John McNulty
John C. McNulty, Ph.D., CRE, P.E.
Principal Engineer
Materials & Corrosion Engineering
  • Menlo Park

Dr. McNulty’s areas of specialization include fracture mechanics and fatigue of materials (metals, glasses, ceramics, and composites), materials characterization techniques, mechanical testing, reliability testing and analysis (Telcordia, MIL-STD, IPC/JEDEC, ISO, and AEC standards), hybrid hermetic packaging (terrestrial and space), failure analysis of components and systems (active and passive biomedical implants, desktop/laptop/tablet/smartphone products, wearable consumer and medical electronics, electricity & gas meters, solar panels & inverters, undersea electronics, automotive electronics, satellite electronics, structural materials, MEMS, ceramic capacitors, lasers, and detectors), Pb-based and Pb-free printed circuit board assembly issues (bare rigid and flexible circuit boards, solder selection and processing, BGA/flip chip underfills, temperature and moisture sensitive components, tin whiskers, electro-chemical migration, CAF, and solderability platings), supplier intervention, and corrective action development.

He has performed consumer product safety risk assessments with respect to US CPSC and EU Rapex guidelines (solar panels, inverters, home appliances, tablets, laptop accessories, diving computers, and motion furniture). He has performed supplier reliability audits on behalf of domestic and foreign OEMs in the US, China, Japan, and Taiwan. He has provided expert witness testimony in product liability cases (consumer electronics; telecommunications systems; industrial sensors; court appointed expert for a solar micro-inverter case; solar panels). He chairs the iNEMI working group on defining reliability requirements for implantable medical devices.

Prior to joining Exponent, Dr. McNulty consulted individually and as an employee of DfR Solutions (2007–2009). He provided engineering services with respect to product and process development, reliability, and failure analysis for clients in the telecommunications, defense (submarine, terrestrial, and space), industrial controls, test and measurement, commercial laser, biomedical, and consumer electronics/opto-electronics industries, and provided training on these services both on-site and at professional seminars and conferences.

Dr. McNulty was also employed in product development and reliability management roles for telecommunication component suppliers as well as a commercial laser component and system supplier (2000–2007). Products included optical switches, MEMS-based components (attenuators, dynamic gain & channel equalizers, tunable lasers, tunable filters & receivers), packaged and unpackaged laser diodes, and diode-pumped laser systems. In these positions, he was responsible for hybrid packaging development and qualification of devices with respect to industry and commercial standards, as well as management of failure analysis, corrective action development, and warranty/recall issues. He was a committee member for the revision of Telcordia standard GR-468-CORE (active devices).

CREDENTIALS & PROFESSIONAL HONORS

  • Ph.D., Materials Engineering, University of California, Santa Barbara, 1997
  • B.S., Materials Science and Engineering, University of California, Berkeley, 1990
  • ASM International, Undergraduate Paper of the Year, 1990

LICENSES & CERTIFICATIONS

Licensed Professional Mechanical Engineer, Washington, #50600

Certified Reliability Engineer, American Society of Quality, #7547

Publications

Huang R, Sorini A, McNulty J. Quantitative solder inspection with computed tomography. 2014 IEEE Symposium on Product Compliance Engineering (ISPCE); May 2014; pp. 82–85.

He MY, Singh D, McNulty JC, Zok FW. Thermal expansion of unidirectional and cross-ply fibrous monoliths. Composites Science and Technology 2002; 62(7–8):967–976.

McNulty JC, He MY, Zok FW. Notch sensitivity of fatigue life in a Sylramic/SiC composite at elevated temperatures. Composites Science and Technology 2001; 61(9):1331–1338.

McNulty JC, Begley MR, Zok FW. In-plane fracture resistance of a crossply fibrous monolith. Journal of the American Ceramic Society 2001; 84(2):367–375.

Singh D, Cruse TA, Hermanson DJ, Goretta KC, Zok FW, McNulty JC. Mechanical response of cross-ply Si3N4/BN fibrous monoliths under uniaxial and biaxial loading. Ceramic Engineering and Science Proceedings 2000; 21(3):597–604.

McNulty JC, Zok FW, Genin GM, Evans AG. Notch-sensitivity of fiber-reinforced ceramic-matrix composites: effects of inelastic straining and volume-dependent strength. Journal of the American Ceramic Society 1999; 82(5):1217–1228.

McNulty JC, Zok FW. Low-cycle fatigue of Nicalon-fiber-reinforced ceramic composites. Composites Science and Technology 1999; 51(10):1597–1607.


McNulty JC, Zok FW. Application of weakest-link fracture statistics to fiber-reinforced ceramic-matrix composites. Journal of the American Ceramic Society 1997; 80(6):1535–1543.

Walls DR, McNulty JC, Zok FW. Multiple matrix cracking in a fiber-reinforced titanium matrix composite under high-cycle fatigue. Metallurgical and Materials Transactions A 1996; 27(7):1899–1908.

Heredia FE, McNulty JC, Zok FW, Evans AG. Oxidation embrittlement probe for ceramic-matrix composites. Journal of the American Ceramic Society 1995; 78(8):2097–2100.

Venkateswara Rao KT, McNulty JC, Ritchie RO. The effects of prolonged thermal exposure on the fracture and fatigue behavior of aluminum-lithium alloy 8090. Metallurgical Transactions A 1993; 24(10):2233–2239.
Book Chapters

Ramamurty U, McNulty JC, Steen M. Fatigue in ceramic matrix composites. In: Comprehensive Composite Materials, Elsevier Science 2000.

Conference Proceedings

McNulty JC, Knadle K, Klein HP, Harnisch T, Dona E, Meskens W, Op de Beeck M, Coder J. Assessment of reliability standards for implantable medical devices. International Conference on Electronic Packaging, Kyoto, Japan, 2015.

McNulty JC. Processing and reliability issues for eutectic AuSn solder joints. Proceedings, 41st International Symposium on Microelectronics (IMAPS 2008), Providence, RI, 2008.

McNulty JC. A perspective on the reliability of MEMS-based components for telecommunications. Proceedings, SPIE, Vol. 6884, 2008.

Schleuning D, Griffin M, James P, McNulty J, Mendoza D, Morales J, Nabors D, Peters M, Zhou H, Reed M. Robust hard-solder packaging of conduction cooled laser diode bars. Proceedings, SPIE, Vol. 6456, 2007.

Rosenberg P, Reichert P, Du J, Fouksman M, Zhou H, McNulty J, Tolman S, Luong C. Highly reliable hard-soldered 1.6 kW QCW laser diode stack packaging platform. Proceedings, SPIE, Vol. 6456, 2007.

Presentations

Sipe J, Mattison D, Long RT, and McNulty JC. Current state of rooftop solar. SFPE Conference, Philadelphia, PA, 2015.

Trenkle J, McNulty J, Zhao K, Brown E, and Huang R. The role of tin plating in arc-induced damage of power supplies. Materials Science & Technology Conference, Columbus, OH, 2015.

McNulty JC. Reliability standards and test methods for wearable devices. Sensors Global Summit, La Jolla, CA, 2015.

McNulty JC. Tutorial: Test methods and analytical techniques for wearable devices. International Society of Testing and Failure Analysis, Portland, OR, 2015.

McNulty JC. Medical electronics initiatives: status update. iNEMI-SMTA-MEPTEC Medical Electronics Conference, Portland, OR, 2015.

McNulty JC. Reliability standards and test methods for wearable medical devices. Medical MEMS and Sensors Conference, Santa Clara, CA, 2015.

McNulty JC. Reliability standards and test methods for wearable devices. Society of Plastics Engineers (SPE) Seminar, Menlo Park, CA, 2015.

McNulty JC, White K, Cooper M, Sheehan P. Product safety for wearables: avoiding product liability issues. Sports & Fitness Industry Association (SFIA) webinar, 2014.

McNulty JC. Reliability standards and test methods for wearable devices. Wearable Sensors & Electronics Conference, Santa Clara, CA, 2014.

McNulty JC, Coder J, Op de Beeck M, Knadle K, Klein HP. Reliability standards for implantable medical electronics. iNEMI-SMTA-MEPTEC Medical Electronics Conference, Portland, OR, 2014.

McNulty JC, White G, Bagheri S, Polito S, Coder J, Leimbeck M. Qualification methods for portable wearable electronics. iNEMI-SMTA-MEPTEC Medical Electronics Conference, Portland, OR, 2014.

McNulty JC, Coder J, Op de Beeck M, Knadle K, Klein HP. Implantable medical electronics – Phase 2 review. iNEMI Project Update Webinar, 2014.

McNulty JC. Failure analysis of electronics. Invited seminar at Coherent, Inc., Santa Clara, CA, 2014.

McNulty JC, Huang R. Failure analysis of electronic packaging. ASME Professional Development Seminar, Sunnyvale, CA, 2014.

McNulty JC. Medical electronics initiatives: Status update. iNEMI Board of Directors Meeting, Berkeley, CA, 2013.

McNulty JC. Assessment of reliability standards for implantable medical devices. AMI Medical Polymers Conference, Woburn, MA, 2013.

McNulty JC. Failure analysis of Pb-free electronics. Professional development course, IPC-JEDEC Conference, San Jose, CA, 2009.

McNulty JC. Processing and reliability issues for eutectic AuSn solder joints. IMAPS Conference, Providence, RI, 2008.

McNulty JC, Hillman CD. Current customer concerns regarding the reliability of solid state drives. IDEMA Reliability Symposium, San Jose, CA, 2008.

McNulty JC. A perspective on the reliability of MEMS-based components for telecommunications. SPIE-Photonics West Conference, San Jose, CA, 2008.

Prior Experience

Chair: Defining Reliability Requirements for Implantable Medical Electronics, iNEMI, July 2011–present

West Coast Office Manager and Senior Member of Technical Staff, DfR Solutions, LLC, 2007–2009

Sole Proprietor, J.C. McNulty Consulting, LLC, 2007–2008

Manager of Reliability, Semiconductor Business Unit, Coherent, Inc., 2005–2007

Director of Reliability, Iolon, Inc., 2001–2005

Product Development Engineer, Optical Switch Corporation, 2000–2001

Staff Research Engineer, Materials Department, UC Santa Barbara, 1997–2000

Associate Engineer, Baxter Healthcare Corporation, 1991–1992

Research Assistant, Lawrence Berkeley National Labs, 1989–1991 

Professional Affiliations

ASM (member)

ASME (member)

IEEE (member)

iNEMI (member)

SPIE (member)

CREDENTIALS & PROFESSIONAL HONORS

  • Ph.D., Materials Engineering, University of California, Santa Barbara, 1997
  • B.S., Materials Science and Engineering, University of California, Berkeley, 1990
  • ASM International, Undergraduate Paper of the Year, 1990

LICENSES & CERTIFICATIONS

Licensed Professional Mechanical Engineer, Washington, #50600

Certified Reliability Engineer, American Society of Quality, #7547