Wayne Pugh

Erie,PA

Summary

Metallurgical Engineer with strong expertise in casting, machining, solidification simulation, and process optimization. Proven ability to collaborate across engineering, quality, maintenance, and sales to drive improvements, resolve production challenges, and ensure high-quality outcomes. Experienced from research through full-scale manufacturing.

Overview

years of professional experience

Work History

Metallurgical Engineer

Grede

03.2026 - Current

Led metallurgical process improvements to enhance product quality and reduce defects.
Deployed DOE to enhance retention of specific alloying elements.
Conducted material failure analysis to identify root causes and implement corrective actions.
Streamlined material certification process by reorganizing data entry and migrating paper copies to online format.
Evaluated supplier materials for compliance with quality standards, ensuring reliability in production processes.

Metallurgical/Process Engineer

The Electric Materials Company

06.2019 - 02.2026

Partner with customers and sales to assess manufacturability and recommend design changes
Identify and resolve production defects through root cause analysis
Collaborate with quality teams to disposition nonconforming material
Lead process improvement initiatives across manufacturing
Maintain ISO process documentation and standards
Assist maintenance teams in resolving equipment failures affecting quality
Use casting simulations to design and optimize gating systems
Develop and implement heat treatment processes to meet specifications
Evaluate supplier materials for compliance, cost-effectiveness, and performance

Undergraduate Research Assistant

Missouri University of Science and Technology

01.2014 - 01.2019

Planned and executed molding, melting, heat treatment, pouring, and testing for PhD candidate research projects
Prepared metallographic samples and captured photomicrographs for professors
Performed tensile, Charpy, fatigue, and compression testing and analyzed results
Fabricated parts for research using mills, lathes, wire EDM, and welding equipment

Metallurgical Engineering Intern

Nucor Castrip

05.2018 - 08.2018

Assisted with process control and optimization in thin strip casting
Conducted metallurgical testing to support quality improvements
Linked process parameters to product performance to enhance consistency
Developed alternative testing methods to compare this new strip manufacturing method and conventional strip manufacturing
Audited quality control processes for continuous casting

Education

Bachelor of Science - Metallurgical Engineering

Missouri University of Science And Technology

Rolla, MO

05-2019

Skills

Simulation Software: MAGMASOFT, NovaCast, QForm
Machining: Manual/CNC Lathe/Mill
Additive Manufacturing: FDM & SLA 3D printing
Metallography
Process development

Root-cause analysis
Computer-aided design
ISO 9001 compliance
IATF compliance
Failure analysis

Timeline