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Expert has extensive knowledge and experience in most processes and methods for joining aluminum, having numerous technical publications, presentations, and patents in the area. He consults with clients on process and equipment selection as well as troubleshooting existing operations. Fusion joining processes in which he is familiar include GMAW, GTAW, electron beam, laser, torch, and resistance spot. He is knowledgeable of many brazing and soldering applications such as flux furnace, dip (salt bath), controlled atmosphere flux (CAB), fluxless vacuum and inert gas brazing, and flux and fluxless ultrasonic soldering. In the area of solid state joining, Expert is familiar with cold pressure, resistance butt, induction, friction, friction stir, and magnetic impelled arc butt (MIAB) welding, as well as diffusion bonding. He has worked with mechanical fasteners including clinches, rivets, and threaded fasteners. His experience in aluminum adhesive bonding extends to pretreatments, thermosets, thermoplastics, and anerobics.


Expert has expertise in forming and machining aluminum product forms. He has assisted clients regarding the effects of alloy and temper on forming and machining response and in cost-effective selection of aluminum product forms and fabrication processes. His knowledge of component fabrication includes sheet metal forming processes (stamping, blanking, stretch forming, hydroforming, bending roll forming, magneform, tool design, and grid stain analysis) as well as metal removal processes (turning, milling, cutting, and chemical milling).

Expert has extensive experience integrating design, prototyping, performance evaluation, and manufacturing process aspects of aluminum-based products. Areas in which he has provided assistance include new product ideation; design for functionality and manufacturability; project/venture value analysis; rapid and cost effective prototyping; product form, alloy and temper selection; manufacturing process selection; and invention and development of manufacturing processes.


Having a broad knowledge of new product and manufacturing process development, Expert's has provided designs for automotive, transportation, aerospace, and machinery industries. He was the principal developer of processes for the manufacture of aluminum automotive heat exchangers; these include radiators, heater cores, engine oil coolers, air change coolers, A/C condensers & evaporators, and cold plates. He was also the principal developer of fluxless brazing and soldering processes.

Applying his knowledge of aluminum to the automotive industry, Expert has developed autobody stuctures. He designed monocoque and space frames fabricated from multi product forms, sheet, extrusions, and castings. Assembly methods with which he is familiar include resistance spot welding, weld bonding, mechanical fasteners, gas metal arc welding, MIAB welding, and magneform. He is experienced with the common infrastructure (steel & aluminum) assembly concept based on resistance spot welding. In addition to his expertise in autobody structure, Expert has designed integral and modular blocks with thermal sprayed bore coatings for use in engine blocks. Lastly, he has developed cast brake rotors with thermal sprayed wear surfaces.


Expert has interfaced with clients in the development and prototyping of various products, including bowling pins; bicycles/motorcycles; cooking utensils; residential air conditioning and refrigeration components; and boats/personal water crafts. He adapted, refined, or invented the required assembly and manufacturing processes for these products.