Jeff Mallat Email and Phone Number

Strategic sourcing of high value, long lead time commodities for large frame industrial gas turbines including: Development of superalloy investment casting suppliersDesign metallurgyRotor forging development leadSuperalloy investment casting metallurgy Coatings engineering leadProperties test and characterization leadMaterial and process specifications leadAmerican and European supplier qualification and developmentExport control officer

Consultant to Factory Director on rotor, casing, and hot gas path component manufacturing. Support of Sourcing operations and material substitutions. Development of laboratory to “world class” status.Technical support to Orlando Service organization.

Responsible for leading a team of engineers in supplier development and process qualification for production of aftermarket hot gas path parts in General Electric and Siemens industrial gas turbine engines. Engineered processes included: investment casting, thermal spray and aluminide coating, welding, brazing, forging, and heat treatment. Also organized materials research and development programs and provided materials selection for design functions.Directed and scheduled supplier development and product qualification assessments. Provided technology consultation to GT hot gas path part reconditioning technology support including failure analysis. Stayed abreast of strategic initiatives and emerging technologies for business improvement. Organized personnel development and succession planning activities.

Acted as Alstom Special Process Specialist for key commodities. Performed rotor forging, casing casting, boiler tube and pipe supplier process qualification and development. Worked with North American, Mexican, European, Asian, and South American suppliers.Supported turbine factory procurement in materials substitution requests. Supported factory operations in rotor welding, machining inspections, and ultrasonic examination.Responsible for outside sales of metallurgical laboratory projects. Directed laboratory testing projects for material and failure analyses. Helped determine export control liabilities in laboratory.Provided metallurgical and welding engineering support to gas turbine design department in Baden, Switzerland.Some notable achievements:- Championed the development of an American--European material conversion standard.- Conducted gas turbine airfoil single crystal base material, MCrAlY and thermal barrier coating assessments.- Developed and qualified suppliers of boiler tube and pipe, including Grade 91.- Helped refine hot corrosion test methods of boiler tube coatings for DOE projects- Wrote low-cycle fatigue and creep properties comparison of stainless steel materials for steam turbine blades.- Passed ASNT Level I test for ultrasonic testing.

Provided guidance to team of 15+ engineers, scientists and technicians regarding unique structural component testing, and failure analyses. Responsible for training of staff to improve skills, performance, and technical knowledge. Maintained scheduling, budgeting, records/sample retention for the laboratory,Kept up with emerging technologies and strategic initiatives to create new business opportunities. Helped organize mentoring and succession planning.Directed all quality management activities related to calibration, maintenance, and utilization of lab equipment, test fixtures, and instrumentation.Participated in root cause metallurgical analyses and investigation of structural component failures. Wrote, reviewed and approved technical reports.Key account manager for power generation, aerospace, and NASCAR teams.Provided technical sales service and quotations for customer project requests.

Started in Field Service as Fact Finder - machinery diagnostics and accident investigation - out of Milwaukee, WI factory. Moved into materials engineering group with met lab in support of the repair shop and GT manufacturing. Helped develop rotor welding capability, GT airfoil base material and coating technologies, and turbine generator life assessment and repair techniques. Performed failure analyses on turbo machinery components. Transferred to Material & Process Engineering department in Orlando in 1999. Participated in design of W501F and W501G gas turbines. Performed advanced materials characterization projects and failure analyses. Became responsible for rotor and compressor materials. Developed, qualified, and supported worldwide suppliers of rotor forgings and compressor airfoils. Finished tenure as plant metallurgist for Charlotte manufacturing and service facility. Responsible for support of turbine and generator design, manufacturing, procurement and QA for the OEM and service factory. Primary focus was on generator materials and processes.Trained and experienced in failure analysis, service recommendations, NDE, materials characterization testing and selection, specification maintenance, product/supplier process qualification, welding/ brazing, American--European material substitutions, and materials development project management. Experience also included materials laboratory supervision, management development training, and Six Sigma Green Belt certification.Some notable achievements:- Conducted extensive materials and coatings characterization projects for GT design properties.- Performed remaining life assessments on fasteners, casings, and rotors.- Led creep notch sensitivity studies in copper alloys.- Saved $100k's with elimination of product inspection for using premium material.- EPRI conference presentation on rotor welding development- EPRI conference presentation on thermal damage analysis in rotor steel.

Administration of engineering team primarily responsible for MD-80/90 design and production support, process analysis and producibility, failure analysis and customer support, materials R&D, supplier qualification and support, specification writing and maintenance, NDT, service repair and rework, coating technology, welding/brazing, fastener technology. Trained and experienced in accident site investigation and failure analysis. Working knowledge of MIL-HDBK-5 (MMPDS) and FAR, AD and SB documents. Involved in MD-90 type certification.Some notable achievements:- Developed and specified vacuum heat treatment procedure for ultra-high strength landing gear steels. - Performed characterization testing on leading edge aluminum alloys for design properties.- Conducted chrome plating replacement research and development studies.

Recruited from college into this position. Trained in metallurgical laboratory and failure analysis techniques. Supported design and manufacture of AH-64A Apache helicopter for U.S. Army. Also supported light helicopter, NOTAR, and 30mm Bushmaster chain gun design and manufacture.