PhD Mechanical Engineer
(Deformation Processing-Mechanical Metallurgy)
• Ph D Degree in Mechanical Engineering
(Deformation Processing-Mechanical Metallurgy), Nagoya University, Japan
• MS Degree in Mechanical Engineering (Metal Forming), Assiut University
• BS Degree in Mechanical Engineering (Production), Cairo University: Honors
• Publications: 23 papers published in academic and technical journals.
• Patents: 10 US Patents awarded (some awarded in Europe)
• Languages: English (Fluent), Arabic (Native), Japanese (Fair), French (Elementary)
With Saft America, Inc. (ALCATEL):
Manager, Batty Eng. & Business Development, Saft America, IP Manager.
Program Manager, Senior Manufacturing Engineer
Hand picked with a team of 9 scientists and engineers to start Saft’s R&D Center in the USA, Jan. 1990.
Successfully had the Lithium Nickel Oxide listed on the US EPA TSCA Inventory.
Established and managed all the Intellectual Property (IP) for Saft America; interfacing with Alcatel IP Department and Saft Patents Attorney since 1992.
Established a worldwide base to supply basic materials for the Li-Ion battery technology.
Developed the high-power Li-Ion Module under the USABC / PNGV Battery Development Program.
Secured the contract of the USABC Ni-MH Battery Development Program and was appointed to be the Program Manager for five (5) years.
On Saft’s Bonus Program, among the management team, at the Advanced Battery Systems
Division, Cockeysville, MD, for the last 10 years.
o Achievements in Advanced Manufacturing Engineering and Processing:
Welding of titanium casing for a thermal battery.
US Patent No. 5,314,544 “High Speed Non-Destructive Cleaning of Metal Foam Substrate of Electromechanical Cell Electrodes.
Cold drawing of a 6-inch shallow molybdenum case of a LiAl-FeS2 high temperature electrochemical cell case.
US Patent No. 5,529,858: “Hermetically Sealed Thermocompression Feed through and Peripheral Seal for High Temperature Lithium Based Cells”.
o Prepared Technical & Cost Proposals, secured contracts: for several battery development programs at Saft America, Inc., also, I managed the module and battery system development efforts of these programs:
• USABC Ni-MH Battery Development: secured the Contract: $18M/3 years, extended to $32M/5 years, and assumed the overall management of the Program (contract was completely handled by Saft division in Bordeaux, France).
• USABC LiAl-SO2 Battery Development: secured the Contract: $18.1M/3 years, assumed the responsibility of developing the Battery Module including the Thermocompression Seal and, the Battery system.
• USABC High power Li-Ion Battery Development Program: I managed the module and battery system development efforts of this program, and developed the following Li-Ion battery systems:
o General Dynamics Land systems RSTV (Hybrid Electric Vehicle) Battery Program: secured the Contract ~ $1.0M, assumed the responsibility of developing the Battery Module, Battery System and the Program Management (6 battery systems were manufactured and integrated into vehicles; 2 per vehicle).
o General Dynamics Electric Boat (GDEB) Lamprey Program: High Power Li-Ion Battery for underwater application: secured the Contract and assumed the responsibility of developing and manufacturing the Battery Module and the Battery System. Three (3) battery modules were delivered.
o US DOD-DARPA CHIPS Li-Ion Battery Program: assumed the responsibility of developing and manufacturing the Li-Ion Battery Module and the Battery System.
o DaimlerChrysler: secured the following contracts, which totaled about $1.8M, and assumed the responsibility of developing the Li-Ion Battery Module and Battery System, as well as the Program Management:
• High Power Li-Ion Battery for the Fuel Cell powered Atrium Mini Van.
• High Power Li-Ion Battery for the Durango HEV.
• High Power Li-Ion Battery for the JR/Dodge Stratus HEV.
• High Power Li-Ion Battery for the Gen 2/Dodge Neon HEV.
o US DOE/ SNL Energy Storage High power Li-Ion Battery System for Distributed Generation Program; secured the contract and managed the program, ~ >$1.3M (The System: Saft’s Battery, Power Control Electronics from Sat Con, and a Capstan 60kW Micro turbine). Developed the Battery system and two Battery systems were manufactured and delivered to American Electric Power (AEP) of Columbus, Ohio, and to Southern Co. Services of Birmingham Alabama, respectively.
With GM, Truck & Bus Group, Baltimore Facility:
Consultant, Product Build Analyst
Successfully completed a series of projects related to the build of the M - Van that included the re-evaluation of some manufacturing and design concepts of the product applying principles of Geometric & Dimensioning Tolerances (ANSYS 14.5).
Represented Baltimore GM Truck & Bus facility at GM Advanced Manufacturing Engineering Meetings.
Reviewed suppliers, manufacturing, and quality testing facilities for the G-Van
(Astro MiniVan) Program.