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Mechanical Engineer, 17 years experience
I graduated in 1987 from Oklahoma State University with a BS in Mechanical Engineering. I had worked for 18 months in the Mechanical Engineering Lab prior to graduation helping students with projects and managing the ME lab including maintaining shop machinery and equipment. After graduation I went to work for L-3 Communications when it existed as E-Systems in Greenville TX in the materials and processes department with responsibility to research, develop, and maintain mechanical process specifications. This included working with the structural test lab in developing and performing testing and also working with production personnel to develop new efficient mechanical process methods such as fastening and joining and also to perform liaison engineering on processes that needed to be updated to meet specification changes. I was also responsible for performing drawing checks for materials and processes references.
I was promoted and transferred to the structural test lab full time where I became continually involved in larger and more varied testing including structural, static, fatigue, environmental, dynamic, mechanical systems, finishing, and electrical and electronic. The size level range of the test articles for this testing included black box, single element, specimen, or coupon level to component level, to subassembly, to complete full scale level with multiple servo control channels. I have been a lead in developing test fixturing and frames for over 15 years. Testing and fabrication materials include both metallics and composites, with the composites including both high performance thermoset and thermoplastic classes. This included R&D of rapid thermoforming of high performance reinforced thermoplastics for external and structural aircraft applications. I was also very much involved in rapid prototype development using a 3D Systems rapid prototype machine.
My responsibilities for the structural testing included test concept development, test fixture design and analysis, data acquisition and control and programming, spectrum and mission profile application, instrumentation, test performance, loading actuator sizing, hydraulic system design and performance, equipment and facilities requirements, labor and financial budgets and allocation, bidding, proposals, test readiness reviews, presentations, test plans, results reports, for both FAA and military certification agencies, calibration, quality control and assurance; DAR, DER, and official witness coordination. Structural testing at L-3 Comm included testing of primary structure, secondary structure, pressure testing, sensor installations, pressure vessel modifications, interior monuments, equipment racks, impact testing. This effort included working with my customers to determine the requirements, meet their requirements, determine the loads and the test environment, determine the control method, design and manage fabrication of the test fixture, install the test article, manage and perform the test setup, coordinate inspection and witnessing authorities, performing the test, reduce the data, disposition the test article and test equipment.
Environmental testing at L-3 Comm included environments of altitude with an 80,000 ft simulation capability, temperature with a range of LN2 cryogenic capability to greater than 2,000F, and or humidity with a range from dry to condensing and testing of equipment or finish and protective coatings. This included simulating a specified environment usually within a chamber and submitting the test article to the conditions. Some specifications required combined environments. Some of the test articles were electronic equipment both in operating and non-operating modes in which equipment interfaces were installed to test the equipment during the application of the test environments. Some structural test articles were subjected to accelerated stress corrosion environments.
Vibration testing at L-3 Comm included working with my customers to determine the requirements, meeting their requirements, conceptualize and develop the test; determine the test environment including frequency ranges, load magnitudes and or psds and or displacements and durations required; limits; type of test was normally either swept sine, random, shock, or manual; instrumentation requirements, write test plans, design and manage fabrication of the test fixture, install the test article, calibration, coordinate inspection and witnessing authorities, performing the test, reduce the data, write test results reports, disposition the test article and test equipment. Tests have included component tests off the aircraft and in fixtures on fiber optic connections, card edge connectors, antennas, refueling doors, fluid seals, and isolator mounts to full scale ground vibration tests on the aircraft for mission sensor and control system effectiveness upon installation to determine resonances and harmonics. I have performed multiple ground vibration tests on aircraft using the swept sine technique with shakers, amplifiers, accelerometers, oscilloscopes, and FFT analyzers.
Mechanical system, air, and fluid testing and development included new and creative environmental control system development to remove the ever increasing quantity of heat within the aircraft. During the system development this included working with cryogenic liquid nitrogen LN2 to simulate the atmospheric temperatures experienced by the aircraft during it’s mission. My group was teamed with another unit and responsible for building a complete simulated large aircraft environmental control system including heat load generation and heat removal. A new vapor cycle system was being installed on an aircraft platform with high heat generation and the system needed to be proven prior to installation. Additional air and fluid flow testing includes ram air duct flow testing using calibrated flow measurement devices, pressure seal testing, blow out panel pressure testing, jet pump cooling flow performance testing, E-4B bleed air duct pressure testing, electronic rack cooling air flow controller performance testing, cold plate thermal transfer testing, cabin pressurization regulation valve testing, cabin wall air diffuser flow pattern testing, aircraft electronic equipment circuit mockup cooling airflow testing with orifice calibration and circuit balancing, liquid cooling system fluid evaluation testing.
Crack growth and fatigue testing including inspection monitoring of crack propagation in reference test panels, composite repaired test panels for structural repairs to primary aircraft structure, and full scale aircraft primary structure. I also have experience with field installations of structural composite patch repairs on in service aircraft.
Electrical and electronic testing at L-3 Comm included aircraft electrical power buss testing and power source switch timing, lightning strike risk assessment of magnesium, and multiple electrical load testing.
I designed, assembled, and implemented a pc accessible LAN in my unit using daisy chain coax cabling that connected to the L-3 Communications thick Ethernet company backbone. This local area network connected multiple platforms on the same network and connected them to the company intranet. I have designed, implemented, and setup several additional LAN networks during my career. I have extensive experience with Microsoft Office products including Word, Excel, Powerpoint, Project, Outlook, and Access database. I am familiar with Unix and OS/2 and the following programming languages basic, C, Fortran, Agilent HP Hewlett Packard VEE and HTML. I have completed 48 graduate points towards an MS in computer science from Texas A&M University-Commerce. This knowledge of networks, computer systems, and electronics helps me efficiently develop solutions, understand operations, and troubleshoot challenges on projects.
Key Skills and Course Work that I have completed include the following.
à ESM 7X7 Advanced Composite Repair for Engineers Course, Boeing Commercial Airplane Company
à VXI Bus Technology Training, Hewlett Packard
à Fracture Toughness and Fatigue Crack Growth Testing, ASTM Standard Technology Training
à Charmilles Numerically Controlled EDM, Charmilles Corporation of America
à Vibration Testing, Spectral Dynamics Division of Scientific Atlanta
à Value Engineering Forty Hour Workshop, Society of American Value Engineers
à Unigraphics CAD Design I & II, E-Systems
à Instrumented Impact Testing Seminar, Dynatup of General Research
à Core Engineering Management, E-Systems
à Core Materiel, E-Systems
à Core Program Management, E-Systems
à Performance Management Process Course, E-Systems
à Verbal Communication Special Workshop, Verbal Communications, Inc.
à FAA Overview, E-Systems
à Interviewing Skills Workshop, E-Systems
à Sleeve Cold Hole Working, E-Systems
à Heat Treatment of Aluminum, E-Systems
à Hazardous Material Waste, E-Systems
à FOD Foreign Object Damage, E-Systems
à Ethics, E-Systems
I changed companies in April of 1998 and joined Sino Swearingen Aircraft Corporation in San Antonio Texas to continue as a structural test lead for FAA structural certification of a new business jet. My responsibilities again included:
o Structural design and analysis for component and full scale test article fixtures
o Structural test concept development
o Test article attachment interface development and testing
o Data acquisition system design and selection
o Servo hydraulic control design, development, and programming
o Certification control system test development and design
o Structural test design drawing planning
o Primary structure testing including wing, fuselage, horizontal, vertical, engine mount, landing gear, dynamic landing gear drop, pressurization, and control system
o Project scheduling and planning of control testing and drawings
o Efficient test performance sequencing based on test article readiness
o Certification Test plan reports
o Certification Test results reports
o Whiffletree associative auto generating spreadsheet based on loading and load point position
o Servo control load system selection and operation
o Instrumentation system selection
o Custom instrumentation solutions
o Mobile test frame design and structural analysis
o Full scale test fixture structural design and analysis
o Preliminary spectrum and mission profile application
o Test article pre-test requirements during manufacturing
o Test performance and execution
o Hydraulic system design and performance
o Equipment and facilities requirements such as compressed air flow and volume for cabin pressurization system, cooling system for hydraulic fluid system, electrical power requirements for single and three phase up to 460 VAC.
o Ground vibration test for flutter analysis, execution and operation
o Labor and financial requirements for budgets and allocation
o Test readiness reviews
o Test concept and results presentations
o FAA Certification test plans
o FAA Certification test results reports
o Calibration requirements
o Quality control and Quality assurance coordination
o Program and project effort risk assessment
o FAA DAR & DER, and official witness coordination
o FAA certification compliance assurance
I have test experience or familiarization with the following specifications.
MIL-E-5400T Electronics Equipment, Aerospace General Specification For
MIL-STD-461 Electromagnetic Emission and Susceptibility Requirement for the Control of Electromagnetic Interference
MIL-STD-810 Environmental Test Methods and Engineering Guidelines
MIL-STD-704 Aircraft Electric Power Characteristics
MIL-STD-7016 Electric Load and Power Source of Capacity, Aircraft, Analysis of
MIL-A-8867 Airplane Strength and Rigidity Ground Tests
MIL-A-8868 Airplane Strength and Rigidity Data and Reports
ASTM B557 Method of Tension Testing Wrought and Cast Aluminum and Magnesium Alloy Products
ASTM C273 Shear Properties in Flatwise Plane of Flat Sandwich Constructions or Sandwich Cores
ASTM D638 Standard Test Method for Tensile Properties of Plastics
ASTM D3039 Tensile Properties of Fiber Resin Composites
ASTM D3410 Compressive Properties of Unidirectional or Crossply Fiber Resin Composites
ASTM D3518 Inplane Shear Stress Strain Response of Unidirectional Reinforced Plastics
ASTM D3528 Strength Properties of Double Lap Shear Adhesive Joints by Tension Loading
ASTM D5379 Standard Test Method for Shear Properties of Composite Materials by the V-Notched Beam Method
ASTM E8 Test Methods of Tension Testing of Metallic Materials
ASTM E399 Plane - Strain Fracture Toughness of Metallic Materials
ASTM E647 Measurement of Fatigue Crack Growth Rates
CFR Title 14 Part 23 FAA FAR Airworthiness Standards: Normal, Utility, Acrobatic, and Commuter Category Airplanes
CFR Title 14 Part 25 FAA FAR Airworthiness Standards: Transport Category Airplanes
I have experience with MTS and Cyber Systems servo control equipment for structural test controls for integration, application, and test execution and performance.
I have worked with RKG Enterprises for over 5 years on a part time basis and I joined RKG full time in March 2003 continuing to work in structural and environmental testing, research & development, and marketing and business development.