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Summary of Expertise:
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Expert has 40 years of experience in designing, building, installing, and operating continuous casting plants. His plants are in America, Europe and Asia. Most plants are for copper and copper alloys in the form of billet, tube, plate, coils, rod and other shapes. He has patents related to continuous casting and has granted licenses worldwide.
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Expert has developed spinodal copper alloys, copper anodes for semiconductor plating, and other commercial alloys. He has extensive data related to copper alloy properties and production.
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Expert has made and installed horizontal continuous casters for copper, brass, bronze, and cast iron.
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Expert notes that many of the casting plants produce copper alloys for sleeve bearings and bearing cages. Expert is expert in the application of copper alloys to bearing applications.
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As an adjunct to the continuous casting plants, Expert has built centrifugal casting equipment for copper alloys.
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Expert has complete knowledge of the heat treatment of most copper alloys, and has developed special heat treatments for spinodal and alpha/beta brass alloys.
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Most of Expert's billet casting machines employ his unique and inexpensive mold designs. From small billets to 10" copper billets casting 12,000 lbs./hr, his mold designs have proved successful.
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All of Expert's copper alloy continuous casting plants incorporate induction melters with features such as argon shield, refining, and degassing techniques. Each plant is equipped with induction furnaces built to his specification.
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Expert pioneered in the continuous casting and heat treatment of aluminum bronze. Further to building continuous casting equipment for aluminum bronze, he has developed commercial heat treatments for the full spectrum of those alloys from 8% aluminum content (alpha alloys) for forming operations to 16% aluminum content (alpha/beta/gamma2 alloys) for wear applications.
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Expert has consulted on manufacture of most wrought and cast brass alloys. He has developed grain refining materials for brass alloys.
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Throughout his experience with copper alloys, Expert has consulted on many brass corrosion problems such as stress corrosion cracking, dezincification, dealuminization, and other problems related to brass and corrosive media.
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Expert holds patents for fine grain development in continuous cast copper alloys. Further, he has developed metal additives to grain refine cast alloys.
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Expert has built several reclamation systems for metal slag (dross). The equipment can be either wet or dry systems. He also will buy and dispose of material to be reclaimed.
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As well as producing every bronze alloy listed in the CDA, Expert has developed special bronzes for gears, sleeve bearings and other hardware—all now in commercial use. He developed spinodal bronzes to replace other copper sleeve bearing alloys used in heavy equipment.
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Expert has developed bronzes for specific applications such as 30% leaded bronze for fuel pump bearings, spinodal bronze for oil well drill bit bearings, and aluminum bronze and manganese bronze bearings for heavy equipment. He has built bearing test equipment for evaluation of sleeve bearing properties. Expert has developed and produced bronze sleeve bearings for many uses, including high-speed fuel pump and supercharger bearings to large heavy-duty bearings for off road equipment.
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Over 40 years, Expert has supervised and owned bronze casting foundries. He has worked with sand casting, chill casting, centrifugal casting, continuous casting and permanent mold casting. He is responsible for many developments in sand additives, mold materials, melting equipment and patterns.
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Expert consults constantly on which materials to use with various corrosive media. He has many case histories related to alloy selection for corrosive environments.
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All Expert's foundries and mills were fitted with reclamation equipment of his design. He has developed and sold several wet and dry systems for reclaiming metallics from foundry and mill residues.
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Expert has identified many causes and cures for casting defects. His metallographic examinations and conclusions have resulted in changes to eliminate casting defects such as shrinkage porosity, gas porosity, hot shortness, and other defects.
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Much of the copper alloy produced by Expert's plants require finishing and cleaning. He has developed both organic and inorganic cleaners, tailored to specific alloys.
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Expert developed and produced a novel copper nickel alloy that successfully withstood seawater and turbulent corrosion. He has consulted on corrosion problems with several manufacturers of bearings, propellers and marine hardware.
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Expert's development of copper alloys has been mainly on property improvement by grain refinement, heat treatment or composition variation. Most mills producing aluminum bronze and manganese bronze use his preferred compositions within specification. Also his patented grain refinement for continuous castings has improved the properties of several alloys used for gears and high-speed sleeve bearings.
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Expert's processing experience includes casting, drawing, machining, extrusion, rolling, and finishing of copper alloys. Most of his consulting work involves continuous casting, machining, drawing, and extrusion.
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Expert has developed copper casting (99.9%+) for most founding methods. He has perfected melting schemes, deoxidizers, and degassers. He has been successful producing oxygen free continuous cast copper rod and tube.
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Expert's developments and patents have increased properties of copper alloys, well beyond their former typical features. Mechanical and chemical grain refinement as well as proprietary heat treatments have been applied to materials used for bearings, gears, bearing cages, and other hardware copper alloys. Several manufactures specify copper alloys made according to his criteria.
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Copper and copper alloy melting information is part of Expert's operating history. He has information on melting all copper alloys, including melt treatments to yield optimum cast metal. He is experienced in all types of furnaces, basically concentrating on induction melting.
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Copper waste in the form of foundry residues or process scrap is dealt with in respect to Expert's reclamation operations. He has found many uses for copper waste, related to mixes for alloying.
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Expert has developed brass more resistant to dissolution of zinc because the castings or billets for wrought brass have been grain refined, providing thinner grain boundaries. After consulting on the problem for many years, he has convinced consumers to use corrosion inhibited brasses or other substitute copper alloys.
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Expert has built and operated direct chill (DC) casters producing billets as large as 24" diameter. He has proprietary designs for molds superior to those supplied by other machine builders. He can supply complete plants--DC casters, water towers, pumps, heat treat furnaces, and laboratory equipment.
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All of Expert's mills employ electric induction melters. He works closely with the largest furnace maker in the world when clients ask for melting equipment to be included in casting plant design. He is familiar with all aspects related to the melting process from refractories to molten metal treatment.
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Several years past, Expert developed a continuous cast copper alloy containing 30% lead that is now specified for most military and commercial aircraft fuel pump bearings. This alloy can only be produced using his patented die design. This development also has been adopted for the casting of high leaded supercharger bearings. The most important feature of these alloys is the very fine dispersion of lead particles throughout the metal matrix. Expert's fine grain, high-leaded continuous cast bronze bearings operate in 80,000 rpm exhaust-driven superchargers. He has worked with manufacturers, developing hydrodynamic bearing materials that must also operate at slow speeds without high wear. His bearing test equipment has been useful in evaluating high-speed hydrodynamic wear.
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Expert's manufacturing experience affords complete case histories of metal failure analysis. He has worked with manufacturers and insurance companies, consulting on metal failure analysis. His findings have been the basis for fixing responsibility and cause for all types of metal failure.
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Expert has extensive knowledge regarding material selection for given applications. Manufacturers submit designs and operating parameters and he proposes and provides suitable material. Most applications involve copper alloys or steel.
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Expert's operating experience has shown the correct heat treatment for copper alloys. He has discovered that many brasses can be strengthened by heat treatment, whereas the literature claims that is not possible. He is expert in developing required properties by heat treatment of aluminum bronzes, spinodal bronzes and other copper alloys.
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All of Expert's materials have been produced using the bearing design criteria contained in the CBI literature. Further, he has built and used bearing wear test machines to prove the value of various sleeve bearing materials. He developed and proof tested special spinodal bronzes to replace traditional materials.
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Although "copper" is a broad category, Expert has been involved in or has knowledge of most uses and production operations concerning copper. He has been on the ASTM committee for copper and copper alloys.
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Expert has cast copper alloys by every means, including continuous casting, permanent mold casting, sand casting, centrifugal casting, rapid solidification casting, and zone refinement casting.
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Expert has consulted on cases where he developed custom coatings for preventing corrosion. Also, with electric furnace makers, he has developed means to reduce corrosion in copper alloy components of water-cooled electric power supplies.
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Expert has manufactured many items in the traditional "gunmetal" alloy UNS C90500. He developed gear and bearing applications for this alloy.
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Expert has developed and produced leaded tin bronzes for bearing, gear, and hardware applications. He has built several continuous casting plants for the manufacture of these alloys.
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Expert has perfected the optimum composition for several manganese bronze alloys where it has been difficult to meet specified physical properties. He has built plants for casting manganese bronze. He has developed heat treatments for several manganese bronze alloys.
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He has assisted many foundries and mills, developing means to use residues and refine melts of nonferrous metals.
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His experience related to tin bronzes covers the full spectrum from foundry operations, metallurgical properties, heat treatment and uses. He has built several casting plants for producing tin bronzes.
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Using his patented continuous casting process, it is possible to produce bronze bearings for pumps and superchargers running at speeds in excess of 80,ooo rpm.
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Show Secondary and Basic Areas of Expertise |
Localities:
Expert may consult nationally and internationally, and is also local to the following cities: Detroit, Michigan;
Warren, Michigan;
Sterling Heights, Michigan;
Livonia, Michigan;
Dearborn, Michigan;
Westland, Michigan;
Columbus, Ohio;
Cleveland, Ohio;
Toledo, Ohio;
and Akron, Ohio.
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Education
