Consultant, Kevin Kennedy Associates Inc.
Providing expertise in materials science and engineering, metallurgical engineering, mechanical testing and tribology, research, laser surface treatment, forensic investigation and analysis, failure analysis, and related expertise to a wide variety of clients..
Co-founder and Chief Technologist, Consulting Firm
Serving clients through consulting and research & development in welding, forging & stamping development, failure analysis, and materials tests. Forging of carbon steel, alloy steel, stainless steel, copper, aluminum, titanium, and alloys. Welding of carbon steel, alloy steel, stainless steel, cast iron, aluminum, inconel, titanium, plastic, and ceramics. Developed laser-induced aluminum-iron oxide thermite reaction based welding of non-wetting dissimilar materials
Senior Packaging Engineer, Intel Corporation
Recognized for his innovation in stamped Cu-Si-Ni alloy contacts for connectors and sockets, and in solder mount technology of large form factor connectors. Led replacement of stamped Cu-Be alloy for land grid array connector application. Led introduction of lead-free soldering in surface mountable land grid array connector. Received multiple awards for innovation and problem solving in surface mount technology, and in Cu and Al heat sink and integrated heat spreader stamping. Resolved non-uniformity in stamped 0.4mm thin contact using finite element analysis of stamping process. Authored “Large Land Grid Array Surface Mount Technology: Challenges in Manufacturing”, Manufacturing Excellence Conference, IMEC08, San Diego, CA, June, 2008.
Post-Doctoral Researcher, University of Tennessee, Knoxville, TN
Projects included: Laser-Material Interaction: Fractal Nature of Topography Evolved During Laser-Material Interaction. Laser Induced Coating and Surface Modification of Metals and Ceramics (Steel, Aluminum, Titanium, alumina) and Structure-Property-Process Correlations. Laser Induced Surface Modification for Improved Biocompatibility of Titanium Alloy Implants. Investigated structure-property-processed correlation in laser-processed titanium alloys. Performed research on laser surface coating of aluminides on steel. Traveled to Indian Institute of Technology, Kharagpur and conducted research on synthesis of laser induced amorphous surface structure. Used following material characterization techniques: optical microscopy, SEM/EDS, EBSD, TEM, X-ray diffraction, Auger microanalysis, mechanical testing, nanoindentation. Wrote research proposals. Published and periodically reported research results. Trained and assisted fellow students in laser processing of material research.
Graduate Research Assistant, University of Tennessee, Knoxville, TN
Projects included: Laser Induced Coating and Surface Modification of Metals and Ceramics (Steel, Aluminum, Titanium, Alumina): Structure-Property-Process Correlations Laser assisted dressing of alumina grinding wheel Development of Aluminum-Iron Oxide exothermic (thermite) reaction based composite and coating Investigated structure-property-processed correlation in laser-processed aluminum alloys. Performed research on laser surface treatment of aluminum alloys. Used following material characterization techniques: optical microscopy, SEM/EDS, EBSD, TEM, X-ray diffraction, Auger microanalysis, mechanical testing, nanoindentation. Assisted in research proposal preparation. Wrote proposals for Shared Research Equipment (SHaRE) program and High Temperature Materials Laboratory User Facility program of Oak Ridge National Laboratory (ORNL). Managed and carried out collaborative research projects in microscopy, tribology, and nanoindentation. Published and reported research result. Authored 11 journal papers and 6 conference papers/presentation. Trained and assisted fellow students in laser processing of material research.
Intern, Ford Motor Co, Dearborn, MI
Project: Ultrasonic Welding of Aluminum Alloys 5754 and 6111. Characterized structure and property correlation in ultrasonic welding of aluminum alloys for auto body applications. Characterized structure and property correlation in stamping of aluminum alloys for auto body applications. Developed a welding process and warm stamping process amenable for age hardened aluminum alloys. Received Letter of Appreciation for Director, Ford Research Laboratory.
Engineer, Metallurgist, Tractor Engineers Ltd, Bombay
Formerly Associate of Caterpillar Inc. manufacturer of excavator, oil drill, heavy-duty conveyor. Identified, initiated and led and managed cost reduction and quality and performance improvement projects in material, process and supplier selection, and design. Performed failure analysis, customer complaints analysis and supervised in field component repair. Tested and analyzed materials and products. Developed and introduced new testing methodology for new and existing products. Introduced in situ microscopy for large, in field or repaired components. Resolved materials related Issues in Design and Quality Investigated into and solved the problem of inconsistent machinability of centrifugally cast high-Cr white cast iron liner sleeve used in oilfield applications. Identified root cause in material failure and processing problems. (e.g., thermal treatment, surface treatments, casting, forging, machining, sintering, welding). Investigated high strength bolt failure and solved the problem of temper embrittlement. Received performance linked reward for solving problems in wear and inconsistent hardness of steel cast idlers. Identified, initiated and led cost reduction and quality and performance improvement efforts. Initiated and led solving problems of carburizing process. Resulted in almost zero rejection. Evaluated new technology and made recommendations to management, customers and suppliers. Use of continuous casting steel based on my recommendation reduced the input steel cost by 5% and cut the lead-time by 2 weeks. Provided materials related input to customers, marketing, manufacturing and design. Performed materials selection, process selection, sources and technology evaluation in development of indigenous sprocket for excavator. Operated and maintained laboratory equipments. Tested and analyzed materials and products using optical microscopy, SEM/EDX, wear test, chemical analysis, mechanical testing, corrosion testing. Developed technical specifications for materials, products and testing methods. Certified Internal Auditor for ISO 9000. Assisted in implementation of and audit for ISO 9000 for special processes. Supervised 15 workers in materials processing operations: heat treatment, carburizing, surface treatment. sintering, casting, forging.
Metallurgical Engineer, Caterpillar
Receive accolades for solving forging and welding issues in 15B40 steel excavator rollers. Developed earthmover parts manufacturing process. E.g., heat treated steel sprocket section forging. Developed forging process of large idlers with 50 tons press. Solved high strength bolt head failure related to warm forging (head upset) problem. Automated heat treated steel sprocket welding, excavator and bulldozer parts manufacturing and repair. Developed welding process of high cross-section and pipe. Developed process and parameters for in situ welding repair of high value components.