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He has extensive experience in brazing starting with his PhD (Penn State) in brazing of structural ceramics. He worked on the Alumnia-Titanium system using an active braze alloy of Ag-Cu-Ti composition. Active brazing has found wide acceptance in brazing of structural ceramics and can be used to braze carbides and nitrides as well. He has also worked on industrial brazing projects using resistance welding as a heat source to melt the braze prefrom placed between two components.

He has worked on numerous projects using capacitor discharge welder to make resistance welds. Capacitor discharge welder is an energy source where the electrical energy is stored in charged banks of capacitors and discharged through a transformer into a resistance welding head and to the parts being welded. He has worked with clients from all manufacturing sectors including fine welding for medical devices to structural welds for automotive applications. He has effectively utilized the benefits of CD welders to focus weld heat the weld interface and their capability to provide a quick burst of energy suitable for welding conductive parts to solve problems for the customers.

He has worked on many welding applications where dissimilar metals/alloys need to be welded for medical, aerospace, and sensor applications. He has helped customers choose alloys that would reduce the problems caused by welding of dissimilar metals by proper selection of process, design, metallurgy, and filler alloys. Another strategy he has used to avoid problems with dissimilar metal welding is to use solid-state bonding processes to avoid mixing of the two metals. For a medical device customer application, he selected an appropriate intermediate filler foil for a resistance welding application that produced excellent results.

He has worked on many fusion welding projects including arc welding, laser welding, resistance welding, and electron beam welding. He has assisted customers with selection of a suitable fusion welding process followed by design of parts suitable for that process, and assisted in setting up process parameters to produce satisfactory welds. Over the last 12 years he has assisted numerous customers from all sectors of manufacturing including automotive, aerospace, medical devices, and appliances in fine tuning their fusion welding processes.

He has considerable experience in laser welding from small-scale conduction mode welding to 5 kW large scale keyhole mode welds. He has conducted substantial amount of research in this field leading to two patents. One for a laser weld monitor to be used with pulsed welding and one for a new green welding laser. The green welding laser was designed to facilitate welding of copper which tends to reflect at YAG frequencies and is difficult to weld.

He has extensive experience in practically all metal welding processes including fusion welding, solid-state welding, and brazing/soldering. He has helped clients with selecting a suitable process based on metallurgy, part design, and performance requirements of the parts in service.

Over the last decade, he has worked with many clients with microwelding needs. Microwelding is a specialized field of welding that deals with welding of small components such as those found in medical devices, electronics, sensors, and light bulbs. He has successfully welded wires less than thousandths of an inch with a resistance welder. He assists customers with all challenges related to microwelding including part design, process selection, and metallurgy.

He has investigated multiple impulse resistance welding and published a paper on the same subject. Multiple impulse welding is the process of sending multiple pulses of energy into the same weld location to form a bond. He analyzed and concluded that multiple impulse welding in resistance welding allows the user to focus the heat at the weld interface without causing bulk heating. He has used the logic successfully to weld parts had significantly different heat balance and to control weld metal expulsion.

He has extensive experience in the field of spot welding including multiple publications. He has conducted training classes on spot welding and has taught more than a 1000 engineers at more than 50 companies on the art and science of spot welding. Spot welding is another name for resistance welding though there are other processes such as laser welding and arc welding that also can make welds in individual spots. He has worked with clients to assist them in choosing the most suitable and robust spot welding process for their application.

Laser welding is commonly used autogenous welding process for welding metals and alloys. Laser welding can be used to make individual spot welds or can be used in a pulsed mode with overlapping spot welds to form a hermetic seal. Overlapping spot welding mode works well in situations where shallow welds are required and heat input into the part has to be contained. Continuous wave welds are used for forming a seam with deep penetration. Laser welding typically requires a shielding gas to protect the molten metal. Lasers can be used to weld practically all metals and alloys including dissimilar metals, some aluminum alloys, steels, stainless steels, and titanium. Typical problems include cracks, porosity, shallow weld penetration, and weak welds.

He has worked on numerous projects on welding metals and alloys. He has assisted customers in selecting metals based on their weldability and has helped customers with weld joint design. He has guided customers in selecting suitable welding process based on part design, weld metals, and weld requirements that can include strength, corrosion resistance, and visual appearance. In addition to setting up the process, he provides assistance with testing and assessment of weld quality that relates to weld performance. He is frequently called on to provide weld troubleshooting assistance on processes that are in production but have issues with quality and excessive scrap. He has assisted customers with implementing weld monitoring systems for online quality checks and has provided assistance in setting up a welding quality control plan that includes statistical sampling, nondestructive testing, and metallurgical evaluation.

He has worked with multiple clients on solving arc welding problems in high volume production environments in automotive applications. He has assisted these customers with process refinement in robotic welding applications to produce hermetic seam welds and to solve problems related to fusion, porosity, and undercutting. He has also provided training on arc welding fundamentals to technicians and engineers.

He has assisted customers in understanding the fundamentals of projection welding which is special form of resistance welding where one of the parts being welded has a projection. The projection can be produced by forming, stamping, machining, or coining. He has assisted customers in refining the process parameters to produce strong welds without excessive expulsion and has helped setup weld monitoring systems to gauge welding quality by measuring outputs such as current, voltage, and displacement.

He has used his expertise in laser to assist clients with using lasers for many laser processes including cutting, drilling, welding, and marking. His experience with laser research and two patents on lasers gives him the ability to consider all aspects of materials processing using laser energy including different frequencies, pulse widths, power densities, repetition rates, and quality. He teaches a two-day class on lasers and materials processing that includes one day of classroom based training and a day of laboratory demonstrations.

Ultrasonic welding is used for welding both plastics and metals by using ultrasonic energy to soften the parts being welded and forging them together. Ultrasonic welding is a truly solid-state process that is commonly used for welding soft metals such as copper and aluminum and most thermoplastics. Important factors include part design, fixture design, cleanliness, and horn/anvil design before one can focus on tweaking the welding parameters.

He provided consulting for a battery manufacturer to diagnose cause of cracks forming adjacent to the welds. The process was modified to produce a weld morphology that avoided formatin of cracks.He provided weld process selection and process fine tuning to produce robust welds at a medical device manufacturer. Issues with the clients current process was traced back to insufficient control of the welding process and defective fixtures used to hold the parts.He assisted an automotive manufacturer of safety devices to assess the root cause of the defects attributed to the laser power supply. The root cause was traced to incorrect fixturing of the thin metal foils.He helped an aerospace client design a part to be robust for a brazing operation by proper selection of part desing, braze alloy, flux, process, and tool design. Process robustness was critical since the parts will be used in a satellite.He suggested and produced welded assemblies for a sensor device to measure temperature inside deep-drills for oil wells.