Gio Bacigalupo
Madison Heights
Summary
Results-driven metallurgical engineer with a proven track record in quality and process development. Successfully decreased annual non-conforming defects while improving hot stamp part stability through innovative process analysis. Aiming to transition into a Quality Engineer role to drive operational excellence.
Overview
25
25
years of professional experience
Work History
Metallurgy Manager
Autokiniton
Detroit
10.2021 - Current
- Reduced non-conforming defects for products with free -ferrite going through an austenitizing furnace from 187K to 60K a year.
- Improved dimensional stability of hot stamp parts by analyzing quench time and thermal imaging effects on process efficiency.
- Coached, mentored, and trained entry level metallurgy technicians to enhance job performance and skill development.
- Analyzed production processes for continuous improvement opportunities.
Process Metallurgist
Metals Technology Corporation
Carol Stream
12.2019 - 02.2020
- Collaborated with customers to identify requirements and recommend heat treating and alloy choices, ensuring desired physical properties were achieved.
- Analyzed failed heat treatments and adjusted recipes for successful reheat treatments.
- Define and process level 3 PPAP documentation for new business.
- Assessed quoting documentation and evaluated feasibility for new projects.
Quality Manager/ Metallurgist
Premier Thermal Solutions
Lansing
11.2018 - 08.2019
- Developed and implemented heat treating recipes and processing instructions for spherodized annealing, oil quenching, tempering, and phosphate conversion coatings, training operators to ensure adherence and consistency.
- Oversaw daily operations of quality lab staff, ensuring efficient workflow and strict adherence to quality standards, contributing to overall lab performance.
- Investigated and implemented 8D corrective actions, addressing root causes and enhancing product quality.
- Maintain compliance with IATF, CQI-9 and CQI-12 standards
Metallurgical Engineer/ Quality Lab Supervisor
Gestamp
Chelsea,
12.2017 - 10.2018
- Trained quality, metrology, and metallurgy technicians on ISO 17025 Quality manual standards to enhance lab proficiency
- Developed internal measuring techniques ensuring compliance with Ford MIG welding quality standards
- Provided weld quality insights to continuous improvement team, addressing and mitigating systemic issues
- Ensure labs meet OSHA and local government standards
- Design high efficiency lab layout to meet the customer needs
Metallurgist
Scherdel Sales & Technology
Muskegon
10.2015 - 09.2017
- Write, improve and develop material specifications for internal manufacturing and suppliers (examples of successful implementation of specifications: shorten down time between different heats, properties of anisotropic materials in the stamping operations, controlling the microstructure in metastable alloys)
- Assessed stamping processes to minimize downtime between heat changes by reducing clearance variation for improved shearing of rolled strip and adjusting EDM processing parameters for enhanced surface finish and extended tooling life.
- Evaluated material suppliers for anisotropic materials through supplier audits, ensuring control of material properties in longitudinal and traverse directions.
- Supported purchasing by sharing expertise in international material standards.
- Implement Nitriding Process of stainless steel piston ring expanders. (The company's intention was to bring the process to the US. I received training in the process at the facility in Germany)
Metallurgist
NN Autocam Precision Components
Kentwood
09.2011 - 10.2015
- Specified NDT testing requirements and defined restricted chemistry and mechanical properties for incoming bar and rod, ensuring compliance with industry standards.
- Developed material specifications for over 200 long bar and rod products both domestically and internationally.
- Conduct material analysis to help quality and product teams to meet strict requirements for fuel injection components
- Performed failure analysis to identify root causes and recommended manufacturing changes using SEM/EDS to analyze origins of manufacturing residues.
- Provide direction for heat treatment rework of unqualified product in order to reduce scrap
- Collaborated with manufacturing quality engineering to analyze statistical data, contributing to continuous improvement initiatives.
- Purchased equivalent steels for fuel injection components by evaluating market options.
Pilot Plant Operator/ CNC Machinist
SKF USA Inc (NATC)
Plymouth
10.2009 - 06.2010
- Verified daily quality operations using pin gauges, bore gage, and dial gages to maintain standards.
- Executed assembly operations on ball and stud assembly machines to ensure product integrity.
- Operated experimental hard turning lathe, adjusting CNC program to meet quality specifications.
Quality Engineer/Metallurgist
SKF Bearing Industries
Glasgow
07.2007 - 09.2008
- Respond to customer quality complaints (tools used: 8D, 5 why)
- Supervised quality control laboratory technicians to ensure compliance with quality standards
- Performed root cause analysis and implemented corrective actions to resolve quality issues
- Review, edit and implement changes to the CQI-9 Heat Treat Self-Assessment procedures
- Administer the layered process audits (LPA)
- Executed product parameter verification against reject masters to maintain product quality
- Monitor and provide direction for inductor performance and capability
- Dimensional analysis of bearing raceway using profilometer and other metrology equipment
Metallurgy and Chemistry Technician
SKF USA Inc (NATC)
Plymouth
05.2001 - 07.2007
- Analyzed chemical composition of steels using optical emission spectroscopy to ensure compliance with specifications
- Conducted metallographic examinations of bearing quality steels (primarily 52100) to assess material integrity
- Evaluated the physical properties of materials (hardness, micro-structure, JK inclusion cleanliness ratings)
- Executed root cause analysis on warranty returns and test samples to identify failure mechanisms
- Performed X-ray diffraction to determine retained austenite
- Performed grease analysis using an FTIR to develop an internal library of grease composition signatures via the "finger print region"
Education
Bachelor of Science - Material Science and Engineering
University of Michigan
Ann Arbor, MI01-2011
Skills
- Tensile Tester (Instron)
- Metallurgy lab equipment
- OES (arch spark) chemical analysis
- X-Ray diffraction analysis for retained austenite
- FTIR analysis experience on different greases
- Microscopy and Paxit analysis software experience
- Wilson, Zwick Rockwell tester
- Automatic micro hardness tester for case depth analysis
- Comparator profile experience
- Experience using talysurf inline 2D profilometer
- Refractometer experience
- Metallurgical chemistry
- Metrology experience
- Failure analysis photography
- Failure analysis writing
- SEM/ EDS operator
Name
baciggio@gmail.com, 313-335-2464, 369 E. Barrett Ave, Madison Heights, Mi 48071
Timeline
Metallurgy Manager
Autokiniton
10.2021 - Current
Process Metallurgist
Metals Technology Corporation
12.2019 - 02.2020
Quality Manager/ Metallurgist
Premier Thermal Solutions
11.2018 - 08.2019
Metallurgical Engineer/ Quality Lab Supervisor
Gestamp
12.2017 - 10.2018
Metallurgist
Scherdel Sales & Technology
10.2015 - 09.2017
Metallurgist
NN Autocam Precision Components
09.2011 - 10.2015
Pilot Plant Operator/ CNC Machinist
SKF USA Inc (NATC)
10.2009 - 06.2010
Quality Engineer/Metallurgist
SKF Bearing Industries
07.2007 - 09.2008
Metallurgy and Chemistry Technician
SKF USA Inc (NATC)
05.2001 - 07.2007
Bachelor of Science - Material Science and Engineering
University of Michigan