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Robert A. Miller
SUMMARY
Dynamic, analytical problem solver with demonstrated ability to develop materials solutions for existing and future industrial and aerospace applications. Resourceful in working with diverse teams to put together the necessary background knowledge, raw materials, test data, specifications, and use instructions to commercialize cost-effective new products and methods.
EXPERIENCE | R. A. MILLER MATERIALS ENGINEERING , Indianapolis, IN | 2003-Present |
Materials Consultant
Providing expert private consulting services to industry in the areas of materials engineering, sourcing, quality assurance, applications, and business/market development, with primary concentration on the thermal spray coatings industry. Clients to date include producers of thermal spray powders and coatings, a recycling company, and engineers of large scale outdoor artwork. | DELORO STELLITE , Goshen, IN | 2008-Present |
Senior Materials Engineer Writing alloy and powder specifications, and bills of material, for welding, laser cladding and thermal spray powders. Providing technical sales support to answer customer and sales team inquiries about materials and applications. Assisting purchasing department in the sourcing of raw materials. | BELCAN CORPORATION , Indianapolis, IN | 2004-2008 |
Specification Writer Provided engineering services to Roll-Royce Corporation aircraft engine plant in Indianapolis, to enable Rolls-Royce to outsource lab evaluations performed for repair engineering vendor qualification. Tasks included drafting specifications and other work documents, acting as liaison between internal and external test laboratories, and assisting repair and R&D engineers in using the documents. PRAXAIR SURFACE TECHNOLOGIES , Indianapolis, IN, and
TAFA (acquired 1999 by Praxair), Concord, NH and Pearland, TX | 1995-2003 |
Senior Market Development Specialist, 2002-2003
Determined the nature, scope, and potential of new markets for atomized alloy powders made by Praxair, and gained sales to those markets directly and through the sales force.
· Completed thorough market assessment of powder consolidation technologies and powder deposition technologies, discovering multi-million dollar sales potential.
· Visited potential customers in these markets in North America and Europe, leading to numerous field test programs to qualify powders.
· Helped powder plant to adjust to produce the needed compositions, particle sizes, and quality levels.
Materials Manager, 2001-2002
Sourced raw materials for the powder plant, maintained appropriate inventory levels, and sold recyclable materials.
· Saved estimated $300K+ by finding alternative sources of nickel, cobalt, and chromium raw materials, including melt stock (cathode) grades and powders.
· Negotiated national recycling contract, then sold major backlog of recycle materials.
· Instituted system to monitor and control raw materials inventory levels using Oracle.
Senior Product Development Engineer, 2000-2001
Wrote new powder specifications for raw materials and finished products added to Praxair's system as a result of its purchase of TAFA.
· Completed the conversion of powder specifications to the Praxair system.
· Completed orderly transition of TAFA's QA files and samples to Praxair.
· Completed special project to develop and implement inspection of raw materials and recycle materials for radiation, to meet standards.
Senior Materials Development Engineer (TX), 1998-2000
Sourced and purchased raw materials for production and R&D of thermal spray powders, evaluated supplier performance, directed QA testing and certification of raw materials and finished products, wrote powder specifications, and gave general support to R&D activities.
· Developed new higher quality, lower cost powder sources and grades, now in active use in production or in R&D programs.
· Developed comprehensive approved supplier list.
· Spearheaded efforts to replace dissociated ammonia with nitrogen/hydrogen blends, resulting in installation of gas equipment which improved sintered quality of cemented carbides.
· Led effort to benchmark thermal spray performance of cemented carbide powders.
Manager, Materials Development (NH), 1995-1998
Directed laboratory and spray test characterization of developmental and standard thermal spray powders and wires, wrote powder and wire specifications, and issued application recommendations to the field.
· Developed a revolutionary copper-nickel-indium arc spray wire.
· Sourced, tested, and added numerous powders and wires to the product line.
· Set up modern labs for sample preparation, metallography, and physical testing.
· Created complete specification books for wire and powder products.
SULZER PLASMA TECHNIK, Troy, MI
| 1988-1994 |
Product Development Engineer
Developed and characterized gas atomized and composite thermal spray and vacuum brazing powders, and assisted in scale-up to full scale production. Advised sales personnel and customers on how best to spray the powders, and developed detailed parameter sheets for newly introduced powders. Also investigated gas atomization processes using Design of Experiment methodologies, to improve product yields. Supervised the in-house chemistry lab from Fall 1993.
· Rapidly developed and scaled up a line of self-bonding thermal spray powders.
· Developed novel abradable seal powders and their coatings (several US patents). | AIR PRODUCTS & CHEMICALS INC. , Trexlertown, PA | 1983-1988 |
Senior Development Engineer
Applied R&D Department, Developed novel applications for industrial gases.
· Set up arc spray coatings lab with custom gas train and custom wire feed apparatus. Organized testing of arc spray coating processes using inert or reactive gas atomization in place of compressed air, to improve coating integrity.
· Initiated and helped to develop a patented gas-phase silicon diffusion coating process.
| METCO INC. , Westbury, NY | 1978-1983 |
Senior Materials Engineer
Developed, characterized, and created standard parameters/methods for a wide range of thermal spray powders, wires, sealers, and spray processes. Also advised internal and external coating users on optimum selection of materials and deposition methods. In 1981-1983, worked specifically on coatings for special applications, such as protection of black liquor recovery boilers and pulp digesters in the kraft paper industry.
| ASARCO INC. , South Plainfield, NJ | 1974-1978 |
Research Metallurgist
Developed and characterized non-ferrous (Pb- and Cu-base) alloys and applications, including studies of the Pb-Sn-Ca ternary phase diagram in connection with hardener alloys for maintenance-free battery grids. | HOWMET CORPORATION , Whitehall, MI | 1973-1974 |
Development Engineer
Developed Hot Isostatic Pressing methods for healing defects in cast Ni-base and Ti-base turbine components and surgical implants.
EDUCATION
M.S., Metallurgy & Materials Science Department, Massachusetts Institute of Technology
B.S., Metallurgy & Materials Science Department, Massachusetts Institute of Technology
PROFESSIONAL ACTIVITIES
Member, Journal of Thermal Spray Technology Committee
Member, Thermal Spray Society (ASM International) Safety Committee Member, American Welding Society
PATENTS, PAPERS
Eight US patents (with various co-inventors) with Sulzer, Air Products, and Metco, covering powders and processes for gas turbine abradable seal coatings and other composite coatings, a metal-base bond coat for plastics, and a silicon CVD diffusion coating. In various industry forums, papers and presentations on thermal spray processes and products, some in published proceedings.
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Professional Background 
