Mark Bonesteel
Senior Aerospace Materials & Process Engineer
Melbourne,FL
Summary
Versatile metallurgical and aerospace materials engineer with 27+ years of expertise in materials and process engineering within top aerospace companies. Specialized in ring, die and forge rolling, permanent mold casting, and high-frequency induction welding. Recognized subject matter expert in additive manufacturing, diffusion bonded structures, laser peening and LFW tailor-made blanks. Developed advancements for AM thermal processing and dissimilar metal weld joint efficiency. Knowledgeable about aerospace metallic material sourcing ( aerospace grade AM powder, billet, bar,plate & sheet) mechanical testing, heat treatment and quality engineering.
Overview
24
24
years of professional experience
61
61
years of post-secondary education
1
1
Language
Work History
Senior Principal Material & Process Engineer
Northrop Grumman
01.2021 - Current
- Providing daily engineering solutions for design and vehicle engineering involving processing of aerospace materials including metallics, composites and interface materials leading to 10% increase in mission effectiveness
- Achieved 15% reduction in downtime through corrosion mitigation in design and operational maintenance
- Addressing supply chain constraints with expertise in aerospace QMS and supplier quality metrics. Reduced bottlenecks by qualifying alternate materials and consumable suppliers.
- Delivering turnkey aerospace materials solutions, specializing in raw materials and value-added processing. Knowledgeable in metallics special processing and materials testing as audited by Nadcap and a2la.
- Delivered exceptional client experiences by cultivating strong relationships and addressing concerns with quick turnaround.
Senior Materials & Process Engineer
Collins Aerospace (Raytheon Technologies)
02.2009 - 09.2020
- Influenced material selection, reducing costs and enhancing reliability
- Streamlined damage tolerance and lifetime requirements, saving one man-year and achieving $300K cost recovery per program
- Led A320neo program support, ensuring 99.99% dispatch reliability
- Authored material and process specifications, spearheading new processes.
- Collaborated with cross-functional teams to improve product quality, resulting in increased customer satisfaction
- Mentored junior engineers in best practices for process design, optimization, and troubleshooting techniques
- Evaluated new technologies and equipment upgrades to enhance overall process capabilities, ensuring market competitiveness
- Developed documentation, diagrams, and specifications to meet project requirements and regulatory standards
- Conducted root cause analysis to identify, prioritize and eliminate process losses
- Collaborated with cross-functional teams to develop and implement process changes
Materials & Process Technology Engineer
The Boeing Company
01.2006 - 01.2009
- Enabled performance improvement for 787 flight control (flaptracks) and 747-8 landing gear systems (structural alloy selection)
- Conducted supplier qualification audits and statistical data analysis of material property data
- Provided flight cycle durability enhancement for ferrous alloys using special process modifications.
- Down-selected high strength aerospace alloys for performance on airframe, wings and landing gear.
- Conducted K1scc studies to measure corrosion performance of new alloys.
- Presented technical findings to stakeholders, ensuring clear understanding of project status and goals
- Collaborated on interdisciplinary teams to develop creative, cost-effective solutions for complex projects
Chief Quality Engineer
Firth-Rixson Viking (Arconic)
Reno, NV
03.2003 - 05.2005
- Oversaw a 25% increase in business for titanium, ferrous, superalloy, and aluminum ring forgings
- Managed heat treating, process control, and special process audits.
- Point of contact for Nadcap pyrometry, materials testing, supplier process and quality systems audits.
- Conducted detailed audits to ensure adherence to ISO 9001 standards, maintaining a high level of compliance throughout the organization
- Supported organizational growth initiatives by participating in new business proposals or customer presentations showcasing the company''s commitment to delivering high-quality products
- Developed inspection plans based on design specifications, ensuring all critical dimensions and performance criteria were verified throughout the manufacturing process
Metallurgical Laboratory Manager
Conam-AMS, Inc. (Element)
Santa Fe Springs, CA
03.2000 - 01.2003
- Implemented technical upgrades, improving process efficiency by 30%.
- Wrote test procedures for new test methods and customer requirements.
- Managed five test lab employees on staggered shifts in fast-paced, quick turnaround work environment with high turnover.
- Interfaced with aerospace prime source controllers, customers, suppliers and auditors.
- Reduced turnaround time for sample analysis through effective scheduling and prioritization of tasks
- Evaluated new technologies and equipment to identify potential upgrades that could improve overall lab performance
- Enhanced laboratory safety by conducting regular inspections and updating safety training materials as needed
- Developed and implemented standard operating procedures for laboratory processes, resulting in consistent quality of work
Education
Masters of Business Administration -
University of Redlands, Southern California
Redlands, CA 09.2014 - 05.2016
Bachelor of Science - Metallurgical Engineering
University of Nevada, Reno - Mackay School of Mines
Reno, NV 09.1991 - 05.2024
Statistical Process Control (SPC) Certification - Management Academy
Gavilan College
Gilroy, CA 06.1998 - 09.2024
Mandarin Chinese - Language Arts
University of California, San Diego
San Diego, CA 02.2010 - 05.2010
Skills
Lean manufacturing
Affiliations
- ASM International (Aeromat Organizing Committee)
- AWS
- TMS & AIChE alum
- Member of Delta Phi Alpha (German Honor Society)
- Member of Mu Alpha Theta (Mathematics)
Timeline
Senior Principal Material & Process Engineer
Northrop Grumman
01.2021 - Current
Masters of Business Administration -
University of Redlands, Southern California
09.2014 - 05.2016
Mandarin Chinese - Language Arts
University of California, San Diego
02.2010 - 05.2010
Senior Materials & Process Engineer
Collins Aerospace (Raytheon Technologies)
02.2009 - 09.2020
Materials & Process Technology Engineer
The Boeing Company
01.2006 - 01.2009
Chief Quality Engineer
Firth-Rixson Viking (Arconic)
03.2003 - 05.2005
Metallurgical Laboratory Manager
Conam-AMS, Inc. (Element)
03.2000 - 01.2003
Statistical Process Control (SPC) Certification - Management Academy
Gavilan College
06.1998 - 09.2024
Bachelor of Science - Metallurgical Engineering
University of Nevada, Reno - Mackay School of Mines
09.1991 - 05.2024