Daniel P. Dennies, Ph.D., P.E., FASM

Dr. Dennies is a licensed metallurgical Professional Engineer (P.E.) in the state of California. He has over 30 years of experience in various raw material, forging, aerospace, and aircraft related industries as a technical specialist, technical manager, and program manager. The majority of his career has been in the aerospace industry working on projects such as the Space Shuttle Main Engine, the National Launch System, the National Aerospace Plane, expendable launch systems like Delta and Titan, and the International Space Station. He has also worked on other projects including commercial aircraft such as the Boeing 787, military aircraft such as the C17 Transport and B1-B Bomber, proprietary programs such as the Ground Based Missile Defense and the X-37B Experimental Reusable Unmanned Space Plane. In addition he has worked on projects concerning the biomedical devices, fasteners, and energy industries.

Dr. Dennies has accumulated experience with a wide variety of materials, processes and test mechanisms through his association with the design, testing, failure analysis, and manufacturing aspects of these programs. His broad areas of expertise include failure analysis, engineering design support, material and process selection, material testing, customer or supplier interaction, and program development and management. He is a member of multiple professional organizations, where he has served on the board of trustees and several national committees, many as chairman. He has over 10 professional awards and was awarded a patent in 1988.
Dr. Dennies has taught multiple courses a year since 2000, has given numerous technical presentations, and is highly published including a book on failure analysis in 2005.

Books Authored

Dennies DP. How to Organize and Run a Failure Investigation. Published by ASM International, August 2005.

Publications

DeVries PH, Ruth KT, Dennies DP. Counting on fatigue: Striations and their measure. Journal of Failure Analysis and Prevention 2010 Apr; 10(2):120–137. Best Paper of 2010 Award.

Dennies DP. A review of the findings and recommendations of the Columbia Accident Investigation Board. Journal of Failure Analysis and Prevention 2006 Feb; 6(1):17–21.

Dennies DP. The future of failure investigation in the aerospace industry. Journal of Failure Analysis and Prevention 2006 Feb; 6(1):22–27.

Dennies DP. Apollo 1 fire and its effect on the space industry. Proceedings, Material Science and Technology Conference 2005, Failure Analysis Symposium, pp. 31–46, Pittsburgh, PA, September 25–28, 2005.

Dennies DP, Fischer MA. Flaws in large 7050 aluminum ring rolled forgings. Journal of Failure Analysis and Prevention 2004 Feb; 4(1):63–68.

Dennies DP. The organization of a failure investigation. Journal of Failure Analysis and Prevention 2002 Jun; 2(3):33–41.

Dennies DP. Microstructure comparison of high strength Inconel 718 nuts. Proceedings, International Symposium on Superalloys 718, 625, 706 and Various Derivatives, pp.443–454, Pittsburgh PA, June 17–20, 2001.

Dennies DP. Laboratory experiment capabilities aboard the International Space Station. Proceedings, 13th International Symposium on Experimental Methods for Microgravity Materials Science, Long Beach, CA, June 11–14, 2001.

Dennies DP, Toosky R. A 25 year study of titanium hydride formation by uphill diffusion in dissimilar titanium welds. Proceedings, ASMI and AWS 5th International Conference on Trends in Welding Research, pp.657–662, Pine Mountain, GA, June 1–5, 1998.

Toosky R, Van Raden R, Dennies DP. Evaluation of titanium hydride formation in resistance seam welded dissimilar titanium joints. Proceedings, ASMI and AWS 5th International Conference on Trends in Welding Research, pp. 628–631, Pine Mountain, GA, June 1–5, 1998.

Dennies DP, Gibeling J. The effect of thermal treatment on the cryogenic mechanical properties of Cast 5Al-2.5Sn ELI Titanium. Proceedings, 7thWorld Conference on Titanium, pp. 121–129, San Diego, CA, June 28–July 2, 1992.

Dennies DP, Gibson, VA, Horn RM. Hydrogen evaluation of Incoloy 909 for the NLS liquid hydrogen TPA turbine. Proceedings, 1992 Conference on Advanced Earth to Orbit Propulsion Technology, Workshop on Hydrogen Effects on Materials in Propulsion Systems, pp. 95–100, NASA Marshall Space Flight Center, AL, May 19–21, 1992. Also, Summary Proceedings, 5th Workshop on Hydrogen-Materials Interactions, pp. 369–378, Scottsdale, AZ, September 23–25, 1992.

Gibson, VA, Dennies DP, Horn RM. Assessment of candidate rocket propulsion materials in a gaseous hydrogen environment. Proceedings, 1992 Conference on Advanced Earth to Orbit Propulsion Technology, Workshop on Hydrogen Effects on Materials in Propulsion Systems, pp. 85–94, NASA Marshall Space Flight Center, AL, May 19–21, 1992.

Dennies DP. Cast 5Al-2.5Sn ELI titanium heat treatment study for low cost cryogenic turbopump rotating hardware. AIAA/SAE/ASME 27th Joint Propulsion Conference, AIAA Paper No. 91–1927, Sacramento, CA, June 24–26, 1991.

Dennies DP, Janser G. Thermomechanical processing study of A286 for low cost turbine materials selection. AIAA/SAE/ASME 27th Joint Propulsion Conference, AIAA Paper No. 91-1928, Sacramento, CA, June 24–26, 1991.

Dennies DP, Smith J. Improved material property estimates using small sample sizes. AIAA/SAE/ASME 27th Joint Propulsion Conference, AIAA Paper No. 91-1926, Sacramento, CA, June 24–26, 1991.

Dennies DP, Swain R. Low cost design guidelines for the Aerojet ALS advanced development LH2 Turbopump. AIAA/SAE/ASME 27th Joint Propulsion Conference, AIAA Paper No. 91-2036, Sacramento, CA, June 24–26, 1991.

Dennies DP, Parsons TD. Oxidation characteristics of 440C CRES in GOX Environments. Lubrication Engineering, ASLE 1986 Oct; 42(10):601–607.

Kumar A, Dennies DP, Parsons TD. Surface analysis of thin oxide films on a stainless steel. Proceedings, International Symposium for Testing and Failure Analysis (ISTFA), pp. 322–328, Los Angeles, CA, October 22–26, 1984.

Dennies DP. Attention graduating engineers, requirement: Communication skills. USC Engineer Magazine 1984 Winter; 35(2):15–16.

Dennies DP. Attention graduating engineers, requirement: Communication skills. Metals Progress Magazine, ASM International Editorial Section, December 1984.

Presentations and Published Abstracts

Dennies DP. Failure analysis of flight hardware made from Custom 465. Material Science and Technology 2010, Failure Analysis and Prevention Symposium, Houston, TX, October 17–21, 2010.

Dennies DP, Wert D. Precipitation aging study of Custom 465 CRES H1050 condition to support flight hardware failure analysis. Material Science and Technology 2010, Failure Analysis and Prevention Symposium, Houston, TX, October 17–21, 2010.

Dennies DP. Hydrogen embrittlement testing of Custom 455 CRES for International Space Station hardware. Material Science and Technology 2010, Failure Analysis and Prevention Symposium, Houston, TX, October 17–21, 2010.

Dennies DP, Golden J. Failure analysis of flexhoses for the International Space Station. Material Science and Technology 2010, Failure Analysis and Prevention Symposium, Houston, TX, October 17–21, 2010.

Dennies DP. Strategy for career development. Material Science and Technology 2010, Perspective for Emerging Materials Professionals: Early Strategies for Career Development Symposium, Houston, TX, October 17–21, 2010.

DeVries PH, Ruth KT, Dennies DP. Counting on fatigue: striations and their measure. Proceedings, Microscopy and Microanalysis 2009 Conference, Instrumentation and Techniques Symposia, Failure Analyses: Practical Metallography/Fractography in Case Studies Session, Richmond, VA, July 26–30, 2009.

Dennies DP. Evaluation of a trimetallic joint. Proceedings, Microscopy and Microanalysis 2008 Conference, Physical Sciences Symposia, Failure Analysis: Real World Applications and Case Studies Session, Albuquerque, NM, August 3–7, 2008.

Wooten J, Dennies DP. Metallographic evaluation of electron beam melted Ti-6Al-4V. Proceedings, Microscopy and Microanalysis 2008 Conference, Physical Sciences Symposia, Failure Analysis: Real World Applications and Case Studies Session, Albuquerque, NM, August 3–7, 2008.

Dennies DP. Engineering challenges of emerging processes. Material Science and Technology 2007, What We Can Learn From Failure Analysis Symposium, Detroit, MI, September 16–19, 2007.

Dennies DP. Apollo 1 Fire and its effect on the space industry. Material Science and Technology 2005, Failure Analysis Symposium, Pittsburgh, PA, September 25–28, 2005.

Dennies DP. A review of the findings and recommendations of the Columbia Accident Investigation Board. Materials Solution Conference and Exposition 2004, Failure Analysis and Prevention Symposium, Columbus, OH, October 18–20, 2004.

Dennies DP. The future of failure investigation in the aerospace industry. Materials Solution Conference and Exposition 2004, Failure Analysis and Prevention Symposium, Columbus, OH, October 18–20, 2004.

Dennies DP. Corrosion of a titanium shaft. Materials Solution Conference and Exposition 2003, Failure Analysis and Prevention Symposium, Pittsburgh, PA, October 13–15, 2003.

Dennies DP, Fischer MA. Flaws in large 7050 aluminum ring rolled forgings. Materials Solution Conference and Exposition 2003, International Symposium on Aluminum Applications, Pittsburgh, PA, October 13–15, 2003.

Dennies DP. How to organize and run a failure investigation. Materials Solution Conference and Exposition 2002, Failure Analysis and Prevention Symposium, Columbus, OH, October 7–12, 2002.

Dennies DP. Microstructure comparison of high strength Inconel 718 nuts. ASM Materials Solution Week, Practical Failure Analysis: The Symposium, Indianapolis, IN, November 5–8, 2001.

Dennies DP. Microstructure comparison of high strength Inconel 718 Nuts., International Symposium on Superalloys 718, 625, 706 and Various Derivatives, Pittsburgh PA, June 17–20, 2001.

Dennies DP. Laboratory experiment capabilities aboard the International Space Station, 13th International Symposium on Experimental Methods for Microgravity Materials Science, Long Beach, CA, June 11–14, 2001.

Dennies DP. The International Space Station—Where is it today? Aeromat 2001, 12th Annual Advanced Aerospace Materials and Processes Conference and Exposition, Long Beach, CA, June 11–14, 2001.

Dennies DP, Lee T. The effect of atomic oxygen exposure on a space station fastener lubricant. Aeromat 2001, 12th Annual Advanced Aerospace Materials and Processes Conference and Exposition, Long Beach, CA, June 11-14, 2001.

Dennies DP. Hydrogen Embrittlement of 52100 Bearings for the International Space Station by Thin Dense Chrome Plating Process," by Dennies DP, Aeromat 2000, the 11th Annual Advanced Aerospace Materials and Processes Conference and Exposition, Seattle, WA, June 26-29, 2000.

Dennies DP. Mechanical property failure of Space Station trunnion pins due to microstructure and heat treatment. Aeromat 2000, 11th Annual Advanced Aerospace Materials and Processes Conference and Exposition, Seattle, WA, June 26–29, 2000.

Dennies DP, Toosky R. A 25 Year Study of Titanium Hydride Formation by Uphill Diffusion in Dissimilar Titanium Welds. ASMI and AWS Fifth International Conference on Trends in Welding Research, Pine Mountain, GA, June 1–5, 1998.

Dennies DP, Van Raden R, Toosky R. Evaluation of titanium hydride formation in resistance seam welded dissimilar titanium joints. ASMI and AWS Fifth International Conference on Trends in Welding Research, Pine Mountain, GA, June 1–5, 1998.

Dennies DP, Gibeling J. The effect of thermal treatment on the cryogenic mechanical properties of cast 5Al-2.5Sn ELI Titanium. 7th World Conference on Titanium, San Diego, CA, June 28–July 2, 1992.

Dennies DP, Horn R. Hydrogen evaluation of Incoloy 909 for the NLS liquid hydrogen TPA turbine. 1992 Conference on Advanced Earth to Orbit Propulsion Technology, NASA/Marshall Space Flight Center, AL, May 19–21, 1992.

Dennies DP, Horn R. Assessment of candidate rocket propulsion materials in a gaseous hydrogen environment. 1992 Conference on Advance Earth Orbit Propulsion Technology, NASA/Marshall Space Flight Center, AL, May 19–21, 1992.

Dennies DP. Cast 5Al-2.5Sn ELI Titanium heat treatment study for low cost cryogenic turbopump rotating hardware. AIAA/SAE/ASME 27th Joint Propulsion Conference, AIAA Paper No. 91-1927, Sacramento, CA, June 24–26, 1991.

Dennies DP. Thermomechanical processing study of A286 for low cost turbine materials selection. Aeromat 1991, 2nd Annual Advanced Aerospace Materials and Processes Conference and Exposition, Long Beach, CA, May 20–23, 1991.

Dennies DP, Smith J. Improved material property estimates using small sample sizes. AIAA/SAE/ASME 27th Joint Propulsion Conference, AIAA Paper No. 91-1926, Sacramento, CA, June 24–26, 1991.

Dennies DP, Swain R. Low cost design guidelines for the Aerojet ALS Advanced Development LH2 Turbopump. AIAA/SAE/ASME 27th Joint Propulsion Conference, AIAA, Paper No. 91-2036, Sacramento, CA, June 24–26, 1991.

Dennies DP, Parsons T. Oxidation characteristics of 440C CRES in GOX environments. 40th Annual ASLE Meeting, Las Vegas, NV, May 6–9, 1985.

Dennies DP. A review of new materials, fabrication techniques and coatings for advanced turbopump bearing applications. 40th Annual ASLE Meeting, Las Vegas, NV, May 6–9, 1985.

Kumar A, Dennies DP, Parsons TD. Surface analysis of thin oxide films on a stainless steel. International Symposium for Testing and Failure Analysis (ISTFA), Los Angeles, CA, October 22–26, 1984.

• Independent Consultant and Senior Managing Consultant, ESI, 2008–2011
• Independent Metallurgical Consultant, 1993–2008
• Technical Fellow, Metallurgy and Failure Analysis, The Boeing Company, 1996–2010
• Senior Regional Metallurgist, Carpenter Technology Corporation, 1994–1996
• Senior Engineering Specialist, GenCorp, Aerojet Propulsion and Ordinance Divisions, 1988–1994
• Technical Director & Quality Control Manager, Arcturus Manufacturing Corporation, 1986–1988
• Technical Manager – Material, Rohr Industries, Inc., 1985–1986
• Member of the Technical Staff, Rocketdyne Division, Rockwell International Corporation, 1979–1985
  
  

• American Society for Materials International (ASMI)
  • Member since 1977
  • Society Board of Trustees, 2006–2009
  • Foundation Board of Trustees, 2004–2007
  • Various National Committees, 1996–present
  • MS&T and Aeromat Conference Organizer and Session Chair 2001–present
  • LA Chapter Executive Committee, 1994–present
• International Metallographic Society (IMS)
  • Member since 2005
  • Board of Directors, 2010–2012
  • M&M Conference Session Chair, 2005, 2007, 2008, 2009, 2010, 2012
• American Society of Mechanical Engineers (ASME)
  • Member since 1984
• American Welding Society (AWS)
  • Member since 1979
• Society for the Advancement of Materials and Process Engineering (SAMPE)
  • Member since 1989
• The Minerals, Metals and Materials Society (TMS)
  • Member 1993–2003
  • Professional Engineering Examination Committee 1994–2006
• National Aerospace Standards Committee (NASC)
  • Technical Advisor 1994–2004