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Resume of UFE
Consultant

EXPERTISE AND SERVICES

Product, Operations, Fatigue Failure Analysis Expert Consultant
Expertise in foundry molten metal processing and application, product and operations management, and metallurgical and sales engineering.

Additional areas of related expertise include Applications Engineering, Technical Sales, Automotive Metallurgy, Foundry Metallurgy, and Investment Casting Consulting.

This KKAI Associate offers expertise specific to Direct Production of Aerospace Casting, Direct Production of Commercial and Military Castings, Production of High Quality Aerospace and Medical Alloys, production of ultimate state-of-the-art Clean Steel Technology Alloys, Induction Melting, and Melting Productivity.

Among our many metallurgical experts, this associate provides an expert source of specialized capabilities and background in Clean Steel Technology, Casting Defects, Heat Treatment, Machinability, Alloy Development, General Metallurgy, and Alloy Sales.

Additional experience and specialization includes problem solving, quality issues, training, expert witness, alloy development, foundry alloy sales, foundry processing of steel, stainless steel, nickel, cobalt base alloys, glass fiber forming, iron, nickel and cobalt-based air and vacuum melted master alloys for the remelt industry.

More specific related areas of expertise include AOD refining, horizontal continuous casting, manufacture of piston rings, cylinder liners, pistons, purchased parts, powdered metal, die cast and investment cast parts, material specifications, quality audits, diesel engine precombustion chamber alloy, automotive air conditioning compressor pistons, sintering techniques, and aluminum alloy modification

PRINCIPAL INDUSTRIES SERVED
Automotive, Marine, Medical, Metallurgy, Recreational Equipment

EDUCATION
B.S., Metallurgical Engineering with Physical Metallurgy Option, Michigan Technological University, Houghton, MI

PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.

Providing product and operations management, metallurgical and sales engineering, metallurgy, failure analysis, forensic engineering, consulting and related expertise for a wide variety of clients.

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Metallurgical Expert, Consultant, Expert Witness

Provided applied metallurgical expertise in problem solving, quality issues, training, expert witness, alloy development and foundry alloy sales. Co-developed training programs used by American Foundrymen's Society for areas of foundry processing of steel, stainless steel, nickel and cobalt base alloys. Developed foundry process sequence used by steel and investment casting foundries. Invented new cobalt base alloys for enhanced temperature and life capabilities in glass fiber forming environments.

Manager, Metallurgical Services, Cannon-Muskegon Corporation, Muskegon, MI

Developed, coordinated, and facilitated activities producing iron, nickel and cobalt-based air and vacuum melted master alloys for remelt industry. Coordinated departmental activities including operating, manufacturing, engineering, planning, sales, maintenance, and research and development to effect operational efficiency and economy. Directed and coordinated preparations of sales promotion of products manufactured or services performed to develop new markets, increase share market, and to obtain competitive position in industry. Directed start-up of new $6M facility, employing AOD refining and horizontal continuous casting, producing highest quality air melted alloy available for remelt purposes. Established customer problem-solving center, recognized as best in the master alloy field. Penetrated new and existing markets, resulting in 300+% increase in sales.

Product Metallurgist, Engine & General Product Parts, Sealed Power Corporation, Muskegon, MI

Managed all materials and processes utilized in the manufacture of piston rings, cylinder liners, pistons, purchased parts, powdered metal, and die cast and investment cast parts for company engaged in producing automotive parts for the original equipment marketplace and distribution of aftermarket replacement parts. Developed and maintained material specifications and quality audits for all parts to maintain quality leadership. Developed diesel engine precombustion chamber alloy saving General Motors $1M in first production year. Significantly reduced Investment Casting Division’s scrap rate from 30% to 7% in 6 months. Succeeded in obtaining automotive air conditioning compressor piston business for Powdered Metal Division using unique sintering techniques. Established aluminum alloy modification system for maintaining alloy strength in die cast rack and pinion steer columns.

Project Metallurgist, Sealed Power Corporation, Muskegon, MI

Planned, directed, and coordinated research projects involving new material and coating development related to piston rings, cylinder liners, and miscellaneous parts manufactured by the powdered metal, die casting, and investment casting processes. Established wear and fatigue tests for piston rings and cylinder liners. Developed ultimate fatigue-resistant AISI 9254 steel compression ring for Detroit Diesel Allison. Solved marine hardware corrosion problems for Investment Casting Division. Solved golf head breakage problems encountered in field.

ADDITIONAL EXPERIENCE

Instructor, "Metallurgy" and "Engineering Materials"
Laboratory & Metallurgical Assistant
Process Engineer

HONORS AND AWARDS
ASM (American Society for Metals) "Outstanding Young Member"
ICI (Investment Casting Institute) "Best Technical Paper Award" and "Best Technical Presentation Award"
AFS (American Foundrymen's Society) "Most Outstanding Contribution to the Investment Casting Industry"

PROFESSIONAL AFFILIATIONS
American Society of Metals
American Foundrymen's Society

Please note that this is an abbreviated CV. A fully detailed unabridged CV is available under special circumstances.

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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax

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