Quality Engineer Engineering Support
Resume:
CURRICULUM VITAE
PERSONAL DATA
Full Name: Ossama Said Elsebaie
E-mail: *************@*****.***
Profile: www.linkedin.com/in/ossama-elsebaie-6a748643
OBJECTIVES
Lead and implement the best rolling practices to ensure consistent high quality lithium foil products. Maintaining all melting furnace, casting, and rolling equipment to ensure optimum operating condition to produce high quality aluminum castings. Implement proper quality controls to maintain high quality products and respond to all internal and external audits. Design, perform tests, and compile data to write technical reports for external customers. Gather and present all the KPI data for melting and casting department on a weekly basis. Oversee all the external heat treatment processes for new mill rollers. Lead training of new engineering staff and technicians on best casting and quality control practices.
INDUSTRY WORK EXPERIENCE
Lithium Foil Development Engineer V 11/ 2023 to present.
Albemarle Corporation Kings Mountain, NC
●Implement all the metallurgical and the rolling fundamentals for ultra-thin lithium foil.
●Develop the rolling process for ultra-thin lithium in terms of identifying the raw materials, specifications, rolls type, lubricant, thickness profile, and quality test.
●Lead all the design of experiments related to the rolling process.
●Compile the rolling experiment data, and analysis and
●Develop the necessary metallurgical and quality tests to ensure finished foil product meet the customer requirements.
●Work with business and sales team in the new product development (NPD) and prepare customer samples for qualification.
●Lead continuous improvement projects related to the rolling mill machine.
●Participate in the MOC, lab safety audit, PSSR, and all HSE activities.
Technical Metallurgical Manager (Contract) 01/2023- 11/2023
CCL Metal Science (Aluminum Continuous Casting) Clinton, NC
●Lead and implement all the best metallurgical melting, molten metal treatment, cleaning, and charging practices.
●Oversee and improve all the rotary strip continuous casting procedure.
●Manage all metallurgical quality lab, implement all the required tests, and approve all results.
●Oversee the hot and cold mill rollers purchases and tracking record.
●Lead the lining and refractory repairs for all melting and holding furnaces.
●Train all new technicians to perform all the required tests.
●Improve and implement the best hot and cold aluminum rolling practices.
●Lead failure analysis and root cause investigations of aluminum product defects.
●Gather and present all the KPI data for melting and casting department on a weekly basis.
●Respond to all technical inquiries to improve the process, and support quality and sales.
●Commissioning and qualifying all equipment of filtration system for the casting.
●Lead continuous improvement projects and cost saving meeting for melting, casting, and rolling processes.
Senior Metallurgist Engineer (Contract) 08/ 2022-01/ 2023
Cleveland Cliffs McDonald, TN
●Oversee and troubleshoot the hot-press furnace, and the quality of quenched steel parts.
●Specify, and qualify all incoming steel coils materials to meet customer requirements.
●Develop and optimize materials specification and set up the relevant tests with a cross-functional team to meet customer specifications.
●Ensure tensile, hardness, bending and microstructure meet customer specifications.
●Ensure hot stamped steel parts have the proper Al-Si coating thickness.
●Lead failure analysis and root cause investigations of cold and hot stamped steel defects.
●Respond to daily technical inquiries from process, quality, and sales teams.
●Participate in the management meeting for continuous improvement and cost saving.
●Lead and develop an elevated level of training for lab technicians.
Staff Metallurgist Engineer 01/ 2021 – 06/ 2022
Tesla Inc. (Aluminum High pressure Die Casting) Fremont, CA, USA
●Oversee and troubleshoot the Striko stack melting furnaces and degassing holding furnaces to ensure enough metal produced for continuous die casting machines (HPDC).
●Implement the charging plan, melting system, degassing, Sr-modification, and proper cleaning instructions to high-quality metal to the die casting machines.
●Lead the refractory relining process for the stack-melting furnace.
●Specify, and qualify all raw materials and additives to produce high quality castings.
●Lead and develop a prominent level of training for furnace technicians.
●Review metal chemistry and do necessary additions to comply with Tesla requirement.
●Ensure tensile, hardness, bending and crush tests meet the internal design specifications.
●Implement proper re-melting process of scarp castings to reduce the overall castings cost.
●Lead failure analysis and root cause investigations of aluminum casting defects.
●Develop new alloys, and materials specification to meet Tesla specifications.
●Gather all the KPI data to monitor the uptime and efficiency for melting equipment and present them in the management meeting on a weekly basis.
●Commissioning and qualifying of all equipment of air exhaust abatement system.
●Participate in the staff meeting for continuous improvement, and cost reduction projects.
●Help the EHS team to comply with air district and environmental regulations.
Staff Metallurgist Engineer 10/2019 – 01/ 2021
CERA-MET LLC (Aluminum Investment Casting) Bethlehem, PA, USA
●Plan the different melting charges for diverse types of aluminum silicon alloys (355, 356, 357) based on the customer specification.
●Review and approve the composition of the different alloys using a spectrometry machine
●Review the heat treatment process and approve all the charts.
●Evaluate and approve the mechanical properties according to the military and aerospace specifications (hardness and tensile)
●Lead failure analysis and root cause investigations of aluminum castings defects.
●Lead and develop training for all furnaces and foundry technicians.
●Gather all the KPI data to monitor efficiency of melting equipment, and heat treatment.
●Respond to the daily technical inquiries from the foundry, heat treatment and sales teams.
●Support Quality to maintain NADCAP/ISO certification and respond to all materials testing and heat treatment NADCAP audit inquiries.
●Communicate special testing requirements with approved NADCAP certified labs.
●Participate in the continuous improvement meeting of the aluminum casting performance.
●Design, develop and perform tests and compile the data to write technical reports
Metallurgist Engineer (Contract) 03/ 2019 – 10/ 2019
AVIVA METALS (copper continuous casting) Lorain, OH, USA
●Develop new copper, brass, and bronze alloys by controlling the parameters of the direct chill continuous casting process (VDC-HDC), heat treatment, and the microstructure.
●Analysis and approve the composition of brass and bronze alloys using a spectrometry machine and make any adjustment to the molten metal.
●Respond to the daily technical inquiries from the foundry and sales teams.
●Evaluate and approve mechanical properties using hardness and tensile testing machines.
●Gather all the KPI data to monitor the casting and heat treatment processes.
●Failure analysis of continuous castings products for internal and external issues.
●Arrange and communicate all special materials testing with approved suppliers.
●Participate in the management review committee meetings for continuous improvement.
Metallurgical Heat Treatment Engineer (Contract) 08/ 2018 – 02/ 2019
Precision Resource Cambridge- ON- Canada
●Failure analysis and root cause investigation of heat-treated steel products.
●Metal chemistry, mechanical properties, and microstructure characterization.
●Gather all the KPI data to monitor the heat treatment processes (carburizing, nitriding)
●Quality control of steel products for automotive industry
●Shop floor support for internal, customer and suppliers’ incidents.
●Champion scrap reduction plans and respond to customer complaints.
●Read and understand engineering drawing (GD&T) and CMM reports.
●Strong knowledge of ISO 9001, IATF / TS 16949, and quality tools (SPC-PPAP-PFMEA)
Metallurgical Engineer (Plant is permanently closed) 07/ 2017 – 07/ 2018
Magna International Inc (Aluminum Low pressure Die Casting Perth- ON- Canada
●Verify metal chemistry, mechanical properties, and microstructure analysis of low-pressure die aluminum casting.
●Failure analysis of aluminum casting products for automotive applications.
●Quality control of aluminum alloys castings for automotive industry.
●Shop floor support for internal, customer and supplier incidents.
●Expert in performing structured problem-solving tools (8D, fault tree analysis) and recommending corrective and preventive actions.
●Champion scrap reduction plans and respond to customer complaints.
●Gather all the KPI data to monitor the casting scrap and heat treatment processes.
●Read and understand engineering drawing (GD&T) and CMM reports.
●Strong knowledge of ISO 9001, IATF / TS 16949, and quality core tools (APQP-PPAP-MSA-SPC).
RELEVANT EXPERIENCE
●Professional in performing mechanical testing of aluminum, steel, copper, and magnesium alloys (tensile – fatigue - notched -Charpy impact - hardness).
●Hand on low pressure and high pressure, and investment casting of and melt treatments processes of aluminum, and copper alloy.
●Hand on experience in powder metallurgy and mechanical alloying of tungsten heavy alloys (Milling- compaction-sintering-characterization).
●Hand on heat treatment processes (annealing - tempering- aging- solution treatment).
●Expert in the failure analysis of aluminum, steel, and copper products.
●Metallography, fracture analysis and microstructural characterization using optical, scanning electron microscopy (SEM/EDS), and X-ray diffraction (XRD).
●Assist with the training/mentoring of new engineering staff and technicians.
●Expert in performing structured problem-solving tools (8D, fault tree analysis) and recommending corrective and preventive actions.
●Read and understand engineering drawing (GD&T) and CMM reports.
●Strong knowledge of ISO 9001, and quality core tools (APQP-PPAP PFMEA-SPC)
RESEARCH WORK EXPERIENCE
Research Metallurgist IV 11/2011 – 07/ 2017
Royal Military College (Defense Canada) Kingston, Ontario, Canada
●Development and production of novel tungsten-base heavy alloys by mechanical alloying technique for kinetic energy penetrators - project with Army Research Laboratory (ARL) United States of America
●Tensile strength, hardness, and fracture analysis of cartridge brass alloy sheets
●Fatigue and tensile strength characterization of friction welded polymer for air-intake automotive applications.
Research Metallurgist 09/ 2003 – 08/2010
Industrial Advanced Technology of Light Metals, University of Québec (UQAC) with General Motors Company (GM-Powertrain – USA).
●Improving the microstructure, hardness, and the impact toughness of Aluminum-Silicon-Copper-Magnesium Cast alloys (319- 356 and 413) for cylinder head, engine blocks, and vehicles wheel for General Motors powertrain-USA.
Research Metallurgist 03/2000 – 08/ 2003
(Semi manufacturing ferrous and Non-Ferrous Foundry - Central Metallurgical R&D Institute)
●Development and casting of novel grain refiner of Al-Ti-C composite for high strength Aluminum-Zinc alloys - Aluminum Egypt Company.
●Improving the wear resistance of cast aluminum-silicon composites
●Production of aluminum composites under industrial conditions
CHARACTERIZATION AND TECHNICAL SKILLS
●Professional in performing mechanical testing including tensile testing, hardness, fatigue, creep, and Charpy impact test according to ASTM standards.
●Operate professionally all metallography laboratory equipment including specimen preparation, cutting, grinding, rough polishing, fine polishing, and etching.
●Perform the routine metallographic examination, analytical investigations, and failure analysis including microstructural evolution, grain size measurement, and volume fraction of the entire microstructural features using image analyzer.
●Operate Scanning Electron Microscope (SEM/EDAX), optical microscopy and X-ray diffraction (XRD).
●Design, develop and perform industrial projects, compile scientific data, and write technical reports for industrial purposes.
●Crystal structure characterization and detecting new phases by X-ray diffraction (XRD)
EDUCATION
●Ph.D. - Metallurgical Engineering 2006 –2010
University of Québec - Chicoutimi, Québec, Canada
●Master of Engineering (MEng) 2010 - 2011
Queen’s University, Kingston, Ontario, Canada
●MSc- Metallurgical Engineering 2003 –2006
University of Québec - Chicoutimi, Québec, Canada
●BSc – Metallurgical Engineering 1993-1998
Suez Canal University – Suez, Egypt
COMPUTER LITERACY
●Excellent and professional working knowledge of MS Word; MS Excel; MS Access; and MS PowerPoint
●Ability to quickly grasp software of any new equipment.
●Programming Languages in Matlab, Intermediate skills in FEM.
LINGUISTIC SKILLS
●Fluent in English and French
PROFILE (PERSONAL SKILLS)
●Critical thinking and strong analytical
●Well-organized, self-reliant, resourceful, and effective team member
●Decision-making, and problem-solver
●Excellent written and verbal communication.
PUBLICATIONS
More than 12 articles have been published in notable scientific journals and conferences (copies available upon request).
REFERENCES
●Grant Pattinson, Materials Engineering Manager, Tesla Inc., Email: **********@*****.***
●Sal Alshabani, Advanced Engineering manager, Apple, Email: **********@*******.***
●Kevin M. Jaansalu, Associate Professor, Department of Chemistry and Chemical Engineering, Royal Military College of Canada, Kingston, Ontario. Tel: 613-***-**** ext. 6049, Email: *****.********@***.**
●Muhammad E. Aslam, Production Manager, Magna International, Grenville Castings Division, 1 Conlon Drive, Perth, Ontario. Email: **********@*****.***
●F. H. Samuel, Department of Applied Science, University of Québec (Chicoutimi), 555 Boulevard De l’Université, Chicoutimi, QC, Canada. Tel: 418-***-**** ext. 5406, Email: *****-************@****.**
●B. J. Diak, Associate Professor, Department of Mechanical and Material Engineering, Queen’s University, Nicol Hall, 60 Union Street, Kingston, Ontario, Canada. Tel: 613-***-****. Email: ****.****@*******.**
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