Shane Brooke

Managed the Materials and Processes Team at Glenn Research Center, ensuring line management and project management received updates on significant M&P accomplishments, technical risks, issues, and resolutions.

• Facilitated weekly M&P meetings to address technical issues and communicate project needs within the Materials and Processes Division at GRC.
• Approved M&P Flight Certification Packages and generated Materials Certification Letters for all flight projects at GRC.
• Contributed expert M&P support in engineering review boards, material review boards, panels, and committees to resolve flight hardware non-conformances.
• Support the High Temperatures and Smart Alloys Branch Chief as Alternate Technical Authority for Materials and Processes: (NASA-STD-6016), Welding (NASA-STD-5006), Additive Manufacturing (NASA-STD-6030), and Non-Destructive Evaluation (NASA-STD-5009). Activities include approving technical decisions on flight programs and providing technical input to agency standard updates.
• Functioned as the Universal Stage Adapter (USA) M&P Discipline Element Monitor, working alongside the program manager, contracting officer, chief engineer, and other discipline leads to ensure M&P technical proficiency and adherence to USA contract provisions.
• Managed M&P Sub-System for Gateway's Power Propulsion Element (PPE), overseeing contractor performance and addressing technical issues while identifying and mitigating risks.

As the Deputy Branch Chief of the High Temperatures and Smart Alloys Branch, I assisted the Branch Chief in leading a highly productive branch of six teams (Analytical Sciences Group, Shape Memory Alloys, Refractory Alloys, Nickel Based Alloys, Magnetic Alloys, Materials and Processes) composed of 20 Civil Servants and 10 contractors.

• Identified and communicated potential issues to Division and Program Management that could hinder achievement of project milestones.
• Supported Branch Chief in conducting mid-term and year-end performance reviews and developing assessments and plans for FY23/FY24.
• Participated in the interview and selection process for the Analytical Sciences Group (ASG) Team Lead.
• Analyzed Statements of Work and Requests for Quotes to secure funding for Shape Memory Alloy (SMA) development for lunar tire applications.
• Submitted a Space Act Agreement with The Ohio State University, to help foster GRC/OSU R&D collaboration.
• Advocated for outside work, to support material testing of Maraging Steel 250 for Orion's heat shield bolts, obtaining crucial thermal property data in support of Artemis II.

Managed material and process compliance for multiple projects, coordinating with contractors and project leads to implement NASA-STD-6016 requirements.

• Coordinated weekly meetings, providing M&P input across multiple engineering disciplines.
• Tracked and reported technical issues impacting production to project management, enabling timely resolution and minimizing production delays.
• Identified technical risks and developed mitigation strategies, delivering thorough program risk assessments to project management to inform decision-making.
• Monitored M&P discipline elements as Discipline Element Monitor (DEM) on USA contract, providing weekly and monthly progress updates, contributing to award fee discussions, and evaluating contractor performance.
• Experience in manufacturing, assembly and operations of large space flight structures in addition to material testing, non-destructive evaluation and process development.
• Supported Manufacturing Readiness Reviews, Engineering Review Boards, Technical Data Reviews and various other meetings needing M&P input.
• Lead reviewer for project Material Identification and Usage Lists (MIULs), Material Usage Agreements (MUAs), and other M&P related documents.
• Utilized knowledge of large scale manufacturing to assist in the completion the USA Manufacturing Test Demonstration article, the first NASA composite structure to utilize a hot bonded vertical joint.

As the Lifting Devices and Equipment Manager, I oversaw Glenn Research Center’s lifting program, ensuring OSHA and NASA Lifting Standard compliance.

• Managed the Orion Crew Capsule Critical Lifts associated with environment testing at NASA's Armstrong Test Facility.
• Mitigated operations-related safety hazards by providing engineering expertise and guidance.
• Provided consultation on matters involving risk identification, mitigation and acceptance
• Performed independent assessments and process verifications to assure operational compliance with NASA policies and procedures.
• Participated in engineering reviews and made recommendations for institutional and test-specific hazards
• Provided analyses and recommendations for operational safety decisions.
• Conducted 2018 Institutional, Facility and Operations Safety Audit (IFOSA) for Lifting Devices and Equipment, identifying six compliance findings.
• Developed and implemented Corrective Action Plans for each finding, enhancing GRC’s Lifting Devices Program.

As the lead welding engineer for the Manufacturing Division at Glenn Research Center, I provided weld engineering and manufacturing support to all weld related center level projects.

• Developed welding procedures and processes for advanced aerospace materials.
• Assisted development of Linear Friction Welding process for joining single crystal to polycrystalline Ni-based superalloys, contributing to advanced manufacturing capabilities.
• Supported research and development efforts in joining high temperature alloys.
• Supported R&D efforts in additive manufacturing of metallic materials using laser powder bed fusion, advancing innovative joining techniques.
• Resolved design, material selection, and fabrication process issues to enhance welding outcomes.
• Evaluated welding processes to maintain compliance with industry regulations.

Supported EDLE in resolving technical issues for all manufacturing and production aspects of SLS Core Stage Element (CSE) at Michoud Assembly Facility (MAF), ensuring smooth operations.

• Collaborated with prime contractor on facility and manufacturing planning, process development, and logistics, contributing to streamlined production workflows.
• Coordinated manufacturing activities with other EDLEs (Structures & Environments, Propulsion, Vehicle Management, Vehicle Operations, Test, and Systems Engineering).
• Assessed and documented production risks for SLS Core Stage, enhancing risk management strategies.
• Clarified essential technical support needs to enhance workflow.
• Presented monthly technical reports to Materials and Processes Lab and Core Stage management.

Led development of Conventional Friction Stir Weld (C-FSW) process for Ares I Upper Stage, advancing project’s welding capabilities.

• Led development of Self-Reacting Friction Stir Weld (SR-FSW) process for Ares I Upper Stage, enhancing weld quality and reliability.
• Project Lead on ARES I Upper Stage and Space Launch System Friction Pull Plug Weld Development.

Project Lead on the C-FSW Manufacturing Demonstration Article (MDA).

• Delivered weld engineering support across various Friction Stir Weld (FSW) tools and managed multiple FSW development activities.
• Ensured daily weld assignments and objectives were met.
• Evaluated Non-Destructive Evaluation (NDE) and mechanical test results.
• Highlighted key accomplishments related to project milestones.
• Authored the C-FSW Manufacturing Demonstration Article (MDA) Barrel Manufacture Plan.
• Authored Friction Pull Plug Weld Manufacturing Plan for Ares I Upper Stage.
• Achieved first successful Friction Pull Plug Closeout Weld on Common Bulkhead MDA, marking a key project milestone.