Gus Aouf

**W*** Douglas Rd, Naperville IL *****

630-***-****

addzqz@r.postjobfree.com

SUMMARY OF QUALIFICATIONS

Chemical engineering professional:

Chemical Engineer, Materials Process Engineer, Aircraft Manufacturing, ROHS Compliance Verification, Telecommunications Sealants.

Patents/Disclosures:

Protective coating and method of application.

Systems for sealing electrical connection.

A manufacturing process for packing sealant into housing.

Expendable multi infrared decoy chemical design.

Security Clearance.

PROFESSIONAL EXPERIENCE

Chemlab Chemiluminescent, Plainfield, IL. January 18 – Current

Process Chemical Engineer/Chemist May 11 – August 15

Responsibilities:

Organic synthesis of CPPO (Oxalate).

Solvent distillation and material recovery such as: Pentanols, Methanol, Toluene.

Vacuum distillation of excess solvents at various temperatures.

Purification of CPPO using a specific organic solvents and filter aides at low temperature.

Provided supervision and technical assistance for the operation of glass lined reactors.

Supervised and monitored reaction rates and concentrations that were involved during the synthesis process of making the chemical Oxalate (The primary chemical in glow sticks used by the U.S army including Infrared glow sticks).

Provided supervision for proper handling of chemical waste and hazardous materials that are generated during the synthesis.

Perform chemical analysis using HPLC & GC instrumentations.

THREE-FIVE years’ experience with extrusion and injection mold of LDPE and HDPE.

Silicones Vulcanization- dental impression silicone formulator:

Selectivity of polymer chains, polymer chain length, polymers chain reactive functional group, cross linkers, crosslink density, fillers, catalyst, chemical compatibility, dimensional stability, chemical compatibility and shrinkage, enthalpy and entropy changes during the vulcanization process.

Study of additional reactions of various unsaturated functional silicones to cross linker and their effect on the shrinkage and dimensional stability on the resulting polymer.

Polyurethane Vulcanization- Polyurethane Sealant Gel formulator:

Selectivity of Polymer Chains, Polymer chain length, Polymers chain relative functional group, cross linkers, crosslink density, fillers, catalyst, Homopolymer, Antioxidants, Fungicides, UV stabilizers, chemical compatibility, cone penetration value, elongation, ratio, chemical compatibility and shrinkage, enthalpy and entropy changes during the vulcanization process.

Rubber Vulcanization and formulation- Self-study.

This includes: Natural Rubber (NR), Styrene-Butadiene Rubber (SBR), Butyl Rubber (BR), Neoprene,

Nitrile Rubber (NBR), Ethylene Propylene Rubber (EPM, EPDM), Polyisoprene (IR).

Curing system: Sulfur-Based curing, Non-sulfur curing.

Fillers: filler and Their Effect on physical properties, Particle Size and Surface Area, Structure, Surface Activity.

Modulus and Tensile Strength.

Advanced Composites:

Study of two courses on composite material technologies provided by NIAR (National institute for Aviation Research). This includes: Graphite and matrix material properties carbon fibers epoxies, esters and polyimides, ASTM D3039-00 Tensile properties of polymer matrix in composite materials, ASTM D5379-05 V Notch shear stress test.

Study of organic synthesis of various commonly used epoxides resins and compounds used to form the matrix of advanced composites such as DGEBA, DGEBF, NOVOLAC, N. N. N TGML.

Curing reaction of epoxides group with either addition curing agents of ammine, anhydride or catalyst (Lewis Base or Acid).

Study of process of producing carbon fibers from polyacrylonitrile PAN or pitch precursor.

Nordam INS, Tulsa, OK September 15 – Dec 17

Material and Process Engineer II

Responsibilities:

Manage Phosphoric acid anodizing tank line of aluminum alloy, 2024-T3 and 7075-T6 per BAC5555

Composite bonding using structural adhesive, 3M, AF-163-2K and Cytec FM 73.06PSF

Maintain Trichloroethylene degreaser bath

Experience with TrueChem software.

Perform validation/ verification testing.

General Dynamics Company, Woodbridge, VA Nov 10 - Apr 11

Environmental Lead, Material and Process Engineer ESOH (Contract Position)

US Marine Corps, Amphibious Expeditionary Fighting Vehicle, Land and Armament System- Defense

The premier global defense, security and aerospace company.

Responsibilities:

Reviewed and analyzed military standards and specification for specified prohibited and restricted materials. The accepted specifications and materials will be integrated into parts and material management and MSDS data base which will aid designers and engineers in selecting hazardous free parts and materials.

Performed chemical analyses, chemical compatibility and interactions on materials involved and used on the vehicle.

Peer review of materials and specifications for and interactive technical manuals including system, subsystem and critical item components specifications.

Work with and implement the following Acts and regulations: (NEPA) National Environmental Policy Act, (EPCRA), (TASCA) Toxic Substances Control Act, (CWA) Clean Water Act and (RCRA) Resource Conservation and Recovery Act. Provided by the US Marine Corps.

Kilgore Flares Company LLC, Toone, TN Jan 09 - Apr 09

Formulation Chemical Engineer, Product Development and R&D (Contract Position)

Pyrotechnics and Energetic Materials, Solids Mixing, US Air Force- Defense and Commercial

A major producer of Infrared flares for the DOD.

Responsibilities:

Perform physical and chemical analysis on materials that are involved in making flares and their impact on the IR output. These include drum particle size distribution, particle size, particle surface area, carbon content and their effects on reaction rate/time and composition. These flares are used by DOD as countermeasures tools for protecting military jet fighters, helicopters and bombers IR seeking missiles.

Generated flare invention- disclosure for B-52 bomber ALA project, “Expendable Multi IR Decoy Design”. A unique design concept for producing expendable flares generating multi IR signatures, closely tailoring the perimeters of any proposed IR performance envelope while offering modularity and substantial savings in initial material usage. The concept of this invention can be adapted and used on many other IR flare design projects.

Granted federal explosives license/ permit by Bureau of Alcohol, Tobacco, Firearms and Explosives.

Interim secret security clearance.

Lear Jet Aircraft Company, Wichita, KS Dec 07 - Sep 08

Materials & Process Engineer, Aerospace (Contract Position)

A major corporate jet manufacturer serving numerous industries.

Responsibilities:

Perform analysis of material composition through evaluation of material chemical compatibilities with epoxy paint and coating, insulation, thermally conductive sealants, fillers, silicone and polyurethane, adhesion promoters, epoxy primer, top and clear coat, O-rings, strippers, heat transfer, refrigerants,

composites, chemical conversion, conformal coating on aircrafts circuit boards and mitigation to contain tin whisker growth and various polymers fields and applications.

Provide guidance and understanding of chemical interactions between the above Materials.

Investigation study related to tin whiskers growth phenomena, and the impact of ROHS compliant electrical components on airworthiness of Learjet aircrafts.

Perform root cause analysis and corresponding corrective action.

Delta Airlines, Technical Operation Center, Atlanta, GA Apr 07 - Dec 07

Materials & Process Engineer, TechOps Center, Aerospace (Contract Position)

A major air travel provider.

Responsibilities:

Review process and materials specifications for FAA 121 and FAA 145 certifications.

Establish process and material equivalents for OEM CMM’s, AMM’s, and all other aircraft maintenance related manuals.

Create and modify Process Standards involving cleaning processes, lubricants, coatings, adhesives and plating.

Perform quality check and testing on rubber products.

Interface with OEM’s to modify Delta Processes in order to obtain materials and process equivalence.

FBI clearance.

Boeing Commercial Airplane Company, Renton, WA Jan 06 - Dec 07

Material & Process Engineer. Validation/ Verification/Aluminum /Composites (Contract Position)

A major airplane manufacturer serving the international commercial and domestic defense industries.

Responsibilities:

Perform qualification testing on room temperature curing, rubber-like Polysulfide sealants intended for use in sealing aircraft integral fuel tanks.

Manage own projects, write and execute sealants and coatings test plans. Conduct material testing on proposed sealants and coatings candidate materials per Boeing BMS5-45 integral fuel tank sealant specifications.

Hands on experience with building test specimens using Boeing specifications like lap-shears, peels, tensile and elongation, repairability, squeeze-out life, heat resistance and weight loss, low temperature flexibility, dynamic performance, corrosion of aluminum alloys and storage stability in which all will be used in conjunction with other test methods in order to determine the chemical and physical properties of sealants along with there degree of adhesion and cohesion strength on various substrates.

Hands on experience in using and operating of lab equipments and instrumentations like tensiometer, viscometer, dielectric analyzer, durometer, image analyzer, fadeometer and others. Adopt and execute specified test methods and lab procedures for data acquisition on the build or prepared specimens.

Execute test methods and experiments in order to determine the degree of adhesion of sealant on primed and non-primed, abraded or non-abraded chromic acid anodized or Alodine treated aluminum and composite surfaces.

Work closely with manufacture engineers on finding a substitute for the chromated primer used as a sealant detackifier on brush, fillet and injection seals and faying surface applications.

Performing qualification testing on two-component room temperature fast cure polyurethane coating used as a secondary fuel tank barrier for the central section of the integral fuel tank using BMS5-81.

Work closely with different vendors and sealants manufacturers like PPG Aerospace and AC-Tech on development of new generation of sealants and coatings that meet Boeing current and future needs.

Perform root cause analysis and corresponding corrective action.

Specification and standard used for the integral fuel tank and fuselage:

BMS5-45(Integral Fuel Tank Sealant), BAC5719(Chemical Conversion Coating for Aluminum), BAC5019(Chromic Acid Anodizing), BMS10-20(Corrosion Resistant Finish for Integral Fuel Tank, Primer-Aluminum), BMS10-11(Chemical and Solvent Resistant Finish, Primer-Aluminum), BMS8-276(Advanced Composite 350 F Cure Carbon Fiber Tape and Fabric), BMS10-123( Integral Fuel Tank Primer for Composite, Titanium and CRES Surfaces) and many other ASTM and Aerospace specifications.

Expertise with carbon fiber, familiar with fiberglass & Kevlar (organic fibers) fabrics in prepreg forms using phenolic, epoxy & BMI (bismaleimide) resins; familiarity with manufacturing of these prepregs and the test methods required for qualify them.

Bagging and curing composite material using temperature, pressure and vaccume.

BAE Systems, Santa Clara, CA Aug 04 - Nov 05

Environmental and Material and Process Engineer (Contract position)

Land and Armament, Defense US Army

The premier global defense, security and aerospace company.

Responsibilities:

Reviewed and analyzed military standards and specification for specified prohibited and restricted materials. The accepted specifications will be integrated into parts and material management data base which will aid designers and engineers in selecting hazardous free parts and materials.

Contacted industry and technology leaders on materials and coatings investigated new substitutes, replacements, processes and coating alternatives to hexavalent chromium, pretreatments, cadmium plating, nickel plating, lead soldering used on many components and parts of BAE military vehicles like electronics, fasteners, gaskets, plates and others. The approved substitute will be added to the list of materials in the preferred material control document and incorporated into the environmental design guide to provide designers, engineers and subcontractors in early stages with information related to design, processes and environmental requirements and compliance.

Participate in material substitution of prohibited/restricted materials mandated by the U.S army on all armored vehicles of the FCS (Future Combat System) project.

Performed part analysis and material specifications review on BAE military vehicles using DoD, MIL, Fed, ASTM, ASME, SAE, ISO, company specifications and standards.

Participate in propulsion battery trade and design study of the ESS (Energy Storage System) for nickel metal hydride, lithium nickel dioxide and lithium manganese oxide.

Participated in design, selectivity, characterization, and environmental evaluation of various heat transfer fluid and coolant candidates used on combat vehicles of the FCS project.

Perform critical properties thermodynamic calculations on the candidate heat transfer fluids used for cooling modules of lithium ion and nickel metal hydride batteries.

Exposure to the latest corrosion and environmental testes, search, study and reports performed and generated by NAVAIR, Army, US Marin Corp, Air Force, Boeing and others using alternative non-hazardous coatings on their weapon systems.

Perform safety and environmental evaluation of BAE future use chemical devices and there accidental release impact on personnel and environment.

Perform chemical and characterization study on CARC (chemical agent resistant coating) for surface treatment and coating of BAE military and combat vehicles.

Work closely with vendors and manufacturing in developing a new generation of environmentally compliant corrosion resistant coatings and paint system alternatives for FCS vehicles use.

Work with the following Acts: (NEPA) National Environmental Policy Act, (EPCRA), (TASCA) Toxic Substances Control Act, (CWA) Clean Water Act and (RCRA) Resource Conservation and Recovery Act. Provided by the US Army for the FCS Program.

International Dental Supply, Chicago, IL Jul 01 - May 03

Formulation and Test Validation Chemical Engineer (Contract Position)

Polymer and Composite, Product Development, R&D, Medical Device

A local dental supply manufacturer.

Responsibilities:

Formulated Platinum Catalyzed Silicone dental impression materials based on addition reactions.

Perform material selectivity and biocompatibility study of dental impression material chemical make-up with skin, gum, teeth enamel, saliva and others.

Perform clinical /material testing on viscosity, flow properties, dimensional accuracy, chemical compatibility with cast materials and others for optimum bite registration and detail reproduction of the jaws and teeth.

Initiate 510(K) FDA Premarket Notification for chemical compliance submission.

Marconi Communications, Warrenville, IL Apr 97 - Jul 01

Corrosion & Coating Engineer, OSP/ R&D, Polymer Formulation, Product Development

A major supplier of Asynchronous Transfer Mode, Gigabit Ethernet and internet protocol products.

Responsibilities:

Responsible for the environmental sealants used in all telecommunication products generated at North American operations.

Participate in a new material development/sealants and coatings to protect and prevent copper, aluminum and steel from corrosion.

Formulated with (Caschem Chemical Company) two parts moisture cured dielectric polyurethane self- healing polymer gel sealant/adhesive based on MDI/ isocyanate/hydroxy terminated group chemistry.

Formulated two parts platinum cured dielectric silicone self-healing polymer gel sealants based on

Functional siloxanes group chemistries.

Worked with different vendors on formulation and production of mineral based dielectric greases and potting compounds used as a sealant in the telecom devices.

Worked closely with product design and manufacturing engineering groups to develop product systems that will incorporate the sealants effectively.

Developing and instituted test programs to validate and verify sealant and product compliance to Bell Core spec. TR-NWT 975-937 and others.

Perform corrosion/ environmental validation tests include water immersion, salt fog, aging, temperature and humidity cycling, insulation and contact resistant, UV exposure and more.

Produce samples for customer/field trial.

Perform root cause analysis and corresponding corrective action.

Sylvania Chemical, Toledo, OH Oct 95 - Mar 97

Chemical Engineer, Chemical Plant, Pharmaceutical

Local/self owned Chemical products manufacturer.

Responsibilities:

Formulate batches of analgesic lotions with methyl salicylate, eucalyptus oil, thyme oil and others.

Compound antibacterial soaps with Triclosan/PCMX as active ingredients.

Managed controlled testing of pH, temperatures and composition for optimal conversion of materials.

San-Mar Laboratories, Elmsford, NY Feb 93 - Nov 95

Batch Maker, Production Supervisor, QC Personnel, Skincare formulator, Pharmaceutical

Technology – driven FDA, OTC, Drug, Cosmeceutical, HBA manufacturer.

Responsibilities:

Handled various types of surfactants and emulsifiers used for making crème and lotions.

Formulating and compounding batches for cosmetic firms such as Estee-Lauder, Clinique, Borghese, Victoria Secret, Limited Express, Thompson Medical and other chain stores.

Performed pH, viscosity, and air content measurement to met GMP requirements.

Miscellaneous Work Experience:

Metal Treatment Supervisor

Responsibilities:

Metal pickling and surface preparation for paint and enamel coating.

Chemical Lab Technician

Responsibilities:

Unit operation, steam distillation, and pH measurements.

EDUCATION

Bachelor of Science, Chemical Engineering, University of Toledo.

TRAINING

Course work in Thermodynamics, Mass Transfer, Heat Transfer, Fluid Machines, Element of Transport Phenomena, Plant Design, Reactor Design, Bio Separation, Analytical Chemistry, Pulp and Paper Technology, Air Pollution Control, Material Science, General Biology, Human Anatomy & Physiology, Medical Terminology, Computer Aided Design with ASPEN, TUTISM, UNIFAC, and FORTRAN.

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