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Metallurgical Engineer

Warsaw, IN, 46582
June 27, 2019

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James Carlson

Principal Research Engineer-Metallurgist

Warsaw, IN 46582


Research, Development and Manufacturing

• Medical device materials and process development

• Coatings and surface pretreatment for enhancing drug adhesion and storage

• Biocompatability research on metals and alloys

• Understanding In718 stress rupture problem

• Microalloy steel applications for commercial vehicle steering components

• Application of sinter hardening to low alloy steel powder metal components

• Assisted with launch of new products

• Fracture analysis and manufacturing problem solving expert

• Development of ductile fracture during plane strain sheet metal forming

• Author of 8 publications, both international and US patents (Cook Inc, MED Inst and Guidant) Cost Reduction

• $16.5 million CoCr savings per year by adding second supplier

• $9.1 million titanium alloy savings per year by adding second supplier

• $3.5 million dollar per year lean microalloy steel pitman arm($45.5 million to date)

• Welded and drawn tubing in place of seamless for various applications

• Testified in product liability case on behalf of Cook Medical and TRW, Inc.

• Instituted semi - automatic metallographic specimen preparation and optical emission spectroscopy at TRW, Inc.


• Managed $1.8 million dollar per year production testing laboratory group at Haynes, Intl.

• NADCAP certification in November 2000

• QS 9000 certification 1997 - 2000

• Managed projects and technicians at TRW, Inc.

• Taught in - house courses in metallurgical engineering at TRW, Inc.

• Award winning teaching assistant at Purdue University James M. Carlson, Ph.D.

Willing to relocate: Anywhere

Authorized to work in the US for any employer

Work Experience

Principal Research Engineer-Metallurgist

Zimmer Biomet - Warsaw, IN

October 2014 to October 2018

Responsible for handling metallurgical/material issues for the Global Strategic Sourcing Dept. Qualified VSMPO and Remelt Sources as new suppliers for Zimmer. Working with qualifying other new suppliers and supplier transfer projects. Involved with remediation issues associated with the Polaris and Trident projects. Conducted failure analysis and root cause investigations as required Assisted Research and ATS Laboratory with projects as required. Conducted metallurgical/materials training as required and 17 year involvement with the ASTM F04.12 and F04.15 subcommittees. Cook Medical

MED Institute, W. Lafayette and COOK INC - Bloomington, IN 2004 to October 2014

Research Engineer - Metallurgist (Product Discovery/Research/Manufacturing Engineering Teams) Responsible for Cook Medical metallurgical issues and challenges. Projects involved wire reinforced catheters, wire reinforced Flexors/introducers, wire guides, stents, embolization coils, filters, etc. Developed new nitinol alloys (high strength and enhanced radiopacity), new FeNiCo shape memory alloy, bio-absorbable materials. Work has encompassed everything from day to day manufacturing/ quality assurance issues to graduate level research being conducted within our company. Published several patents and several are in the queue.

Principal Engineer - Advanced Stent Materials and Technology Group GUIDANT CORPORATION - Santa Clara, CA

2001 to 2003

Responsible for implementing a new stent material with certain attributes for a world leader in cardiovascular medical devices. Assisted with improvement of adhesion, drug storage capability and drug release kinetics of drug eluting stents. Assisted with stent product development, assisted carotid - peripheral with development of a new radiopaque stent and provided metallurgical expertise including failure analysis and material problem solving to various business units of the corporation. Wrote several patents in the area of stent research and development. Adjunct Faculty Member


Taught two sections of undergraduate physics laboratory. The area of emphasis was mechanics. Manager of Production Testing - Engineering and Technology Department HAYNES INTERNATIONAL - Kokomo, IN

2000 to 2001

Responsible for the daily operation of production laboratory facilities for a world renowned cobalt and nickel based superalloy producer. Oversaw operation of chemistry laboratory, machine shop, metallurgical control laboratory, and mechanical testing laboratory. Involved with several quality improvement projects including: optimizing the results from X - Ray Fluorescent and Optical Emission Spectrometer, understanding the origin of In718 stress rupture failures, decreasing the amount of required testing, capital investment for the laboratory, and improving the computer capabilities of the laboratory.

Principal Engineer


1995 to 2000

Served as assistant to Chief Engineer - Materials Engineering. Oversaw Lafayette Plant Receiving

- Inspection function. Plant achieved Q.S. - 9000 certification last 3 years. Assisted with new product launches(Gen. 3 column, EV power steering pump, global and enhanced DL - socket, lean production micro alloy steel pitman arm, improved intermediate steering column, and torque rods) and implementation of cost reduction proposals. Fracture analysis(coatings, metallic, and polymeric) and manufacturing problem solving expert. Issued reports. Oversaw operation of laboratory equipment and trained personnel. Developed materials standards and work instructions. Assisted with FEA of products and developed database of material properties for the Division. TRW COMMERCIAL STEERING SYSTEMS - Lafayette, IN

1989 to 2000

Senior Materials Engineer


1989 to 1995

Conducted fracture analysis and manufacturing problem solving as required. Issued reports. Assisted with new product launches (Gen. 2 column, power steering pump, first/second generation micro alloy steel pitman arm, intermediate steering column) and implementation of cost reduction proposals. Oversaw operation of laboratory equipment and trained personneld. Developed materials standards and prepared department's first quality manual. Oversaw Division FEA team. Graduate Student


Conducted novel research in the area of the development of ductile fracture during plane strain deformation of ferrite - austenite duplex stainless steel and commercial aluminum alloys. Developed models for describing internal shape change during plane strain sheet forming and experimentally confirmed using mechanical testing and metallographic methods. Experienced in optical, SEM, and TEM microscopy, X-Ray diffraction, and a variety of mechanical testing techniques. "Award winning" teaching assistant with 11 semesters of experience in teaching physical metallurgy lecture and laboratory courses. Oversaw MSE 210L(physical metallurgy lab) in fall 1986 and 1987. Management Associate


1982 to 1983

Supervised the plant metallurgical laboratories( chemistry, metallographic, and mechanical testing). Education

Ph.D. in Metallurgical Engineering

Purdue University - W Lafayette, IN

December 1988

M.S. in Metallurgical Engineering

Purdue University - W Lafayette, IN

May 1986

B.S. in Metallurgical Engineering

University of Illinois - Urbana, IL

May 1982


LABORATORY (10+ years), PROBLEM SOLVING (10+ years), FEA (10+ years), TEACHING (6 years), PRODUCT DEVELOPMENT (3 years)

Additional Information


* Project management * People oriented

* Independent thinker * Mentoring skills/teaching & training

* Written/oral communication * New product development

* Rational thinker/analytically driven * Computer literate

* Goal oriented/driven personality * FEA and mechanics literate

* Planning/scheduling * Fracture analysis expert

* Team oriented/leader * Manufacturing problem solving expert

* Cost control/reduction * New material/process development

* Hands on person * Laboratory technique/equipment development

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