Manager Engineer
Resume:
Adil A. Ashary
**** ***** *****, *** ****, CA ***38
acbjtr@r.postjobfree.com
Summary of Experience
Over 20 years of experience in engineering, materials R&D, supply chain management, product development,
aircraft components repair, manufacturing and processing alloys for high temperature applications. Thermal Spray,
EBPVD, CVD coatings and electroplating, corrosion and wear of materials, laser cladding, electron beam welding,
and erosion/corrosion and wear of materials.
Employment History
Bloom Energy Corporation, 1299 Orleans Dr., Sunnyvale, CA 94089
Principal Engineer Jul 2011 - Present
Explore, develop and implement new materials for solid oxide fuel cell power modules with strong emphasis on
low cost solutions
Established a thermal spray coating facility for producing several hundred thousand parts per year
Developed specifications for over 30 coated components
Supply chain development for several national and international coating and alloy fabricator suppliers
Developed high volume plasma spray processes for several million parts per year
Praxair Surface Technologies, Inc. 1500 Polco Street, Indianapolis, Indiana 46224
Engineering Manager Dec 2008 - Jul 2011
New part qualification for EBPVD and PtAl Coatings
Tool designing for EBPVD Coatings
Process improvements
Reduced coating spalling events in EBPVD by more than 50%
Reduced ABF (ammonium bi-fluoride) chemical stripping attack of bond coat on super alloy components
Managed an engineering staff of five engineers
R&D Manager, Semiconductor Processing Equipment Dec 2006 - Dec 2008
Developed plasma spray coatings for plasma etching chamber components
Developed relationships between coating properties and plasma spray process parameters
Carried out an extensive root-cause analysis for “wood grain” defect in alumina coated electrostatic chucks .
Improved the coating process to increase finishing yield from 40% to over 80%.
Evaluated innovative technical solutions for sealing thermal spray yttria coatings with ceramic CVD coatings
Managed production cell at R&D facility with up to full two-shift operation for peak shaving production demand
Developed an improved relationships with extremely demanding customers
Established a new state-of-the-art reach R&D facility
Supervised a staff of six including two Ph.D. engineers
Development Leader Jan 2003 - Dec 2006
Coating evaluation for metal-dusting and anti-coking solutions in olefin and steam cracking petrochemical
processes
Developed a new Ni-40 wt%W nanoscale electroplating process for chrom e replacement
Key contributor to installation and start-up of the Pt plating line for Pt-Aluminide coatings
Designed and installed a lab scale Pt-Aluminide process
Responsible for the Wear Lab, improvement made in the operation of wear lab
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Praxair Surface Technologies, Inc. 6400 NW 72 Avenue, Miami, Florida 33166
Quality and Engineering Manager Oct 1998 - Jan 2003
Overall responsibility for the quality and engineering of the aircraft component repaired at two FAA Repair
Stations operated under FAR 145
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Implemented and managed an ISO-9002 and AS9000 based quality system
Engineering development and source substantiation approvals for the repairs of engine components
Quality system established for a new state of the art hard chrome, nickel and silver -plating facility
Improved quality key performance indicators such as re work cost and on-time delivery by 20% – 40% in a year
Developed and facilitated an electroplating and electro-chemistry training program
Praxair Surface Technologies, Inc. 1500 Polco Street, Indianapolis, Indiana 46224
1996 - 1998 Program Manager 1993 - 1996 Consultant
1990 - 1993 Sr. Project Engineer 1987 - 1990 Project Engineer
Development and improvement of materials and processes. Technical assessment of external technologi es,
materials, processes and product development, worldwide plant and customer support in selection and evaluation
of metallurgical and other materials. Assisted in Marketing and Global Business development. Majo r processes:
Plasma spray, Detonation Gun, Magnetron Sputtering, Laser and Electron Beam Processes.
Implemented process controls in the electron beam welding and associated processes, such as cleaning, heat
treatment and nondestructive evaluation. Designed and installed a cleaning line for aero -engine fan blades.
Increased profitability of the company by reducing EB weld rework rate from over 50% to less than 5 %.
A self-sealing corrosion resistant thermal spray coating developed. AC and DC electrochemical corrosion
techniques were developed. Two US Patents obtained and several hundred thousands in sales per year
achieved.
New chromium carbide based coating system for mating carbon seals for Pratt and Whitney engines. The
coating was found to superior to any existing coating for this application.
Developed several thermal spray techniques for coating advanced carbon fiber composites to broaden their
engineering applications.
Evaluation of existing and development of new thermal spay coatings for different market segments for the
replacement of chrome plate. Several of these systems proved to be not only environmentally beneficial, but
lower overall life cycle cost and improved performance.
Built a new kind of magnetron sputtering system to apply hard TiN and CrN coating on the ID surfaces of long
and narrow cylindrical objects was carried out. Work involved designing and specification to the outside
fabricator and testing of the system on completion.
Failure Analyses: Over fifty failure analyses of industrial components were carried out. Depending on the
results, recommendations were made to the customers and/or the plants.
Castle Technology Corporation, Massachusetts 01801
Senior Materials Scientist Jul 1986 - Apr 1987
Developed a unique coating system for carbon-carbon composites for use at ultra high temperatures
Successfully electroplated iridium metal on carbon-carbon composites
Developed a fluidized bed process for the preparation of synthetic pyrite to be used in LiAl -FeS2 batteries
University of Pittsburgh, Pennsylvania 15261
Post Doctoral Research Associate Jul 1985 - Jun 1986
Research Areas: High temperature oxidation and corrosion behaviors of platinum modified aluminide coating
for gas turbine engines.
Graduate Student Research Assistant May 1980 - Jun 1985
Conducted research on MCrAlY Coatings for the hot section of aircraft engines
Ph.D. Thesis: Adherence of Al2O3 Scales on MCrAlY type Coatings
Developed a new technique to predict useful life of coatings jet engines
Defined optimum concentrations of the rare earth elements for the maximum protection at high temperatures
Awards and Accomplishments
Special Recognition Awards for greatly lowering EB weld rework rate
Two US patents for inventing self-sealing thermal spray coatings
Gold medal for ranking first in the class of 1976
Published fifteen (15) papers in professional journals and over one hundred twenty (120) internal reports. List
of publications available upon request.
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Education
Ph.D. Metallurgical Engineering, University of Pittsburgh
M.S. Iron and Steel Technology, University of Sheffield, U.K.
B.S. Metallurgical Engineering, University of Karachi
Professional Activities
Chaired several technical sessions of professional s ymposia and conferences.
Technical Program Chairman United Thermal Spay and Conference 1997.
Publications
Adil A. Ashary
Professional Journals and Proceedings
1. “Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD A Technical
and Economic Comparison” A. Feuerstein, J. Knapp, T. Taylor, A. Ashary, A. Bolcavage, N. Hitchman,
ASM 2005.
2. “Coatings for use in Steam and Combustion Turbines” R.C. Tucker, Jr. T.A. Taylor, and A.A. Ashary.
Proceedings of the Fourth EPRI Turbine /Generator Workshop, 1-4 August 1995.
3. “Advanced Thermal Spray Coatings for Corrosion and Wear Resistance” A.A. Ashary and R.C. Tucker, Jr.
Advances in Coatings Technologies for Corrosion and Wear Resistant Coatings, Edited by A.R. Srivasta,
C.R. Clayton and J.K. Hironen, Page 89, The minerals, Metals & Materials Society, 1995.
4. “Effect of Reactive Element Additions and Sulfur Removal on the Oxidation Behavior of FeCrAl Alloys.”
M.C. Stasik, F.S. Pettit, and G.H. Meier, Scripta Metallurgica et Materiala, Vol. 31, No. 12, pp 1645 -1650,
1994.
5. “Advanced Coatings and New Uses for Coatings in Turbo-Expanders.” A.A. Ashary and R.C. Tucker, Jr.,
D.S. Rehaut, Proceedings of Third International Turbo-Expander User’s Council, Houston, Texas, 13-15
June 1995.
6. “Corrosion Characteristics of Selected Thermal Spray Coatings”, A.A. Ashary and R.C. Tucker, Jr.,
CORROSION-93, the Proceedings of NACE Annual Conference for 1993 at New Orleans, Louisiana.
7. “Corrosion Characteristics of Several Thermal Spray Cermet Coatings/Alloy Systems”. A.A. Ashary and
R.C. Tucker, Jr., in Surface & Coatings Technology, Vol. 49, P78, 1991
8. “Electrochemical and Salt Spray Studies of Several Alloys with or without Plasma Sprayed Chromium
Oxide Coatings”, A.A. Ashary and R.C. Tucker, Jr. in Surface & Coatings Technology, Vol. 43/44, P 567,
December 1990.
9. “Electrochemical Corrosion Studies of Alloys P lasma sprayed with Cr2O3”. A.A. Ashary and R.C. Tucker,
Jr. in Surface & Coatings Technology, Vol. 40, P 701, December 1989.
10. “Advanced High Temperature Coating Systems Beyond Current State of the Art Systems”. A.A. Ashary,
F.S. Pettit, and G.H. Meier, Final Report on Contract No. 80-00089, Submitted to the Air Force Office of
Scientific Research, April 15, 1986.
11. “Use of Acoustic Emission Study of Oxide Scale Cracking During Alloy Oxidation” A.A. Ashary, F.S. Pettit,
and G.H. Meier, in High Temperature Protective Coatings Edited by S.C. Singhal, 1982.
Patents:
1. US Patent No. 5,336,645 “Nickel-Chromium Corrosion Coatings and Process for Producing It. A.A. Ashary
and R.C. Tucker, Jr.
2. US Patent No. 5,451,470 “Nickel-Chromium Corrosion Coatings and Process for Producing It. A.A. Ashary
and R.C. Tucker, Jr.
3. Application number: 201********, Thermal Spray Coatings for semiconductor Applications.
Praxair Surface Technologies, Internal Technical Reports : Over 120 published.
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