Michael Pfeifer — Active Contributor

Author of Metals Engineering and Product Reliability articles and Metal Conversations podcast.

This author's archive lists contributions of articles and episodes.

About Michael Pfeifer, Ph.D., P.E.

I’m a metallurgical engineer with over 25 years of experience working on product design, manufacturing, and root cause analysis.

Most engineers think of metallurgists only for failure analysis of component failures. While I do that, I also help design teams with component design. I help select alloys and coatings that have the corrosion, fatigue, wear, and creep properties needed to meet reliability requirements. Oftentimes, trade-offs are required between component form and materials to optimize a design for performance, reliability, and cost. I help do that, too.

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MC 018 Engineering to Prevent Hydrogen Embrittlement

Engineering to Prevent Hydrogen Embrittlement

In this episode I discuss the hydrogen embrittlement mechanism and the engineering steps needed to prevent hydrogen embrittlement of steel fasteners.

See our blog post on hydrogen embrittlement to learn more https://www.imetllc.com/steel-hydrogen-embrittlement/

Michael Pfeifer is a metallurgist and metals engineer. He works with design and manufacturing clients to help with component materials selection, manufacturing process development, supplier evaluation, failure analysis and root cause analysis.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

Industrial Metallurgists offer metallurgy and metals engineering consulting and training. The training is geared to design, manufacturing, and quality engineers. More information about Industrial Metallurgists’ services and training is at https://www.imetllc.com/

MC 017 Life (and Engineering) Lessons from Boxing

Life (and Engineering) Lessons from Boxing

In this episode I discuss a lesson I learned from boxing – being purposeful – and how it applies to engineering (and probably other disciplines) and other aspects of life.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 016 Using Failure Analysis to Improve Equipment Reliability

Using Failure Analysis to Improve Equipment Reliability

In this episode I discuss another failure analysis project I worked on – an equipment reliability problem. This example demonstrates how failure analysis is applied to improve reliability.

I also discuss my motivation for working on failure analyses.

This episode is a complement to articles and podcasts available on the Industrial Metallurgists website https://www.imetllc.com/.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 015 Definition of Successful Product

Definition of Successful Product

From an engineering perspective, what is a successful product? In this episode I discuss what I think it is and the influence of metals engineering on product success.

I also discuss three new resources for learning about successful component design, designing for reliability, and various metallurgy and metals engineering topics that apply to product design and manufacturing.

Designing Optimized Components

Design for Reliability Course

Short course series: Metallurgy for Successful Products

This episode is a complement to articles and podcasts available on the Industrial Metallurgists website https://www.imetllc.com/.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 014 Failure Analysis Case Studies

Failure Analysis Case Studies

In this episode I discuss two failure analysis projects I worked on.

This episode is a complement to articles and podcasts available on the Industrial Metallurgists website https://www.imetllc.com/.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 013 Product Reliability and Materials Degradation

Product Reliability and Materials Degradation

In this episode I discuss product reliability. Reliability refers to the ability of a product to perform as needed for a period of time.

This episode is a complement to an article (Designing for Reliability) and short video presentation (Product Reliability and Materials Engineering) available on the Industrial Metallurgists website at https://www.imetllc.com/designing-for-reliability/

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 012 Six-Sigma and Materials Engineering

Six-Sigma and Materials Engineering

In this episode I discuss 6-sigma, statistical process control, and the role of materials engineering in developing capable manufacturing processes.

Materials are used to fabricate components and join components together. And, we want manufacturing processes capable of producing components and assemblies without defects or problems, and whose materials have the desired properties. So, developing and maintaining a six-sigma manufacturing process depends heavily on materials engineering. To learn more about this subject check out https://www.imetllc.com/6-sigma-and-materials-engineering/

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 011 Tribute to Steel Metallurgy Knowledge

Tribute to Steel Metallurgy Knowledge

In this episode I discuss the state of steel metallurgy knowledge and the things this knowledge have enabled including ultra-high volume steel production and the ability to engineer components with a wide range of properties for a wide range of applications.

To learn more about this subject check out https://www.imetllc.com/a-tribute-to-steel-metallurgy-knowledge/ Also, on May 17, 2023 there’s a live online course https://www.imetllc.com/product/steel-metallurgy-webinar/

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 010 A Different Perspective for Seeing Products

A Different Perspective for Seeing Products

How do you look at any product? See just a thing that performs a certain function? In this episode I discuss my perspective on how I see a product – as an assembly of materials – and how it influences how I help design products to meet performance, reliability, and cost goals.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 009 Learning and Professional Development

Learning and Professional Development

In this episode I discuss learning and professional development. There’s so much to know to be an engineer and college courses cover the tip of the iceberg, even if you go to grad school. I learned this early in my career as I was faced with decisions and problems related to topics that I never encountered in school. I also learned that I had to shoulder the responsibility of learning the topics. Some of the learning came from colleagues, some came from taking short courses, and some came from reading textbooks and technical journals. In this episode I discuss my learning experiences and philosophy about learning, the pitfalls of relying on learning just from experience, and resources for learning and professional development.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 008 Design for Manufacturability

Design for Manufacturability

In this episode I discuss Design for Manufacturability related to component fabrication and joining components by welding, brazing, or soldering. Design for manufacturing is concerned with designing components and assemblies that can be repeatedly produced with consistent good quality without hassles, and at low-cost. DFM applies to primary component fabrication processes, secondary processing (coating, heat treating), and joining. Primary component fabrication processes include casting, extruding, stamping and other cold forming, forging, and machining. Secondary processes include heat treating, machining, and coating by painting, electroplating, anodizing and other processes. And joining includes welding, brazing, soldering, and using adhesives.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 007 Failure Analysis of Component Failures and Manufacturing Problems

Failure Analysis of Component Failures and Manufacturing Problems

In this episode I discuss failure analysis component or joint failures during product testing or use and manufacturing problems such as supplier quality problems and manufacturing output that doesn’t meet specifications.

Failure analysis is part of performing a root cause analysis to identify the action, event, or decision that led to a component failing in a product or led to a manufacturing problem. The information from a root cause analysis is used to either fix a problem – in the case of product design and manufacturing – or assign blame – in the case of an insurance claim or litigation.

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

MC 006 You Have to Think Small to Understand Metallurgy

You Have to Think Small to Understand Metallurgy

(Apologies up front – I recorded this episode using the wrong microphone. So, the sound quality is fair. I’ll do better next time.)

There are microscopic structures and processes in metals that have large effects on metal properties, performance, and reliability. Being able to conceptualize these structures and processes goes a long way toward understanding the behavior of metals and the effects of mechanical processing and heat treating on metal properties. In this episode I discuss some of the microscopic structures and their effects on metal properties.

I also discuss recent projects and a bonus at the end – some details about my recent trip to Seward, Alaska

He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

Improving Fatigue Resistance

Fatigue involves localized, permanent damage to metals exposed to cyclic stress. In a previous article I discussed the fatigue mechanism. This article covers factors that can be addressed to improve high-cycle fatigue life

Factors that influence fatigue life

Several design, material, and fabrication factors influence component and joint fatigue life, including the following: [Read more…]

by Michael Pfeifer, Ph.D., P.E. Leave a Comment

MC 005 Metals Engineering Perspective to Component Design

Metals Engineering Perspective to Component Design

In this episode Michael discusses the metals engineering perspective to component design. The concepts actually apply to all materials – metals, polymer, ceramics, and new classes of materials.

No matter the application, the considerations when designing a component are always the same. It’s necessary to understand all the design requirements when selecting materials and finalizing a component’s shape and features. The design requirements include performance, reliability, weight, cost, how the component will be fabricated, and how it will be joined to other components. With this information it’s possible to identify alloys and make changes to the component’s shape and features as needed to meet the design requirements at low-cost. Often, trade-offs between component materials and form are made to optimize the design. This is especially important for design for manufacturability to keep costs down and ensure a receptive supply base.

His company, Industrial Metallurgists, offers metallurgy and metals engineering consulting and training. The training is geared to design, manufacturing, and quality engineers. More information about Industrial Metallurgists’ services and training is at https://www.imetllc.com/

He received a B.S. and M.S. in Metallurgical Engineering from University of Illinois and a Ph.D. in Materials Science and Engineering from Northwestern University. He is a Professional Engineer, licensed in Illinois. He’s wrote a book – Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost.

For more information about Michael go to https://www.imetllc.com/about/

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