Metal Conversations
Metal Conversations is a podcast hosted by Michael Pfeifer of Industrial Metallurgists, LLC. The show focuses on metallurgy and metals engineering as they apply to product design and manufacturing. Topics include alloy selection, supplier selection, developing manufacturing processes, and addressing quality issues. It provides practical insights for engineers and professionals working with metal components.
Episodes
29 Metal Fatigue
In this episode Michael Pfeifer discusses metal fatigue. Fatigue is a common component failure mechanism that involves localized, permanent damage to metals exposed to cyclic stress.This episode is a companion to several articles and resources on the Industrial Metallurgists, LLC websitePrevent product delays: design to prevent fatigueFatigueImproving Fatigue ResistancePreventing Metal Fatigue----
28 Re-introduction
In this episode Michael discusses his return to podcasting and re-introduces himself, his engineering pursuits and perspective, and what he'll be discussing in the future.-----------------------------------Michael Pfeifer, Ph.D., PE is a metallurgist and metals engineer at Industrial Metallurgists, LLC. Industrial Metallurgists offer metallurgy consulting and metallurgy training to design
27 Metal Annealing
in this episode, Michael Pfeifer discusses the recrystallization anneal process and confusion regarding the use of the term anneal.To learn more about recrystallization annealing check out this video and article.https://youtu.be/ewb_xlgRt2Qhttps://www.imetllc.com/metal-annealing/---------------------------Michael Pfeifer, Ph.D., PE is a metallurgist and metals engineer at Industrial Metallurgists,
26 Phase Diagrams
Phase diagrams are graphical representations of the phases present in a
particular alloy being held at a particular temperature. Phase diagrams
are used to predict the phase changes that occur in alloys during
heating and cooling. This can be during heat treating, casting
solidification, joining processes that involve molten metal, and
elevated temperature use conditions. This is important b
25 Engineering Mistakes, Causes, and Prevention
Engineering and producing a product or structure involves many decisions and actions, and occasionally mistakes are made. Sometimes they are easy to fix
and not costly. Other times the mistakes take a great deal of effort and money to fix. Regardless, the general categories of mistakes can be put into two categories – mistakes due to process or procedure errors and mistakes due to ignorance.
in
24 Supplier Selection
Supplier selection involves many considerations from several different perspectives, such as design engineering, quality engineering, sourcing, finance, and shipping and logistics.
in this episode Michael discusses supplier selection considerations based on the materials engineering perspective, with a focus on metal stock and metal components.
To learn more about the supplier selection from the
23 Component Design Process
Michael discusses a high level view of the component design process from the metals engineering perspective.
To learn more about the component design process, check out these resources:
https://youtu.be/4qGDbbBe4g4
https://www.imetllc.com/materials-selection/
https://www.imetllc.com/materials-selection-design-requirements/
https://www.imetllc.com/designing-optimized-components/
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22 Product Launch Formula
In this episode, Michael discusses different aspects of product development, product launch, and post-launch where materials engineering will improve product success.Developing and launching a product can be stressful – there are many decisions, problems to overcome, and risks to mitigate. While we’d like the process to go smoothly and be able to calmly meet deadlines, this usually is not the case
21 Residual Stress in Metals
In this episode I discuss residual stress in metalsSee this article to learn more Residual StressThis episode is a complement to articles and podcasts available on the Industrial Metallurgists website https://www.imetllc.com/.---------------------------Michael Pfeifer, Ph.D., PE is a metallurgist and metals engineer. He works with design and manufacturing clients to help with Comp
20 Five Key Metallurgy Concepts
In this episode I discuss five key metallurgy concepts that apply to all metals and are necessary to understand to be able to apply metallurgy to Produce stock metal Design and fabricate low-cost, reliable components. Figure out the root cause of component failures and production quality problems.See this article to learn more Five Key Metallurgy ConceptsWe also offer an online course th
19 Two fundamental metallurgy principles
In this episode I discuss the two fundamental principles that are the foundation of metallurgy and metals engineering.See this article to learn more Two fundamental metallurgy principlesThis episode is a complement to articles and podcasts available on the Industrial Metallurgists website https://www.imetllc.com/.---------------------------Michael Pfeifer, Ph.D., PE is a metallurgist and meta
18 Engineering to Prevent Hydrogen Embrittlement
In this episode I discuss the hydrogen embrittlement mechanism and the engineering steps needed to prevent hydrogen embrittlement of steel fasteners. See this article to learn more Hydrogen Embrittlement of SteelThis episode is a complement to articles and podcasts available on the Industrial Metallurgists website https://www.imetllc.com/.---------------------------Michael Pfeifer, Ph.D., PE is
17 Life (and Engineering) Lessons from Boxing
In this episode I discuss a lesson I learned from boxing – being purposeful - and how it applies to engineering (and probably other disciplines) and other aspects of life.
Check out my articles on the Industrial Metallurgists website https://www.imetllc.com/.
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Michael Pfeifer, Ph.D., PE is a metallurgist and metals engineer. He works with design and manufacturing clien
16 Using Failure Analysis to Improve Equipment Reliability
In this episode I discuss another failure analysis project I worked on - an equipment reliability problem. This example demonstrates how failure analysis is applied to improve reliability.I also discuss my motivation for working on failure analyses.See this article to learn more Example of Using Failure Analysis to Improve Reliability of Production EquipmentSee this video to learn more Example of
15 Definition of Successful Product
From an engineering perspective, what is a successful product? In this episode I discuss what I think it is and the influence of metals engineering on product success.I also discuss three new resources for learning about successful component design, designing for reliability, and various metallurgy and metals engineering topics that apply to product design and manufacturing. https://www.imetllc.co
14 Failure analysis case studies
In this episode I discuss two failure analysis projects I worked on. See this article to learn more Failure Analysis Case StudiesWatch this video to learn more Failure Analysis Case studies: orange peel and faucetWe also offer an online course Metal Failure Analysis---------------------------Michael Pfeifer, Ph.D., PE is a metallurgist and metals engineer. He works with design and manufacturing
13 Product Reliability and Materials Degradation
In this episode I discuss product reliability. Reliability refers to the ability of a product to perform as needed for a period of time. Read this article to learn more Materials and Design for ReliabilityWatch this video to learn more Design for Reliability---------------------------Michael Pfeifer, Ph.D., PE is a metallurgist and metals engineer. He works with design and manufacturing clients to
12 Six-sigma and materials engineering
In this episode I discuss 6-sigma, statistical process control, and the role of materials engineering in developing capable manufacturing processes. Materials are used to fabricate components and join components together. And, we want manufacturing processes capable of producing components and assemblies without defects or problems, and whose materials have the desired properties. So, developing a
11 Tribute to Steel Metallurgy Knowledge
In this episode I discuss the state of steel metallurgy knowledge and the things this knowledge have enabled including ultra-high volume steel production and the ability to engineer components with a wide range of properties for a wide range of applications.To learn more, read this article A Tribute to Steel Metallurgy Knowledge and watch this video A Tribute to Steel Metallurgy Knowledge and Stee
10 A different perspective for seeing products
How do you look at any product? See just a thing that performs a certain function?In this episode I discuss my perspective on how I see a product - as an assembly of materials - and how it influences how I help design products to meet performance, reliability, and cost goals.Read this article to learn more Product design - A different perspectiveWatch this video to learn more Product Design - a di
09 Learning and professional development
In this episode I discuss learning and professional development.
There’s so much to know to be an engineer and college courses cover the tip of the iceberg, even if you go to grad school. I learned this early in my career as I was faced with decisions and problems related to topics that I never encountered in school. I also learned that I had to shoulder the responsibility of learning the topics.
08 Design for Manufacturability
In this episode I discuss Design for Manufacturability related to component fabrication and joining components by welding, brazing, or soldering. Design for manufacturing is concerned with designing components and assemblies that can be repeatedly produced with consistent good quality without hassles, and at low-cost.DFM applies to primary component fabrication processes, secondary processing (coa
07 Failure Analysis of Component Failures and Manufacturing Problems
In this episode I discuss failure analysis component or joint failures during product testing or use and manufacturing problems such as supplier quality problems and manufacturing output that doesn't meet specifications. Failure analysis is part of performing a root cause analysis to identify the action, event, or decision that led to a component failing in a product or led to a manufacturing
06 You have to think small to understand metallurgy
(Apologies up front - I recorded this episode using the wrong microphone. So, the sound quality is fair. I'll do better next time.)There are microscopic structures and processes in metals that have large effects on metal properties, performance, and reliability. Being able to conceptualize these structures and processes goes a long way toward understanding the behavior of metals and the effect
05 Metals engineering perspective to component design
In this episode Michael discusses the metals engineering perspective to component design. The concepts actually apply to all materials – metals, polymer, ceramics, and new classes of materials.No matter the application, the considerations when designing a component are always the same. It’s necessary to understand all the design requirements when selecting materials and finalizing a component’s sh
04 What is Metals Engineering?
Metals engineering is the application of metallurgy (the science of metals) to design and manufacturing decisions and problems involving metals. In this episode I explain the fundamental principles of metallurgy and how they are applied to engineer metals for component design and solving component failures and production quality problems.See this article to learn more What is Metals Engineering?Wa
03 Lessons learned as a process engineer
In this episode I discuss two lessons I learned as a process engineer in the semiconductor fab. One lesson was a real-life example of the effects of manufacturing processes on metal microstructure and the resulting effects on a metal property that was used to monitor a manufacturing process. The other lesson was about the fallacy of engineering or scientific ingenuity.
Michael is a metallurgist a
02 How materials engineering fits in
I discuss my education, my experience working in a semiconductor factory and as part of a product design group, and the many different product design and manufacturing activities I was involved in as a metals engineer. See this article to learn more How Metals Engineering Fits InWatch this video to learn more How Metals Engineering Fits In-------------------Michael Pfeifer is a metallurgist and me
01 Metal Conversations Introduction
This episode is an introduction to the Metal Conversations podcast. Michael Pfeifer from Industrial Metallurgists, LLC introduces himself and gives a brief description of what the podcast series will be about.
Michael is a metallurgist and metals engineer. He works with design and manufacturing clients to help with
Component materials selection
Manufacturing process development
Supplier
