When Experience Counts
Materials and engineering consulting practice specializing in aerospace thermal spray coating evaluation, training, metallurgical engineering, and expert engineering testimony.
FAA Certified
John P. SauerPrincipal Metallurgical Engineer
Comprehensive program management and troubleshooting solutions for materials and manufacturing process requirements across aerospace and commercial sectors.
Managing materials and process engineering programs to improve process quality, consistency, and overall manufacturing workflow.
On-site consulting and diagnostics to identify root causes of out-of-control manufacturing processes and implement corrective actions.
Qualifying environmentally friendly coatings, developing test protocols, and writing process specifications for paint replacement technologies.
Strategic coordination of materials testing and component failure investigations to deliver actionable engineering data and corrective recommendations.
Rigorous metallurgical examinations and investigations to determine primary root causes of mechanical and structural component failures.
Providing equipment, specialized spare parts, and custom PLC-based control systems for GE E50TF121 erosion testing specifications.
Specialized qualification, troubleshooting, and training services for advanced thermal spray, cold spray, and HVOF coatings.
Developing parameters, characterizing powders, and conducting fatigue and corrosion testing to qualify cold spray applications.
Evaluating and qualifying high-velocity oxygen-fuel spray sources and coatings in compliance with aerospace manufacturing requirements.
Customized, FAA-certified onsite training combining classroom instruction with hands-on process experience for operators and engineers.
Instruction in aerospace metallography and evaluation techniques for thermal spray and diffusion coatings.
Troubleshooting thermal spray coating consistency and quality issues using plume sensor diagnostics and monitoring systems.
Expert witness and technical support services for products liability, analyzing and presenting complex metallurgical principles for dispute resolution.
Providing concise, clear, and logical deposition and trial testimony on materials engineering and metallurgical failure analysis.
Developing rigorous failure scenarios, preparing cross-examination calculations, and translating technical data for litigation support.
Aerospace · Manufacturing · Defense · Legal · Industrial
Legal
Conducted a detailed metallurgical analysis on a fishhook that fractured catastrophically during use, revealing extreme variations in manufacturing quality and component hardness. The findings supported a products liability claim that settled successfully following deposition.
Industrial
Investigated the structural failure of an asphalt-based material storage tank that fractured during a weld repair. Analysis of the welds revealed defective welding practices and poor design standards, enabling a settlement after deposition.
Legal
Investigated a fatal steam engine tractor explosion at a county fair. Evaluated the historical equipment and determined the failure cause was severe wall thinning caused by a century of active corrosion, helping secure a favorable settlement for the plaintiff.
Legal
Analyzed a heavy square cross-section trailer hitch assembly involved in a severe towing accident. Technical calculations and physical findings demonstrated that the hitch deformed as designed during the collision, proving sufficient weld integrity and refuting claims of pre-existing manufacturing defects.