Metallurgical Engineer

Senior Metallurgical Engineer — Ironclad Alloys Corp

Pittsburgh, PA | January 2024 – Present

• Managed 5 high-temperature alloy development projects for aerospace applications, adjusting nickel-base superalloy chemistry to increase creep resistance by 18%.
• Directed 12 failure analysis investigations on fractured pipeline components using SEM and EDS, identifying root causes to prevent future failures and saving $320,000.
• Optimized steel casting heat treatment schedules using Thermo-Calc modeling, which reduced furnace cycle time by 14 hours and cut weekly energy consumption by 11%.
• Redesigned slag chemistry parameters in a basic oxygen furnace system, lowering phosphorus content by 15% and increasing overall yield of structural steel by 3%.

Metallurgical Process Engineer — Keystone Foundry & Steel

Erie, PA | August 2020 – December 2023

• Supervised quality control protocols for 18 steel casting runs per month, correcting cooling rate parameters to reduce internal porosity defects by 25%.
• Conducted tensile and hardness testing on 90+ production batches of carbon steel, ensuring 100% adherence to ASTM standards and reducing customer returns by 30%.
• Implemented a new optical emission spectrometry (OES) calibration procedure, which reduced analysis turn-around time by 15 minutes and saved 40 labor hours monthly.
• Collaborated with 4 design engineers to optimize weld geometries for heavy machinery frames, reducing welding defects by 19% and increasing fatigue life by 12%.

Alloy design, Failure analysis, Scanning electron microscopy (SEM), Energy-dispersive spectroscopy (EDS), Heat treatment optimization, Mechanical testing, Metallography, Slag chemistry, Casting and solidification, Thermo-Calc, ANSYS, SolidWorks, ASTM standards, Pyrometry

Superalloy Composition Development

Role: Lead Metallurgical Researcher

Tools: Thermo-Calc, SEM, EDS, Instron Tensile Tester

Developed 1 new nickel-base superalloy formulation that increased creep strength by 22% and extended service life in high-temperature environments by 1,500 hours.

Foundry Defect Reduction Initiative

Role: Process Metallurgy Lead

Tools: SolidWorks, OES Spectrometer, Minitab

Identified source of gas porosity in structural steel casts, modifying deoxidation protocols to reduce scrap rate by 18% and save $45,000 annually.

• Certified Quality Engineer (CQE) - ASQ (2022)
• Metallurgy of Steel Certification - ASM International (2021)

• Professional Memberships: ASM International, The Minerals, Metals & Materials Society (TMS)
• Volunteer Work: Judge for regional high school science fair materials division (2022-present)
• Availability: 3 weeks notice