Engineering Consultant

Dan Carbaugh is a consultant specializing in program management and the application of Computer Aided Engineering (CAE) for the design of metalworking processes for a broad range of materials including aluminum, titanium, steel, and superalloys. Dan retired from Alcoa Wheel & Forged Products in Cleveland after 24 years in a number of engineering and management positions. He started his Alcoa career in the Alumina Refining and Chemicals Division at Arkansas Operations where he was responsible for capital improvements and maintenance of several production departments.

As Manager of CAD/CAM/CAE at Wheel & Forged Products he established electronic documentation techniques that enabled plant wide access to product and tooling information for forged products. As Program Manager for Forged Automotive Products he had Alcoa product & tool engineering and program management responsibilities for forged chassis components for Lincoln, Jaguar and Mercedes programs. Later, as Forging Program Manager he had forging engineering responsibility for Aerospace & Commercial Forging business. The techniques his team developed for minimizing residual stresses and machining distortion reduced manufacturing time on a key Boeing 777 forged part by over 60 percent. This experience has given Dan an exceptional background in heavy-press forging of aluminum and superalloys.

Dan is co-inventor of two patents on thermomechanical processing of large superalloy forgings. He received the Alcoa award for outstanding group achievement in aluminum technology in 1991 and 1992. Dan has BS and MS degrees in Mechanical Engineering from the University of Pittsburgh and Cleveland State University. He is a Licensed Professional Engineer in Arkansas, Ohio and Pennsylvania.