Quality Control Engineer

WAYNE A. TERWILLIGER, P.E.

***** ********* *****, ******** *******, MI 48312 / 754-***-****

********@*******.***

EDUCATION AND LICENSES

. Michigan Technological University, Houghton, Michigan (1987) B.S. in

Metallurgical Engineering, Materials Science and Engineering

. Professional Engineer (FL), Metallurgical Engineering #PE0049160

(1995)

CERTIFICATIONS AND SKILLS

Pratt & Whitney CHTR, Certified Heat Treat Representative March 2011;

Knowledgeable of ISO 9001:2008 "Quality Management Systems-Requirements";

Completed Review Course for Certified Quality Engineer Examination;

Proficient in SteCal - Version 3.0 Predicting Steel Properties

Proficient in IMSE 2000 Version: Interactive Materials Science and

Engineering by Intellipro, Inc.;

Proficient in 2-D and 3-D variable process modeling using Grapher and

Surfer Golden Software;

Proficient in Microsoft Excel, Word, PowerPoint, Outlook, AutoCAD LT 2000,

and DesignCAD by IMSI;

Proficient in MS Excel ANOVA Statistical ToolPak;

PROFESSIONAL ORGANIZATIONS

American Society for Metals (ASM) current member Detroit Michigan Chapter;

American Society for Testing and Materials (ASTM) past committees G-3 and G-

50; National Association of Corrosion Engineers (NACE) member; Society of

Automotive Engineers (SAE) current member; and American Welding Society

(AWS) member 1994-present

KEY STRENGTHS

. Knowledgeable and experienced in the metal processing (heat treating

and metal forming) of carbon and alloy steels, stainless steels,

nickel-base alloys, cobalt-base alloys, and titanium alloys

. Knowledgeable and experienced in failure analysis of carbon and alloy

steels, stainless steel, titanium alloys, nickel-base alloys and

cobalt- base alloys in materials processing

. Knowledgeable and experienced in job order production planning of jobs

and computer development of job routers inclusive of computer

generated processing forms and updates

. Knowledgeable and experienced in failure analysis of automotive and

aerospace parts

. Knowledgeable and experienced with AMS, ISO, MIL, NACE, ASME, ASTM,

PWA,GE, API, PEI, Naval and various other specifications as they apply

to various metal alloy forms

. Knowledgeable & Experienced in NADCAP auditing, process and

requirements in heat treating and materials laboratory testing

. Knowledgeable and experienced with various metallurgical methods FMEA,

failure analysis, metallography, stereomicroscope, SEM and NDT

. Knowledgeable and experienced in laboratory management and oversight

testing consisting of: chemical, corrosion, metallurgical and

mechanical using ASTM methods

. Skilled and experienced in development, implementation and oversight

of a quality control program, and QC Inspection equipment and

operation

. Knowledgeable in ANOVA (analysis of variance) and DOE (design of

experiments) and application

. Knowledgeable and experienced in customer technical service for over

20 years

. Skilled and experienced in team oversight and management and providing

technical support to sales and manufacturing departments

METALLURGICAL ENGINEERING EXPERIENCE

Vac-Met, Inc., Warren, MI (2010 - Present) Plant

Metallurgist/Metallurgical Engineer

Materials:

. NADCAP, FAA Repair licensed and certified Company offers vacuum heat

treating and furnace brazing high temperature metals nickel-base

alloys, cobalt-base alloys, titanium alloys, stainless steels, tool

steels and carbon alloy steels

Heat Treatment:

. Process heat treat computer generated design schedules for individual

materials and parts for various vacuum furnaces, hydrogen retort

furnaces and air furnaces from racking & loading of parts to furnace

programming and final packaging

. Developed computer process design requirements for solution annealing,

mill annealing, stress relieving, aging or precipitation hardening,

austenitizing, and tempering

. Heat Treat Process Design involved review of blueprint of parts,

commercial, customer and formal specifications which incorporated

specific temperatures and times and specified tolerances, ramp rates,

cooling rates and various required gas quenching media (argon,

nitrogen and hydrogen).

. Assisted various customers in developed new product heat treat design

schedules for various new and existing product applications from

medical to aerospace

. Knowledgeable and experience with furnace brazing heat treating

procedures, filler alloys, preparation, alloying and inspection.

Heat Treating Product Defect and Root Cause Nonconformance:

. Assisted in identifying the root cause of nonconformance issues related

to furnace operation, furnace programming time schedules, thermocouple

wire failure or shorting out to cleaning and recalibration of vacuum

gauges

. Identified and revised previous heat treat process design racking and

heat treating schedules to eliminate customer nonconforming/defective

part issues

. Performed metallurgical investigations into resolving customer

manufactured part problems before and after heat treatments and to design

heat treatments to minimize surface finish, material physical property,

size tolerance issues and distortion problems

. Assisted Quality Control in completion of root cause nonconformance and

implementation of corrective action of NADCAP audit major and minor

findings for company operational licensing

Quality Control Laboratory Operations and Material Specifications:

. Oversight of Laboratory Operations which consisted of technician

oversight, assisted in rewriting laboratory operations manual, resolving

materials testing problems by revising procedures, preparing usable

testing forms, calibration forms updated with latest ASTM testing or

calibration procedure and instituting new testing methodology to meet

material specification requirements.

. Knowledgeable and experienced in mechanical testing consisting of

Rockwell portable and electronic hardness testers, Micro hardness

testers, performing sample preparation using the latest programmable

electronic lab equipment, using bench top microscope to perform near

surface examination (IGO/IGA, decarburization, alpha case, carburization

and nitriding; and grain size measurements using the latest imaging

software.

. Assisted quality control department in resolving customer nonconformance

problems and implementing heat treat processing corrective action

procedures.

Florida Environmental Engineering, Inc., Pompano Beach, FL (1992 - 2010)

Chief Engineer

. Failure analysis of various tubing materials polymer based teflon and

teflon-lined HDPE materials to corrosive ozone gas

. Materials selection for corrosion-resistant materials such as

fiberglass, teflon, HDPE and iron-based metal piping materials and

coatings

. Developed engineering designs for the remediation of solvent and

petroleum-impacted soil and groundwater; developed engineering designs

of fuel piping and tank systems

. Reviewed and sealed drawings and technical reports for the design of

power generation fuel systems and remediation systems to various

industry standards such as PEI, API, NACE, ASTM and ASME

. Developed and implemented new groundwater remediation technology at

existing contamination sites; patent currently pending ("Hydroxy-

Zone"); developed software programs for remedial technology research

. Prepared monthly sales forecasting for each department; provided

review and oversight of operating costs, payables, receivables, and

profit; developed project cost templates and profit margins

. Supervised and reviewed the activities of 10 employees (engineers,

geologists, and technicians)

US Environmental Group, Inc., Fort Lauderdale, FL (1990 - 1992)

Environmental Engineer

. Managed asbestos and petroleum tank departments; scheduled and managed

projects; performed review and oversight of soil and groundwater

sampling and test data evaluation; prepared final reports for review

and signature. Responsible for development of customer proposals and

acquiring contracts.

TolTest, Toledo, OH (Jan. 1990 - Dec. 1990)

Metallurgist

Failure Analysis:

. Conducted on-site field inspection and logging of data in the study of

weld failures, cold forming operation component failures, and service

failures of manufactured parts

. Performed laboratory macro graphic fracture examinations to determine

fracture zones (ductile, brittle, or shear) and to determine potential

sites of fracture origin

. Conducted component stress analysis (plane strain, plane stress,

fatigue, and loading conditions)

. Conducted metallographic examinations of microstructure during and

after processing

. Performed mechanical testing of failed components consisting of

tensile and hardness testing

Certification Testing:

. Performed tensile and hardness testing for parts certification in

accordance with ASTM methods

. Conducted part certification testing for welded parts to AWS

certifications and corrosion testing of steel and stainless steel

parts to ASTM methods

. Performed ultrasonic examinations on metals to identify laminations,

thinning, and other defects

. Conducted chemical analysis of metals to meet material specifications

. Conducted metallographic examinations and grain size determination in

steel and stainless steels

Elgiloy, Elgin, IL (1987 - 1990) Metallurgical

Engineer / Quality Control Manager

Materials:

. Company offered precision rolling of thin strip and wire products for

stainless steel, nickel, nickel-cobalt, and titanium alloys

Heat Treatment:

. Developed for individual materials an annealing process design

schedule consisting of specific temperatures, purge gas and annealing

gas, dew point requirements, and furnace speeds

. Implemented aging treatments for stainless steel and for company-

patented cobalt-base alloy

. Assisted in development of increased wire mill and rolling mill

quality anneal process with hydrogen gas conversion from dissociated

ammonia for bright anneal

. Assisted in rolling mill furnace replacement material and design

Metal Forming Operations:

. Conducted and assisted in development of computerized wire drawing and

rolling mill draw and pass schedules for numerous materials

. Performed rolling and wire drawing stress analysis and roll and wire

die design; evaluated lubrication quality at cold forming stages;

prepared final mechanical property graphs for each material

Mill Defect and Root Cause Failure Analysis:

. Improved wire surface quality and minimized surface defects by using

higher quality lubricants and by implementing pH control limits on

wire cleaning chemical bath

. Eliminated wire anneal cracking failures in stainless steel by raising

annealing temperature after determining that cracking failures were

caused by low temperature anneal creating carbide precipitation

. Determined that helicopter spring switch fatigue failure occurred due

to stress concentration around metal burrs after stamping operation;

reinstituted aluminum oxide to deburring operation which removed burrs

and eliminated failures

Quality Control and Material Specifications:

. Developed and implemented company quality control program and quality

control (QC) manual; QC manual included department processing

specifications, periodic measurement and testing requirements, and

calibration schedules for testing equipment and measurement devices

. Performed in-house and vendor audits in accordance with quality

auditing procedures

. Coordinated with company sales department and mill product departments

to meet new and existing customer specification standards, not limited

to AMS, ISO, MIL, ASTM, Naval, and GE

. Organized and maintained customer specifications and added ASTM

testing equipment to materials testing laboratory to minimize

outsourcing costs

Marketing:

. Provided technical expertise in selling company products at materials

conferences

. Met with potential clients and existing customers to showcase facility

operations and quality control

. Worked with clients and engineers to use the company's cobalt-base

patented alloy for new purposes in the medical, dental, and oil and

gas industries

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