Metallurgical Engineer
Resume:
Kris E. Kitchen
Troy, IL ****4
adde7v@r.postjobfree.com
www.linkedin.com/in/kris-kitchen-65963920
Summary
Metallurgical Engineer with 19+ years of experience in the materials industry that has been in a wide range of roles and situations. Technical, sales, and operational experience has led me to have a passion for manufacturing and specialized industrial construction. Purpose driven individual that believes interaction with colleagues, customers, and constant learning is the fuel that results in success. Professional skill set compliments a role in engineering or product management. Recent employment has been primarily between two organizations within the St. Louis metro area; thus, the resume below is not in chronological order. The employment changes were the result of programs ending and the need to continue professional growth. These organizations were left in good standing and allowed me to return easily when new opportunities arose.
Skills
Metallurgy Customer Service Innovation Technical Writing Metal Fabrication Quality Control Critical Thinking Manufacturing Project Management Product Development Communication Problem Solving Education
B.S. Metallurgical Engineering – Missouri University of Science & Technology (formerly University of Missouri- Rolla)
Experience
Integrated Global Services (IGS)
Metal Coating Field Applicator – Thermal Spray
Richmond, VA
Director – Project Management Office (December 2019 – April 2020)
• Provided leadership for implementing a new corporate Project Management Office (PMO) for global alignment and consistency.
• PMO assignments included direct oversight of the following:
Design and achievement of a new project leadership structure that evolved into a Project Manager
(PM) based in the office and Project Superintendent (PS) for managing site execution.
Improved handoff between sales and operations by implementing a two-step process where maximum information sharing would occur before mobilization to customer. This resulted in sales-to- operational score improvement by 10%.
Strong emphasis on customer service with weekly coaching of PM's. This resulted, for example, on- site upselling, improved customer final report quality, and better operational communication with clients. Customer service score in a few months went from 8.5 to 9.4 (out of 10) or 9% improvement.
• Laid off due to COVID-19 and the subsequent cancellation of global projects. Magnesium Elektron dba Luxfer’s Graphic Arts (4 years total) Manufacture of Magnesium Plate/Sheet
Madison, IL (St. Louis Metro)
Operations Manager – Metal Finishing (June 2019 – November 2019)
• Managed the day-to-day operations for the Graphic Arts finishing area. This includes direct supervision of 30+ equipment operators, three floor managers, and one engineer.
• Developed a first-in-first out system for WIP. This resulted in improved housekeeping and efficiency.
• Initiated a bi-weekly “tool box” meeting with floor workforce to improve company communication and develop ideas for process improvement.
Business Development & Marketing Manager (June 2018 – June 2019)
• Returned to organization after opportunity in sales department opened.
• Performed internal justification and market research to launch wrought magnesium alloys into new market for industrial robotics and robot end-of-arm tooling (EOAT). Successfully promoted magnesium into this market in fall 2018 by networking, trade associations, and business development. Several EAOT manufactures currently working on magnesium prototypes, which will be the first-time magnesium has been used in industrial robotics.
• Kicked off corporate web presence by developing content for new Loafer Magnesium Rolled Products webpage (www.luxferga.com), LinkedIn account, and YouTube account. This improved web traffic to Luxfer's site by 50% in two months.
• Assisted outside sales managers with technical and business development that grew 2018 wrought magnesium sales by 3.8%. This included extensive time in Japan to further business in Asia. Sr. Program Manager (December 2014 – January 2017)
• Production lead for patented Elektron 43 (E43) aerospace grade magnesium plate. This included technical liaison for sales visits to clients.
Monitored rolling and stretching of E43 plate by coaching operator during manufacturing. The metallurgy of E43 requires a small window to process correctly at elevated temperature. The close monitoring resulted in a 20% decrease in scrap.
Improved “out-of-flat” E43 plate that was the result of improper cooling after rolling. This was performed by production floor testing during the quenching of the plate and using various scenarios to quantify flatness. This led to a 10% decrease in scrap.
Managed outside heat treat vendor for aging E43. This required specific shipping instructions, correct furnace type, and expediting mechanical testing after returning from heat treater. During this time period, late deliveries of E43 to customers seized.
Managed ultrasonic inspection to map out any subsurface defects and troubleshoot with casting facility.
• Supported aerospace market by developing a North American supply chain for manufacturing of magnesium aircraft seat components using E43.
• Championed Luxfer's participation in SAE non-ferrous alloys standard committee for E43.
• Developed new magnesium alloys to improve room temperature formability with a focus on penetrating electronics and automotive markets.
This included extensive R&D where small slabs were cast and rolled on a R&D mill. Close monitoring on the production floor was required to witness rolling performance.
Completed extensive laboratory testing that included a month-long corrosion investigation using a salt fog cabinet. The following metallurgical analyses techniques were personally performed:
Scanning Electron Microscopy (SEM) with EDS.
Electron Backscatter Diffraction (EBSD) to determine magnesium plate texture (crystallographic orientation).
Optical light microscopy and preparation of samples.
Bend and cup test to determine ductility and formability.
• Left the organization on good terms after the conclusion of the Elektron 43 and new alloy programs. Nooter Construction Company (4 years total)
Industrial Construction Contractor
St. Louis, MO
Group Manager – Specialty Projects (February 2017 – June 2018)
• Managed field service group that repairs chemical pressure vessels, equipment, and piping. This work involved relines, retrofits, and corrosion repairs. Welding services include exotic alloys such as titanium, nickel, and super-duplex stainless steels.
• Grew small volume group revenue in one year from $2.5M to 2.8M through business development.
• Sold large industrial construction/repair projects to two new clients. Projects resulted in gross margins of 25% and 34% respectively with on time service and satisfied customer.
• Revived relationship with past client that resulted in a large industrial repair project located in a competitive geographical area.
Thermal Spray Services Manager (March 2009 – October 2011)
• Initiated a new metal coating product line within the organization that required a ground up approach for marketing and business development.
• Sold boiler metal coating projects to three new clients in an industry new to the organization.
• Performed R&D studies on field applied thermal spray coatings and the required technical reporting to indicate coating performance.
• Delegate for the ASM International Thermal Spray Operator Certification Committee. Cerro Flow Products (3 years)
Copper Tube Manufacture
Sauget, IL (St. Louis Metro)
Metallurgical Quality & Process Engineer (October 2011 – November 2014)
• Improved inefficient processes in extrusion, drawing, and heat-treating operations.
A3 report methodology
Fishbone diagrams
• Monitored heat treating process with daily checks on copper tube grain size.
• Quality liaison between customer and operations.
Owner of all company CAR’s (Corrective Action Report) and communication to manufacturing area for correction. This also included posting Quality Flashes throughout the plant.
Implemented Pareto Charts at every work center to show operators where issues were. This resulted in meeting with operators in controlled environment where solutions could be discussed.
Managed all warranty claims from customer that required metallurgical failure analysis of corroded copper tubing.
• Developed and implemented liquid coating to mitigate copper tube tarnishing during manufacturing. This resulted in over $200,000 of savings by reducing scrap.
• Facilitated lean methodologies such as performing kaizen events and implementing facility wide visual management system. Within three months equipment performance increased by 5%. TechSpec Incorporated (6 years)
Metallurgical Lab and Consulting
Kansas City, MO
Metallurgist (February 2003 – March 2009)
• Executed metallurgical failure analysis investigations using standard methodology such as scanning electron microscopy, optical microscopy, chemical and mechanical property determination, and comprehensive photographic documentation.
• List of projects:
Corrosion Cracking of Heat Exchanger
Failure Analysis of SAE J429, Grade 8 Fasteners
Failure Analyses of Hub Assembly Weldments
Failure Analyses of Failed Fasteners
Dye Penetrant Inspection of Shaft Weldments
Evaluation of Air Interlock Valve after Corrosion Testing per ASTM B117
Analysis of Corrosion Attack on Closed-Loop Condenser Tube Bundles
Microstructural Examination of Cryogenic Processed Copper Wire
Case Depth Analyses of Gear Teeth
Corrosion Evaluation of Medical Hemostats
Evaluation of Water Pipe Failure
Failure Analysis of Helical Foundation Support
Failure Analysis of Bus Wheel Studs
Failure Analyses of Steel Anchor Insert Anchors Located on the N22 Concrete Panel
Stainless Steel Pump Rotor Failure Analysis
Arcing Failures in Insulated Copper Wire
Evaluation of Cold Rolled Electrical Resistance Welded Shapes
Corrosion Analysis of Stainless Steel Water Holding Tank Welds (MIC) Dura-Bar (1.5 years)
Manufacture of Iron Bar Stock
Woodstock, IL
Metallurgist (June 2001 – January 2003)
• Performed daily microstructural and chemical checks of casted iron bar.
• Technical liaison between customer and operations.
• Executed machining studies to enhance marketing and provide customers information.
• Worked with Sr. Metallurgist on new alloy development. 6817 Stadium Drive, Suite 207 ■ Kansas City, MO 64129 816-***-**** – Office ■ 816-***-**** – FAX
www.kcmetallurgicalsolutions.com
Failure Analysis
Of
Failed Fastener
For:
Jason Hentschel
American Racing
6600 Stadium Drive
Kansas City, MO 64129
816-***-**** Office ■ 816-***-**** Fax
Date: May 11, 2007
TSI Report No. 2006
TechSpec Incorporated
Metallurgical Consulting
TSI REPORT 2006
Table of Contents
Section 1: Introduction P. 2
Section 2: Method of Analyses P. 2
Section 3: Findings P. 2
Section 4: Conclusions P. 3
Section 5: Figures 1 – 11 P. 4
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TSI REPORT 2006
Section 1 – Introduction
American Racing had requested that TechSpec Incorporated assist in determining the reason for the failure of a fastener that held hub components together around a motor cycle aluminum wheel. This motorcycle wheel hub was held in place by four zinc plated fasteners with the following dimensions: SHCS 7/16” – 14”x3.5”.
This failed fastener was discovered after the wheel assembly (hub and wheel) had been delivered to the customer. Only one of the four fasteners in the hub had failed and was noticed before the wheel was assembled onto the motorcycle.
The fastener had failed at the radius of the head-shaft interface. By load design (in the case of overload) the fastener should fail in the threaded area of the fastener. American Racing has not seen any other failures in-house or from customers.
Section 2 – Method of Analyses
• Optical Microscopy (macro): Visual inspection of the fracture surface was observed and documented at 10X and 25X magnifications.
• Optical Microscopy (micro): A sample at the fracture surface was micro-sectioned in the longitudinal
(parallel to rolling direction) plane for evaluation. Also, a new fastener sample was micro-sectioned at the radius of the head-shaft interface to compare the microstructure to the failed fastener microstructure. All these samples were then mounted in epoxy resin and polished using standard metallographic preparation techniques. They were then etched in a 2% nital etch solutions to reveal the microstructure of the material. All the cross-sectional samples were documented at 400X – 1600X magnifications.
• Scanning Electron Microscopy (SEM): 20 kV energy was used with backscatter and secondary electron imaging to document the fracture surface details of the failed fastener. These images were taken at 40X – 2000X magnifications.
Section 3 – Findings
The fracture surface of the failed fastener can be seen (optical light) in Figures 1 and 2. Microcracks were observed on the fracture surface. In order to better understand these microcracks, a Scanning Electron Microscope (SEM) was used to view them. The SEM images can be seen in Figures 3 – 5. From SEM analysis, it was determined that the fastener had failed by time-delayed hydrogen embrittlement. Hydrogen embrittlement is a process resulting in a decrease of the toughness or ductility of a metal due to the present of atomic hydrogen. Hydrogen embrittlement results from hydrogen being absorbed into the metal or alloy.
This mechanism can happen in many ways, but the most common source would be from a plating process. This particular fastener had been plated with zinc and this plating process would be the reason for hydrogen pickup. With a tensile stress factor exceeding a specific threshold, the atomic hydrogen interacts with the metal to induce subcritical crack growth leading to final fracture. 3
TSI REPORT 2006
There is normally a delay between the application of stress and the onset of microcracking. This coincides with why the fastener did not fail until after it had been installed, tightened, and delivered to the customer.
The material characteristics of a hydrogen embrittlement failure can be seen in Figure 6. The grains separate on the prior austenite grain boundaries of the hardened martensite to form microcracks that lead to failure (During the heat treatment process the fastener would be brought to a fully austenite microstructure. During the cooling process for hardening, martensite forms. Then a temper heat treatment would be performed to reduce the hardness to specification. This martensite forms from austenite, leaving the appearance of grain boundaries or prior austenite grain boundaries). This grain separation or microcracking from hydrogen embrittlement was also obvious in the micro- sections from Figures 7 – 10. Microcracks or grain separation was observed at the fracture surface of the fastener.
A classic example of hydrogen embrittlement can be observed in Figures 9 and 10. Notice the triple point grain boundary separation in Figure 10. This type of defect indicates intergranular cracking that is typical for hydrogen embrittlement.
An additional fastener was micro-sectioned to compare it’s microstructure to the failed fastener microstructure (Figure 11). This fastener had been loaded above the specified load of 65 ft-lbs and failed in the threaded area. By load design this would be where the fastener should fail. The fracture surface of this fastener had a typical overload/cupped fracture surface. Its microstructure was consistent with the other failed fastener microstructure and both were typical for this type of fastener. No detrimental inclusions (cleanliness, i.e. manganese sulfides) were seen in any of the fasteners’ microstructures.
Section 4 – Conclusions
The failed fastener failed by time-delayed hydrogen embrittlement. The source for the hydrogen most likely came from the zinc plating process. Standard plating practices typically call out for a low temperature bake-out (375 F - 400 F) no more than four hours after the plating process has been completed.
It is unknown why only this particular fastener had time-delayed hydrogen embrittlement. Perhaps it missed the bake-out or was lodged in an unusual place during plating and did not receive the proper processing.
If I can be of any more assistance, feel free to call me with any questions. Sincerely,
Kris Kitchen, President
TechSpec Incorporated
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TSI REPORT 2006
Section 5
Figures 1 – 11
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TSI REPORT 2006
Figure 1: Fracture surface of the failed fastener at the shaft/head interface. Micro crack indications were seen on the fracture surface. These microcracks have been highlighted with green arrows. The red and blue boxed areas can be seen below in Figures 2, 3 and 4.
6
10X
25X
Figure 2: Higher magnification of
fracture surface showing
microcracks at the fracture
surface.
TSI REPORT 2006
Figure 3: High magnification SEM images of the fracture surface on the fastener. Notice how the surface has a rock candy appearance and the prior austenite grain boundaries have been separated. This fracture surface is a text book case of hydrogen embrittlement.
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TSI REPORT 2006
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Figure 4: SEM images of fracture surface. Notice the, microcracks follow prior austenite grain boundaries (arrows). This again shows a text book case of hydrogen embrittlement.
TSI REPORT 2006
Figure 5: SEM image of the fracture surface. Notice how the grains of the material have separated showing signs of hydrogen embrittlement. Figure 6: An illustration showing the characteristics of hydrogen embrittlement. Taken from an unknown German publication.
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Figure 7: Micro-section of the failed fastener through the fracture surface. Again, separation of the prior austenite grain boundaries were observed. The microstructure consisted of martensite and had a microhardness of Knoop 426
(Rc 42). This microstructure would be typical for this type of fastener. Also, no detrimental inclusions were seen in this microstructure. Figure 8: Micro-section of the failed fastener through the fracture surface. 10
400X
400X
TSI REPORT 2006
Figure 9: A classic example of hydrogen embrittlement can be observed in this image. Notice the triple point grain boundary separation (arrows) near the top of the image. This indicates intergranular microcracking that is typical for hydrogen embrittlement.
Figure 10: Triple point grain boundary separation near the fracture of the fastener. 11
800X
1600X
TSI REPORT 2006
Figure 11: Microstructure of an unfailed fastener. The microstructure consisted of martensite with a microhardness of Knoop 440 (Rc 43). This microstructure was consistent with the failed fastener and would be typical for this type of fastener. Also, no detrimental inclusions were seen in this microstructure. 12
800X
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