Intellex Acquires Expert by Big Village

We're thrilled to announce that Intellex has acquired Expert by Big Village, effective March 22, 2024. This strategic move enhances our capabilities and strengthens our commitment to delivering exceptional solutions to our customers.

Stay tuned for more updates on how this acquisition will benefit our clients and experts.

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Expert Details

Nonferrous Cast and Wrought Metallurgy

ID: 739415 Missouri, USA

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Expert possesses over 30 years' experience in aluminum and magnesium alloy manufacturing operations, research and new product development. Expert in the following areas:

Molten metal handling, alloying, refining, metal transfer, protective flux and cover gases, and casting techniques.

Rolling and extrusion operations of a vast array of aluminum alloys (2000, 5000, 6000 and 7000 series alloys) and magnesium alloys (AZ31, AZ61, AZ80, ZK60, WE43, etc.).

Material specifications interpretation and related destructive laboratory metals testing -- including tensile and compression testing, sample preparation and metallographic examination and interpretation.

Technical skill in wrought aluminum and magnesium alloy products include:

Application of magnesium alloy material specifications, including alloy design for specific user-defined purposes, chemical and physical testing, dimensional inspection, heat treat specifications and NDT specs.

Understanding of various metallurgical analytical techniques, applications, and interpretation skills, including sample preparation, optical and scanning electron microscopy, optical emission spectroscopy, glow discharge mass spectroscopy, ultrasonic inspection and dye penetrant inspection.

Thorough grasp of quality and metallurgical requirements for molten metal handling, elemental chemical testing, alloying, refining, casting, extruded, rolling, forging, heat treatment, vast array of magnesium cast, extruded, forged and rolled alloys.

Working knowledge of direct extrusion technology as applied to nonferrous extruded products, including manufacturing methods and process design for solid and multi-void hollow profiles, seamless tubes, and various rolling, heat treatment and finishing operations.


Year Degree Subject Institution
Year: 2003 Degree: Master's Degree Subject: Business Administration, with Honors Institution: Washington University in St. Louis
Year: 1986 Degree: Bachelor's of Science Subject: Chemical Engineering Institution: University of Nebraska - Lincoln

Work History

Years Employer Title Department
Years: 2014 to Present Employer: Undisclosed Title: Executive Vice President Department:
Expert founded this engineering firm to provide expert metallurgical consulting services. Applications, clients and topics in the magnesium industry.
Years Employer Title Department
Years: 2003 to 2014 Employer: Megnesium Elektron North America, Inc. Title: Technical Manager Department:
Expert served as Program Manager for a U.S. Army Research Laboratory project to develop Mg alloy armor plate technology. Managed a $6.9 million project budget, culminating in the first-ever Mg Armor Plate specification.

Successfully championed and implemented project for Sales and Operations Planning with specific focus on sales forecasting issues. In this capacity, achieved Oliver Wight Class A Status.

Chaired several high-visibility projects that included new product development, novel manufacturing processes, and cost-savings initiatives.

Supervised quality assurance, metallurgical engineering and laboratory staff.

Served as primary corporate liaison for all product technical issues.
Years Employer Title Department
Years: 1989 to 2003 Employer: Spectrulite Consortium Title: Technical Manager; Quality Assurance Manager Department:
Technical Manager (2001-03):

Supervised metallurgical engineering, quality management and laboratory staff.
Coordinated all quality-related staff activities during year-long labor strike.

Quality Assurance Manager (1996-2002):

Developed and implemented ISO-9002 / AS-9100 quality system, resulting in Boeing 'Q100' and Lockheed-Martin Corporate 'STAR' Supplier Quality Awards.

Designed, installed and implemented relational database and computer hardware for an automated laboratory material release and certification system.

Supervised all laboratory and plant-wide inspection staff.
Years Employer Title Department
Years: 1989 to 1996 Employer: Spectrulite Consortium Title: Extrusion Production Superintendent, Extrusion Process Metallurgist, QA Engineer Department:
Extrusion Production Superintendent (1995-96):

Directly responsible for all Extrusion Production operations and the shipment of extruded products worth $20+ million in annual gross revenue.

Supervised 6 Extrusion Production Supervisors in a 24/7 operation with over 100 hourly production personnel in a labor union environment.

Redesigned 747 and 777 wing spar extrusions as part of Boeing's "Design/Build Team" to eliminate cost incurred by multi-step machining operation.

Extrusion Process Metallurgist (1992-96):

Implemented extrusion practices that virtually eliminated 5000 and 6000 series alloy tensile property failures.

Negotiated and executed toll contract with Lockheed Martin and designed extrusion & heat treat practices for lithium-bearing 2195 alloy extrusions as part of NASA's SLWT Space Shuttle program.

Quality Assurance Engineer (1989-92):

Designed and implemented plant-wide Statistical Process Control Program.
Years Employer Title Department
Years: 1987 to 1989 Employer: Ralston Purina / Eveready Battery Title: Production Foreman and Process Engineer Department:
Served this high-volume dry cell consumer battery manufacturer as Production Foreman and Process Engineer.

Career Accomplishments

Associations / Societies
TMS - Minerals, Metals and Materials Society (Prior Member)
SAE - AMS Technical Committee (Prior Voting Member)
ASTM - Product Standards Committee (Prior Voting Member)
Beta Gamma Sigma – Business Honor Society (Lifetime member)

Additional Experience

Other Relevant Experience
Expert's business skills include:

Negotiation -- developed through years of experience interfacing with customer and labor union representatives in difficult situations.

Operations management -- where capacities include metals industry production, quality assurance, and metallurgical process engineering.

Strategic management, finance, cost accounting, cost analysis, marketing and negotiations -- all bolstered with formal academic training.

Fields of Expertise

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