Engineering Engineer

ENGINEER EXECUTIVE

Don Bucholz has significant experience in the technical and business

aspects of engineering in the U.S. and abroad. He is an expert in

coatings, thin film metallurgy, wear and corrosion resistance,

welding/brazing, materials engineering, processing, project management, and

product development. He displays the full spectrum of leadership qualities

and engages his staff and team members in an accountable and empowering

manner, such that people want to work with him.

Professional experience

Kennametal/NAVAIR

Advanced Technology Consulting (contract)

May 2010-present

. Directing research on repair of T64 turbine components and wear

resistant coatings for aluminum and titanium

BAE Systems, Lexington, KY September

2008-April 2009

Director of Engineering (consulting)

. Subject Matter Expert, engineering technology and processes in proposal

for United States Special Operations Command (USSOCOM) Special Operations

Forces Support Activity (SOFSA)

Kennametal/Conforma Clad, New Albany, IN

November 1999-February 2009

Global Manager for Advanced surface technologies, Senior Scientist, Vice

President of Technology

. Research, Development and Engineering (RD&E) program and product

development leader

. Processes and materials included welding (GMAW, GTAW, SMAW), vacuum and

hydrogen retort brazing, slurry coating, spray and fuse, machining (CNC,

EDM), Mechanical Desktop, ProE, Unigraphics, Thermocalc, ANSYS tools

. Implemented a stage-gate in Research Development and Engineering (RD&E)

processes emphasizing NPV, ROI, capital equipment budget and alignment

with Strategic Planning

. Responsible for technology road maps and product development areas of

strategic plan and direct connection to corporate goals

. Performed day-to-day monitoring of over 30 product lines, including

alternative materials and processes for solid oxide fuel cells, power

generating equipment and food processing industries (two patents, U.S.

and international in review)

. Directed and obtained FDA approval for materials and processes

. Instituted engineering management cost control measures, including the

application of basic engineering and accounting principles based on

earned value metrics

. Managed multimillion RD&E capital budget, instituted systems of reporting

to support and document IR&D efforts, applied standardization practices

and document control to manufacturing instructions and process procedures

. Personally developed database for the organization and archiving of

laboratory, research, and quality records into design and manufacturing,

processed and developed and introduced SPC practices to RD&E and

operations

. Managed plant facilities, environmental/health and safety (EHS) and

quality organizations in addition to other responsibilities

. Oversaw technology transfer and factory startup in Bangalore, India

. Directed project definition in support of NAVAIR-MCAS Cherry Point for

support of material and process development, CH-47 turbine life extension

.

OEA (Ordnance Engineering Associates) Inc. Aurora, CO

April 1997-June 1999

Director, Production Engineering, Director, Advanced Engineering Process

Development

. Directly responsible for all automated processes (welding, propellant

handling, real-time X-ray imaging) in high volume production of

explosive initiators, automobile safety systems (inflators), aircraft

evacuation slides and ejection seats

. Directed welding process for GMAW, GTAW, PAW, EBW and RW

. Analyzed processes and wrote specifications for procedures and SOP's

eight different product lines

. Key processes were safe and accurate dispensing & conveyance of

propellant and primers on automated production line in conjunction with

joining and bonding processes

. Negotiated sampling plans and acceptance criteria with international

customers based on technical requirements, process specifications and

controls

. Directed and performed failure analysis, resolution of international

customer issues regarding systems, materials and processes performance,

specification and documentation

. Set-up laboratories and test facilities for automated material

preparation and processing

. Redesigned one manufacturing process operation to save $4M in annual

costs and increased production rate, Redesigned another process to reduce

a key component assembly scrap rate from over 6% to less than 3% saving

$3M annually

. Implemented necessary engineering management controls and processes to

earn ISO 9000 registration activities in 1997 for Production Engineering,

and achieved ISO 9000 certification in less than 12 months

IBM Federal Systems, Loral Federal Systems, Lockheed-Martin Federal

Systems, Manassas, VA November 1986-April 1997

Technical Associate, Staff Engineer/Scientist

. Served as technical expert for all metals, fabrication/joining processes

to support mechanical packaging for electronic equipment used in marine

and aerospace applications. Served as Technical Team Leader for Cassini

and ZEUS space programs. Met all technical requirements for flight,

delivering prototype and flight units on time and within budget. Efforts

resulted in successful mission of space flight, Cassini currently in

orbit around Saturn's moon, Titan.

. For Light Airborne Multi-Purpose System (LAMPS) program, oversaw the

manufacturing quality and procurement of the electronic enclosures

installed in the SH-60. Directed the logistics activities during the

installation of the Advanced Signal Processor system (ASP) in the P3

Orion, from materials selection through manufacturing of the enclosures.

. For the installation of sensor stations 1 and 2 in the S3, managed the

mechanical evaluation and testing of high-strength aluminum components

and fastener systems, as well as resolved overall material compatibility

issues.

. Managed specific materials and processes for: SSN-688, SSN-688I, and SSBN-

726 class submarine SONAR enclosures; SH-60 LAMPS signal processor

enclosures; and Advanced Tactical Terminal for MH-53J PAVE LOW. Specified

shielding materials for EMI/RFI team that was responsible for building

radiation hardened (rad-hard) processors and electronic devices.

. Collaborated with mechanical and test engineers to determine best

materials and manufacturing processes to ensure products could withstand

shock and vibration. Installed enhancements that minimized electronic

signatures and made products resistant to EMP and EMI.

AT&T Bell Laboratories, Murray Hill, NJ

November 1982-November 1986

Senior Technical Associate

. Researched and marketed non-ferrous electrical contact materials and

coatings, as well as thin magnetic films for electronic devices, phased

array RADAR and towed array SONAR

Education

. Northwestern University, Industrial Research Institute/Kellogg School of

Management (2003): Evanston, IL. Shaping Innovation Leaders Executive

Program

. Colorado School of Mines (1992 - 1999), Golden, CO. Ph.D. Metallurgical

and Materials Engineering from Center for Welding Joining and Coatings

Research, Funded under Office of Naval Research, Department of

Metallurgical and Materials Engineering

. University of Illinois at Chicago (1978 - 1982), Chicago, IL: BS

Metallurgical Engineering

Professional Associations

. American Welding Society member for over 22 years and Chairman, C3

Committee on Brazing and Soldering for 8 years, Managed domestic (AWS

and ANSI) as well as international standards (ISO and DIN) to bridge and

harmonize the U.S. and European specifications, Authored handbook

chapters and organized international conference activities

. Member of American Society of Mechanical Engineers for 12 years, and

American Ceramics Society and IEEE member for 6 years

. NDT Level II Ultrasonic, Level III Radiography

Publications, Presentations, Patent Applications

Singer, K.M., Bucholz, D.W., Diffusion Barrier Layer and Method of Making

the Same, and Wear Resistant Article with the Diffusion Barrier and Method

of Making the Same, United States Patent Application PCT/US07/07089, 3

March, 2007.

Singer, K.M., Bucholz, D.W., Wear Resistance Brazed Claddings from

Engineered Polymer Suspensions, ACERS Symposium on Advanced Ceramic

Coatings for Structural, Environmental and Functional Applications, ICACC-

S2-2007, Ft Lauderdale, FL, Jan. 2007.

Singer, K.M., Bucholz, D.W., Article Having a Wear Resistance Coating and

Process for Producing the Same, United States Patent Application

PCT/US06/03992, 10 August, 2006.

Juliot, C., Bucholz, D.W., Erosion Resistance of Infiltration Brazed

Tungsten Carbide Cladding, TAPPI Engineering, Pulping and Environmental

Conference, August, 2005

Singer, K.M., Bucholz, D.W., Wear Resistance Brazed Claddings from

Engineered Polymer Suspensions, Materials Science & Technology Pittsburgh,

PA, Sept., 2005;

Bucholz, D.W., Muzzone, L., Eversmann, C., Wear Protection, Tungsten

Carbide Clad Components Can Increase Product Quality and Reduce Costs, Pet

Food Industry, Dec. 2004.

Bucholz, D.W., Brazed Tungsten Carbide Composite Coatings, Eta Phase

Formation and Control, AWS International Brazing and Soldering Symposium,

Chicago IL, Aug, 2002.

Bucholz, D.W., Harley, C.B., Erosion Resistance of Tungsten Carbide Brazed

Cladding in Coal-Fired Power Plants, Electric Power Research Institute

Repair and Maintance Conference, Mobile, AL, June, 2002.

Bucholz, D.W., Liu, S, Edwards, G.R.,Diffusion Bonding of Multilayer

Coatings, AWS, Advanced Brazing and Soldering Technologies, International

Brazing and Soldering Conference (IBSC), pp. 81-92, ISBN 0-87171-629-1,

Albuquerque, NM, 2-5 April, 2000.

Bucholz, D.W., Harley, C.B., Erosion Resistant, Infiltration Brazed

Tungsten Carbide Coatings Used in Fly Ash Conveyance Systems, ASM Heat

Treating International Symposium Proceedings of the 20th Conference; v1,

pp. 1046-1050, ISBN 0-87170-727-6, St Louis, Feb., 2001.

Bucholz, D.W., Saltzman, G.A., Abrasion, Erosion and Corrosion Resistant

Brazed Coatings of Tungsten Carbide, ASM Heat Treating International

Symposium Proceedings of the 20th Conference; v1, pp. 1055-1064, ISBN 0-

87170-727-6, St. Louis, Feb., 2001.

~ References available upon request. ~

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