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Resume of UJP
Consultant

EXPERTISE AND SERVICES

Metallurgical Engineer, Metallurgist, QC, QA, Quality Assurance Specialist, Engineering Failure Analysis, Specialist, Forensic Analysis Investigation Expert Witness Testimony, Engineering Consulting Services
Expertise in international foundry and metals manufacturing, process development, operating cost reductions, quality improvements, market share increases, quality control, and quality assurance.

This associate's experience includes R&D, gating, manufacturing of aerospace investment castings, rollover furnace concept for vacuum super alloys using neutral atmosphere, and new pattern wax replacement.

Knowledgeable in areas including new cast alloys for bearing components, shell dipping ABB robot line, metallurgical lab design, spectrograph and microstructure evaluation, adbond ultra water based shell system, continuous improvement, shell and casting defects training.

Additional experience and specialization includes process, gating , product metallurgy function and quality assurance, carbon steel, low alloy steel, stainless steel, Ni-base, Co-base, Cu-base, Al-base, sand casting, investment casting, foundry production, foundry technical development, grey iron, steel and nonferrous shape sand castings, and reclamation of sands.

Has conducted numerous studies in areas including ingot mold production from blast furnace pig iron, new molding lines for steel and grey iron, waterglass core technology, and casting effects

PRINCIPAL INDUSTRIES SERVED
Machining, Metallurgical, Steel Processing

EDUCATION
M.S., Metallurgical Engineering, University of Metallurgy, Kosice, Czechoslovakia
Diploma of Technologist in Civil Engineering, Presov Community College, Presov, Czechoslovakia

PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.

Providing project management, metallurgical engineering, quality control, quality assurance consulting, failure analysis, forensic engineering, consulting and related expertise to a wide variety of clients.

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Case Studies

Metallurgical Engineer, Metallurgist, Failure Analysis, Forensic Engineering, Consultant

Managed metallurgical functions including R&D and gating, purchasing of all direct materials and major equipment for manufacturing of aerospace investment castings. Investigated and implemented outsourcing in former East block countries (Slovakia and Czech Republic). Developed a rollover furnace concept for vacuum superalloys using neutral atmosphere. Cooperated with Goodrich Corporation R&D in the development of vacuum melt / cast A 286 investment casting alloy. Directed various projects and was responsible for financial analysis and project management for company expansion, and other projects such as roll-over furnace, new pattern wax replacement, new cast alloys for bearing components, shell dipping ABB robot line, design of a complete metallurgical lab with a spectrograph and microstructure evaluation. Introduced Adbond Ultra water based shell system. Was continuous improvement counsel leader as a part of maintaining ISO9001/AS9100. Introduced digital imaging on manufacturing procedures. Organized in-house wax pattern, shell and casting defects training. Designed and implemented a new custom grinding machine for removing gates from investment castings at 500% higher productivity.

Quality Control/ Quality Assurance Manager, Metallurgist

Was responsible for process, gating , product metallurgy function and quality assurance of MIL-I-45280. Maintained aircraft quality standards for investment casting foundry that produced alloys such as carbon steel, low alloy steel, stainless steel, Ni-base, Co-base, Cu-base, and Al-base.

Quality Engineering Manager, Precise Castings Inc., Stratford, Ontario, Canada

Was responsible for process and product metallurgy and quality assurance in sand casting plant and investment casting plant. Foundry production included carbon steels, low alloy, stainless steels, Ni, Cu, Co and Al-base. Designed and implemented metallurgical lab and introduced S.P.C. in shell building.

Process Development Engineer, Wescast Industries, Inc., Wingham, Ontario, Canada

Was responsible for the process and implementation of all projects and D.O.E. runs in the core mold department.

Senior Staff Specialist, East - Slovak Steelworks: ( now U.S. Steel-Kosice) VSZ Kosice, Czechoslovakia

Managed foundry technical development of the largest Czechoslovakian steel plant. Foundry production included grey iron, steel and nonferrous shape sand castings (4,900 ton/year; 5,000 ton/year; and 200 ton/year respectively), and ingot molds (100,000 ton/year). Planned all capital projects in the foundry including reclamation of sands, ingot mold production from blast furnace pig iron, new molding lines for steel and grey iron. Company liaison with consultants and environmental authorities. Provided leadership role in Marketing, Facility Planning, Engineering and Personnel Team. Team produced long range Capital Forecast on an annual basis.

Plant Metallurgist, East - Slovak Steelworks: (now U.S. Steel-Kosice) VSZ Kosice, Czechoslovakia

Was responsible for process, product metallurgy and quality functions. Introduced waterglass core technology (waterglass/FeCr slag system) in the 30 t/hr. continuous mixer, drastically improving the quality of mold internal surface. Implemented practices for cement molding mixture production. Resolved operating deficiencies, which included cracks in mold bottoms and the short life of ingot molds.

ADDITIONAL EXPERIENCE

LANGUAGE SKILLS
Slovak, Czech, Russian and Polish
Polish

PROFESSIONAL AFFILIATIONS
ASM
AFS
ICI
EMTEC
SANDIA NATIONAL LAB

PUBLICATIONS
Publications related to foundry production, ingot mold production from blast furnace pig iron, waterglass core technology, casting effects, and more.

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

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Metallurgical Engineer, Metallurgist, QC, QA, Quality Assurance Specialist, Engineering Failure Analysis, Specialist, Forensic Analysis Investigation Expert Witness Testimony, Engineering Consulting Services
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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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