer, cast iron and welded joints),

prepared materials test samples, conducted various metallurgical and

mechanical experiments and analytical tests, performed failure

analysis and statistical analysis of operating life, furnished test

reports and publications in international journals.

. Developed/reviewed welding process and heat treatment for different

materials and combinations (steels, stainless steels, In718, aluminum

alloys, K418 supperalloy, 42CrMo steel, copper alloys, etc.)

EDUCATION:

. Ph.D. Mechanical Engineering, University of South Carolina,

Columbia, SC, 2004

. M.S. Materials Science, Northwestern Polytechnical University,

Xi'an, China, 1992

. B.S. Materials Science, Northwestern Polytechnical University,

Xi'an, China, 1989

SKILLS:

. Analytical tests: Metallographic, Optical, SEM, TEM, XRD, hardness

testing, NDE&T, etc.

. Mechanical experiments & failure analysis: Tension/bending/torsion,

fatigue/fatigue crack growth rate, mixed mode fracture and fracture

toughness experiments (KIC, JIC, CTOD), and impact testing

. Computer Applications: ANSYS, MathCAD, AutoCAD, Microsoft Office,

MATLAB, Statgraphics

. Programming: C, FORTRAN, LABVIEW, ANSYS APDL, Programmable logical

controller (PLC)

. Manufacturing: Heat treatment, fabrication of metal sheets, welding,

process control & continuous improvement, SPC, 8D process and root

cause analysis, Six Sigma/lean, Shainin Red X problem solving.

PROFESSIONAL ACTIVITIES/ PUBLICATIONS /HONOUR:

. American Welding Society, Full Member of Sigma Xi, the Honor

Scientific Research Society

. Reviewer for 12 international Journals and 2 International Conferences

. 30+ peer-reviewed international journal papers, 2 Research Achievement

Awards and 5 Student awards[pic][pic][pic][pic]

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