Ali Mansouri Email & Phone Number

Tustin, Ca, Us

Collaborate with design, stress, NDT, manufacturing, mechanical systems, & quality engineering teams as the M&P Lead on the Wing IPT, and metallic M&P focal for all other IPTs, on the Delta Spaceship ProgramWrite and maintain the Corrosion Prevention and Control Plan for the Delta Spaceship ProgramContribute to creation of standard materials list and standard hardware list for different vehicles.Create & implement a standardized drawing review process to ensure consistent M&P technical reviews. Trained 14 person M&P team, from associate to specialist engineers, on this process and the checklist tool.Review drawings & standards for both metallics and composites across five different vehicle programs.Audit critical vendors for welding, heat treatment, coating, and other special processes. Mentor junior M&P Engineers in metallics and career development.M&P representative to Engineer Wide Process Improvement Team

Collaborated with a multidisciplinary engineering team to select and validate metallic materials to build the world’s first ever hyperloop transportation system.Identified reliability concerns to structural, thermal, and magnetic systems, quantified these risks, and engineered solutions to reduce themLaunched an in-house macro and microstructure characterization lab to aid in root cause and failure analysis of metallic parts and better correlate properties with processing. Conducted a testing campaign to statistically characterize the variation in magnetic properties of select structural steels not rated for magnetic applications. Subsequently initiated project to correlate these properties with microstructure and proposed a heat treatment option to reduce variation. Provided electromagnetic and mechanical engineers with materials data input to support multiphysics simulations in cases where no reliable information about the properties of interest exists in literature.Mentored and define projects for entry level materials engineer. Additionally create guidelines and educational material to train other members of engineering team in metallurgy, materials testing, and statistical sampling

Provided metallurgical support to quality, production, sales, and design engineering teams to ensure ATI’s nickel-based superalloy aero-engine products meet customer requirements.Served on the MRB team by providing root cause and corrective action for non-conforming product Redesigned ATI manufacturing processes (forging and heat treatment) for parts with a history of failures to be able to meet customer requirementsContinuously improve current processes to positively impact quality, productivity, and costReview order inquiries to access our ability to meet customer requirementsInteract directly with Quality Assurance and supporting the sales team to address any customer technical concerns

Designed and maintained hot die forging tooling using CAD software based on customer dimensional and metallurgical requirements.Use FEM simulations to validate and improve process and tooling designsMonitored production to ensure technicians follow approved manufacturing processes and gave instructions on what to do when manufacturing problems arise.

Irvine, Ca, Us

Perform measurements on Nanovea Mechanical Testers, Tribometers, and 3D Non Contact Profilometers for clients looking for surface characterization of their samples from a wide variety of different industries. Find new applications for different product features and write up application notesLead project to assess viability of adding a surface replica polymer to company portfolioPromoted to Product Development Associate in June 2016

Newport Beach, Ca, Us

Created and upgraded over 100 training files for MSC Nastran and Patran FEA software.Built CAD models and analyzed them for linear, nonlinear, and thermal solutions.Worked primarily with aerospace, automotive, electronic, and rotor dynamic applications.Resolved conflicts in existing training materials and convert classes between different softwares.

Irvine, Ca, Us

Studied long term electrolyte/cathode degradation mechanisms in Solid Oxide Fuel Cell Systems and analyzed corrosion mechanisms in turbine blade material systems exposed to different fuel regimes in a burner rig environmentPrepared metallographic samples, synthesized cathode and electrolyte materials, made test cells, created process documentation, and supervised testsConducted post-test and post failure analysis using optical microscope, electrochemical impedance spectroscopy, scanning electron microscopy, x-ray diffraction, and energy dispersive spectroscopy.Repaired and maintained older lab equipment such as high temperature furnaces and PID temperature controllers

Master Of Science (M.S.), Materials Science And Engineering

Bachelor Of Science (B.S.), Mechanical Engineering, Materials Science Engineering

Education record