Adil A. Ashary
1621 Tiber Court, San Jose, CA 95138
408.896.4356
Summary of Experience
Over 20 years of experience in engineering, materials R&D, supply chain management, product development, aircraft components repair, plasma spray, EBPVD and platinum aluminide diffusion coatings, Ni, Cr Ni-W electroplating, erosion, corrosion and wear of materials, laser cladding, electron beam welding, and Solid Oxide Fuel Cells materials processes.
Employment History
Bloom Energy Corporation, 1299 Orleans Dr., Sunnyvale, CA 94089
Principal Engineer Jul 2011 - Present
• Explore, develop and implement new materials for solid oxide fuel cell power modules with strong emphasis on low cost solutions
• Established a thermal spray coating facility for producing several hundred thousand parts per year
• Developed specifications for over 30 coated components
• Supply chain development for several national and international coating suppliers
• Developed high volume thermal spray processes for several million parts per year
Praxair Surface Technologies, Inc. 1500 Polco Street, Indianapolis, Indiana 46224
Engineering Manager Dec 2008 - Jul 2011
• New part qualification for EBPVD and PtAl Coatings
• Tool designing for EBPVD Coatings
• Process improvements
• Reduced coating spalling events in EBPVD by more than 50%
• Reduced ABF (ammonium bi-fluoride) chemical stripping attack of bond coat on super alloy components
• Managed an engineering staff of five engineers
R&D Manager Dec 2006 - Dec 2008
• Performed statistical analyses, developed relationships between yttria coating properties and plasma spray process control
• Carried out an extensive root-cause analysis for “wood grain” defect in alumina coated electrostatic chucks. Improved the coating process to increase finishing yield from 40% to over 80%.
• Evaluated innovative technical solutions for sealing thermal spray yttria coatings with ceramic CVD coatings
• Managed production cell at R&D facility with up to full two-shift operation for peak shaving production demand
• Developed an improved relationships with extremely demanding customers
• Established a new state-of-the-art reach R&D facility
• Supervised a staff of six including two Ph.D. engineers
Development Leader Jan 2003 - Dec 2006
• Coating evaluation for metal-dusting and anti-coking solutions in olefin and steam cracking petrochemical processes
• Developed a new Ni-40 wt%W nanoscale electroplating process for chrome replacement
• Key contributor to installation and start-up of the Pt plating line for Pt-Aluminide coatings
• Designed and installed a lab scale Pt-Aluminide process
• Responsible for the Wear Lab, improvement made in the operation of wear lab
Praxair Surface Technologies, Inc. 6400 NW 72nd Avenue, Miami, Florida 33166
Quality and Engineering Manager Oct 1998 - Jan 2003
• Overall responsibility for the quality and engineering of the aircraft component repaired at two FAA Repair Stations operated under FAR 145
• Implemented and managed an ISO-9002 and AS9000 based quality system
• Engineering development and source substantiation approvals for the repairs of engine components
• Quality system established for a new state of the art hard chrome, nickel and silver-plating facility
• Improved quality key performance indicators such as rework cost and on-time delivery by 20% – 40% in a year
• Developed and facilitated an electroplating and electro-chemistry training program
Praxair Surface Technologies, Inc. 1500 Polco Street, Indianapolis, Indiana 46224
1996 - 1998 Program Manager 1993 - 1996 Consultant
1990 - 1993 Sr. Project Engineer 1987 - 1990 Project Engineer
Development and improvement of materials and processes. Technical assessment of external technologies, materials, processes and product development, worldwide plant and customer support in selection and evaluation of metallurgical and other materials. Assisted in Marketing and Global Business development. Major processes: Plasma spray, Detonation Gun, Magnetron Sputtering, Laser and Electron Beam Processes.
• Implemented process controls in the electron beam welding and associated processes, such as cleaning, heat treatment and nondestructive evaluation. Designed and installed a cleaning line for aero-engine fan blades. Increased profitability of the company by reducing EB weld rework rate from over 50% to less than 5%.
• A self-sealing corrosion resistant thermal spray coating developed. AC and DC electrochemical corrosion techniques were developed. Two US Patents obtained and several hundred thousands in sales per year achieved.
• New chromium carbide based coating system for mating carbon seals for Pratt and Whitney engines. The coating was found to superior to any existing coating for this application.
• Developed several thermal spray techniques for coating advanced carbon fiber composites to broaden their engineering applications.
• Evaluation of existing and development of new thermal spay coatings for different market segments for the replacement of chrome plate. Several of these systems proved to be not only environmentally beneficial, but lower overall life cycle cost and improved performance.
• Built a new kind of magnetron sputtering system to apply hard TiN and CrN coating on the ID surfaces of long and narrow cylindrical objects was carried out. Work involved designing and specification to the outside fabricator and testing of the system on completion.
• Failure Analyses: Over fifty failure analyses of industrial components were carried out. Depending on the results, recommendations were made to the customers and/or the plants.
Castle Technology Corporation, Massachusetts 01801
Senior Materials Scientist Jul 1986 - Apr 1987
• Developed a unique coating system for carbon-carbon composites for use at ultra high temperatures
• Successfully electroplated iridium metal on carbon-carbon composites
• Developed a fluidized bed process for the preparation of synthetic pyrite to be used in LiAl-FeS2 batteries
University of Pittsburgh, Pennsylvania 15261
Post Doctoral Research Associate Jul 1985 - Jun 1986
• Research Areas: High temperature oxidation and corrosion behaviors of platinum modified aluminide coating for gas turbine engines.
Graduate Student Research Assistant May 1980 - Jun 1985
• Conducted research on MCrAlY Coatings for the hot section of aircraft engines
• Ph.D. Thesis: Adherence of Al2O3 Scales on MCrAlY type Coatings
• Developed a new technique to predict useful life of coatings jet engines
• Defined optimum concentrations of the rare earth elements for the maximum protection at high temperatures
Awards and Accomplishments
• Special Recognition Awards for greatly lowering EB weld rework...
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