Chad Henry Email & Phone Number

Birmingham, West Midlands, Gb

R&D and Production Readiness of Laser Wire Directed Energy Deposition (LW DED) Additive Manufacturing (AM) for Titanium 6Al-4V Alloy for Large-Scale Aerospace ComponentsResearched and developed the philosophy and implemented the concepts for three in-situ control algorithms for GKN's LW DED technology. This created the automation and quality necessary for production. Currently in formal qualification stage with OEM aerospace customer.

Acton, Act, Au

Summary - Guided and tailored CSIRO’s technical capabilities to make them applicable to metallic Additive Manufacturing (AM) for titanium. Then, established and grew a relevant innovation center, Lab 22, for metallic AM to collaborate and engage with academia and industry to grow these technologies for the benefit of the country.Metallic Additive Manufacturing Operations Manager - Create a pipeline of projects with industry. Collaborate with companies to implement technologies such that a positive ROI (Return on Investment) is achieved. Plan, design, collaborate, seek funding, coordinate and write proposals, contract negotiate, secure, and execute (project manage) projects to improve the performance and/or reduce the cost of metallic manufacturing technologies to broaden the application space in industry. - Establish and operate CSIRO’s Lab 22 Metallic Additive Manufacturing Innovation Centre. Manage operational aspects of the facility and equipment. Procure and commission machines and technologies: • Arcam EBM (Electron Beam Melting)• Concept Laser Cusing• Optomec LENS (Laser Engineered Net Shaping)• Voxeljet 3D sand printing• DMG-Mori Lasertec65• Cold SprayTitanium Technologies Stream LeaderProfess the value of titanium to Australia, including to the government, universities, R&D organizations, and industry. Australia possesses much of the world’s titanium ore, but does not add value to it. Create the titanium industry in Australia by developing, maturing, and implementing capabilities at CSIRO, including novel metal powder production, powder to product, and manufacturing technologies. Resource plan with the team and group leaders to ensure strategic goals are be achieved.

Advanced Manufacturing Systems & Prototyping (AMS&P)Explore, develop, and transition advanced metallic manufacturing technologies. Responsible for the strategy and direction of the company for metallic additive manufacturing. Utilize Independent R&D (IRAD) funds efficiently and design experiments so that the results allow for the strategic marketing and strengthening of proposals for larger, follow-on, Contracted R&D (CRAD). Market and insert pre-solicitation influence at potential funding sources. Know when and who to assemble for multiple entity collaborative teams. Perform project manager and principal investigator duties. Logically and formally trade deliverables, costs, and schedules during project progression based on results to date.IRAD Projects include:• Infrared (IR) Monitoring of Powder-Bed Electron Beam Melting (Arcam’s EBM) for Better and Alternative Processing and NDI• Surface Roughness Improvement via Non-Traditional Machining for Improved Fatigue Resistance of Additive Manufactured Components• Component Repair via Wire-Fed Electron Beam Additive Manufacturing (Sciaky’s EBAM)• Alternate and Low Cost Powder for Additive Manufacturing and Solid-State Compaction.CRAD projects include:• Distortion Control and Non-Destructive Inspection for Electron Beam Additive Manufacturing (Sciaky’s EBAM)• Titanium Net Shaping (TiNS) - Press, Sinter and Hot Isostatic Pressing and Powder-Bed Electron Beam Melting (Arcam’s EBM)• Forging Affordable Solid-state Titanium (FAST) - Low-Cost Powder Derived Near-Net Forgings• Innovative Mass Production of Affordable Consolidated Titanium (IMPACT) - Low-Cost Powder Derived Roll Compacted Sheet• Shared Data Set Generation for Design Allowables for Powder-Bed Electron Beam Melting (Arcam’s EBM)• Non-Destructive Testing of Direct Manufactured Titanium (NDI of DM Ti) for Wire-Fed Electron Beam Additive Manufacturing (Sciaky’s EBAM).

Air Vehicle Structural Design, F-35 Materials and Processing (M&P) Established and maintained metallic material specifications and process specifications for the database utilized by designers for the F-35 Program. Interacted with Integrated Product Teams (IPT’s) outside of Air Vehicle and served as a contact for part and assembly suppliers and raw material suppliers on metallic material and process issues. Applied knowledge of material science and related technologies to review concepts and evaluate technical factors in order to recommend material selection and manufacturing actions for attainment of F-35 design objectives. Planned and implemented in-house R&D and coordinated with raw material producers to develop new alloys and/or product forms to fulfil performance and cost standards. Project Lead on a corporate wide Copper Beryllium Replacement program.

Fort Worth, Texas, Us

Provided metallurgical engineering to the Stress and Design groups to meet their engineering requirements. Considered material properties, alloy content, material cost, heat treatments, wear resistance, coatings, corrosion protection, material compatibility, producibility, manufacturing cost, availability, and other aspects. Groups supported include Rotors, Transmission, Airframe, Liaison, Tooling, and Structural Testing for multiple programs including the Huey and Cobra Upgrade, V-22 Tiltrotor, all commercial ships, and Ground Handling and Support Equipment. Frequently travelled to Bell Canada to provide Metallurgical expertise.Responsible for full life cycle of the following R&D programs in effort to produce components more affordably, quicker, and/or better performing:• Optimization of Beta Solution Heat Treat and Over Age (BSTOA) of 6Al-4V Titanium for High Cycle Fatigue Resistance• Pre- and Post- Weld Heat Treatments of Precipitation Hardened 17-4 Stainless Steel• Titanium 6-2-4-2 vs. Inconel 625 for High Temperature Fatigue Resistance• Super Plastic Forming of Thick Aluminium Sheet Metal for Structural Applications• Powder Coating for Fretting and Galling Resistance in Thermal Fit Sleeves and Bearings• Investigation of Cadmium Plating Alternatives