metallurgist

Cell phone: 312-***-****

Reza Haghayeghi ***********@*****.***

**** ******* ***., ***.***, Austin, TX 78731

Linkedin Profile: https://www.linkedin.com/in/reza-haghayeghi-b362b752/

I am an US Citizen and a senior casting metallurgist (PhD) with 16 years experiences in industry and academia.

Senior Metallurgist/ Casting Engineer

I am a metallurgist with great experiences in foundry and casting of non-metallic alloys especially Aluminum and Super alloys. My expertise in leadership, team working, problem solving, personal effectiveness and communication skills are cooperating all-in-all to fulfil the projects at the highest level of standard. Adept at building strong relationships with management, personnel and clients.

Knowledge & Skills

Quality

Lean manufacturing, Lean enterprise, Kaizen, Six Sigma, PPAP, APQP, PPM, Failure analysis (FMEA, Fishbone diagram, 5 Whys), Process manufacturing efficiency/optimization, Auditing foundry, quality control, Quality escapes, containment

Materials and Processes

Die-casting (Giga casting), gravity casting, Twin roll casting, Injection molding, Investment casting, Single Crystal casting (Czochralski process (CZ), Floating zone (directional solidification), and the Bridgman technique), Additive manufacturing, Heat treatment, Forging, Process development.

Good understanding on Physical metallurgy, Cast/ wrought Alloys, heat transfer, Additive manufacturing, Composites, Solidification processes and Crystallography

Materials testing (Tensile, corrosion, hardness, Non-destructive testing…)

Materials Engineering principles, Metallography, Mechanical Metallurgy (Fracture, Fatigue, Creep, Stress-Strain analysis), Structural design, Microstructure analysis, Evaluation and root cause analysis and explaining phenomena per evidence.

Materials characterization certificate (SEM, TEM, OM, EBSD, HRTEM, and EBSD, XRD, XRF, Mass spectrometry, etc.)

Utilizing and developing variety of standards (ASTM, ASM, EN, etc.), ISO 9000 and ISO 14001, Overseeing production quality and ensuring quality standards

R & D on alloy development for casting processes

Data Acquisition

Collection of data signals for process parameter and their connection via neural network, lean methodology

Project Management and Engineering Economics

Audit & tracking and management of projects to ensure timely and proper completion

Time value calculations for decision making in engineering projects

Ability to manage multiple priorities under tight deadlines, Risk management

Problem solving

Ability to define problems, establish facts, critical thinking & drawing valid conclusions.

Ability to interpret an extensive variety of technical instructions

Dealing with several abstract & variables.

Employment History

Sr Casting Quality Engineer Tesla (Austin, TX) Nov 2022-Present

Job Scope: Enhancing the quality of products by improving the process and optimization the process parameters. Quality and metallurgical analyses of parts for root cause determination and applying fishbone diagram to improve processes.

Accomplishments:

Optimizing process parameters of die casting for less defects and less scrapping (Lean Enterprise, Lean Manufacturing)-resulted into 27% less scrapping

Developing process parameters, shot curves, spray adjustment and die modifications

Leading solidification projects for alloy development based on solidification characteristics

Developing an inspection spec for the technicians to be able to identify defective parts.

Failure analysis, Metallurgical testing, Materials characterization (SEM, OM, EDX, XRD)

Sr Casting Supplier Quality Engineer Toyota Motor Inc HQ (Dallas, TX) Jan 2022- Nov 2022

Job Scope: Develop Toyota requirements, systems, and procedures to ensure effective and consistent operations are in place. Leading projects for metallic part & process confirmation, including: Managing and / or conducting suppliers’ parts evaluations and process reviews. Empowering suppliers by applying Genchi Genbutsu approach for problem-solving by finding the root cause in process.

Accomplishments:

Developing Die Cast suppliers, defining process parameters, die design, Magma soft simulation discussion

Materials characterization (SEM, HRTEM, EBSD, XRD) for root cause analysis for metallurgical failures

Creation of a defect atlas for every alloy & supplier-For each supplier and alloy, common products’ defects, root causes and solutions were created.

Sr Casting Quality Eng. Volvo Truck (Hagerstown, MD) March 2020- Jan 2022

Job Scope. Ensuring that production would meet metallurgical performance and all supplied parts pass the metallurgical criteria.

Accomplishments

Designing the alloy according to Volvo quality specification (focusing on permeant and HPDC)

Optimizing the metallurgical requirements to have added value to Volvo products

Materials characterization (SEM, OM, EDX, XRD), Failure Mechanism explanation, Analysis of thermal-mechanical stresses

Helping design and engineers to select right alloy and process resulted into extensive cost saving

Senior Metallurgist, Met lab Supervisor GF Linamar (Asheville, NC) March 2018-March 2020

Job Scope: Managing the quality of products and projects development. Aluminum and Magnesium die cast products quality check. Performing destructive and non-destructive tests, evaluations and analysis of results for acceptance or rejection determinations according to written instructions and customer specifications (BMW, Volvo, Ford, Honda, etc.)

Accomplishments

Implementing the metallurgical lab at GF Linamar for first time with greatest facilities

Obtaining ISO 17025 for Metallurgical lab for having reliable results for customers

Effective communication with customers for metallurgical results interpretation

Resolving a Volvo product problem and modifying a recommended alloy from Ford which resulted into lean enterprise for GF Linamar and the customers

Alloy and process suggestion to multi customers resulted into extensive cost saving

Failure analysis, Materials characterization

Assistant Professor Azad University (UK) Feb 2011-Jan 2018

Job Scope: Teaching, conducting research and publishing results, advising undergraduate and graduate students, resolving industrial problems through funding proposals and providing public, departmental, college, and university service.

Accomplishments

Generating $5.5M funding from research projects

Publishing more than 45 international articles in peer reviewed scientific Journals

Supervising 10 PhD candidates and 35 Master students

Process casting quality engineer British Airways (UK) May 2009-Feb 2010

Job Scope: Metallurgical Investigation and research to resolve quality issues and enhancing products. Quality management per ISO AS9100 and suppliers’ development to meet BA quality spec.

Accomplishment

Creation of a wax for investment casting that resulted into 45% less time for dryness, 37%less energy consumption rather than available waxes

Developing a single crystal of superalloy that surpassed all available alloys for mechanical properties

Working closely with 2 suppliers helped them to get certified by British airways.

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