David Wills
David P. Wills, P.E., CFEI, CVFI
Senior Managing Engineer
Materials & Corrosion Engineering
  • Miami

Mr. Wills addresses issues related to failure and nonperformance analysis of engineered materials including metals, ceramics, polymers, and composites. He has metallurgical and materials engineering experience, which includes corrosion analysis. Mr. Wills performs fracture analysis of materials using microscopy, metallography, scanning electron microscopy, and photography techniques. Other areas of expertise include fabrication and machining methods, tube and heat exchanger fabrication, and prototype development. Mr. Wills has experience with welding and cutting methods and performs weld inspections.

He analyzes surface coating applications and properties. He conducts fire investigations. He also has particular experience with aluminum process metallurgy; aluminum ingot casting technology and machinery, and aluminum extrusion machinery, tooling, dies, and materials. In the area of accident investigation, Mr. Wills addresses industrial and marine equipment failures, slip and fall issues, boating, and marine accidents. Mr. Wills is trained in underwater inspection and photography.

CREDENTIALS & PROFESSIONAL HONORS

  • M.B.A., Business Administration, Nova University, 1985
  • B.S., Metallurgical Engineering, University of Missouri, Rolla, 1977

LICENSES & CERTIFICATIONS

U.S. Coast Guard Captain’s License, 50 Gross Tons, 1985

Licensed Professional Engineer, Florida, #41264, 1988

American Welding Society Certified Welding Inspector (CWI), 1994

NACE Protective Coatings and Linings, 1994

American Boat & Yacht Council (ABYC) (Marine) Accident Investigation, 1998

American Boat & Yacht Council (ABYC) Metal Corrosion in Boats, 1999

National Association of Fire Investigators Certified Fire and Explosion Investigator (CFEI), 2002

National Association of Fire Investigators Certified Vehicle Fire Investigator (CVFI), 2009

Certified English XL Tribometrist (CXLT), 2002, 2008, 2013

American Boat & Yacht Council (ABYC) Technical Certification-Diesel Engines, 2013

American Boat & Yacht Council (ABYC) Technical Certification-Diesel Engines, 2014

American Boat & Yacht Council (ABYC) Technical Certification-Marine Electrical, 2015

American Boat & Yacht Council (ABYC) Master Technician Certification, 2015

Publications

Hoffman JM, Reitman M, Donthu S, Ledwith P, Wills D. Microscopic characterization of CPVC failure modes. Proceedings, ANTEC 2009, Society of Plastics Engineers, Chicago, IL, June 2009. Best Paper Award in Failure Analysis & Prevention.

Select Reports

Wills DP, et al. Cause of outboard separation from transom…Fastener issues identified. Exponent, Failure Analysis Associates, Inc., Report, January 2014.

Wills DP, et al. Sinking of Zorro due to over-speed marine diesel. Exponent, Failure Analysis Associates, Inc., Report, January 2011.

Wills DP, et al. Airport acid wash damage to stainless steel terminal façade. Exponent, Failure Analysis Associates, Inc., Report, January 2009.

Wills DP, et al. Sodium hypochlorite generator failure, Exponent Failure Analysis Associates, Inc., Report, May 2008.

Wills DP. Investigation of a jacketed stainless steel pipe failure at Wellman, Inc. Exponent Failure Analysis Associates, Inc., Report, March 2007.

Wills DP. Investigation of a failed CPVC fire sprinkler pipe at the Cipraini Condo. Exponent Failure Analysis Associates, Inc., Report, January 2007.

Wills DP. Aqua Novia Piping Failure. Exponent Failure Analysis Associates, Inc., Report, May 2006.

Wills DP. Sacajawea-Fort Lauderdale shipyard incident of November 18, 2004. Exponent Failure Analysis Associates, Inc., Report, December 2005.

Wills DP. Investigation of pitting corrosion in new stainless steel distillery pipeline. Exponent Failure Analysis Associates, Inc., Report, October 2004.

Wills DP. Investigation of corrosion on the Research Vessel Walton Smith; condition assessment and remedial recommendations. Exponent Failure Analysis Associates, Inc., Report, December 2003.

Wills DP. Investigation of the failure of several PVC water mains. Exponent Failure Analysis Associates, Inc., Report, November 2002.

Wills DP. Design, operation and safety review of four Glatt GPCG-200, 2-bar fluid bed processors at Andrx Pharmaceuticals Incorporated. Exponent Failure Analysis Associates, Inc., Report, October 2001, with L.A. Swanger.

Wills DP. Swing gear failure on a Kobelco track excavator. Exponent Failure Analysis Associates, Inc., Report, August 2001.

Wills DP. Investigation of the condition of aging transit buses. Exponent Failure Analysis Associates, Inc., Report, May 2000.

Wills DP. Engine room fire aboard the Starbrite. Exponent Failure Analysis Associates, Inc., Report, May 2000.

Wills DP. Hat Trick vessel runaway incident at Roscioli Yachting Center on November 15, 1998. Exponent Failure Analysis Associates, Inc., Report, July 1999.

Wills DP. Airboat Propeller Failure. Failure Analysis Associates, Inc., Report, June 1998.

Wills DP. Investigation of cracking in a spiractor water treatment cone. Failure Analysis Associates, Inc., Report, September 1997.

Wills DP. Investigation of fractures in G.E. mixing valves. Failure Analysis Associates, Inc., Report, March 1997.

Wills DP. Corrosion of starboard oil/water separator on the Florida Responder. Failure Analysis Associates, Inc., Report, October 1995.

Wills DP. Hull corrosion damage on the MV Gulf Coast Responder. Failure Analysis Associates, Inc., Report, January 1994.

Wills DP. Multi-layer chemical vapor deposition coating for extrusion die mandrels. Report 84-TB-04, Atlantic Richfield Metals Co. Research and Development, March 1984.

Prior Experience

Plant Manager, Continuous Extruded Products, Inc. (Kaiser Aluminum), 1985–1988

Senior Research Metallurgist-Extrusions, ARCO R&D, 1982–1984

Ingot Process Engineer, Anaconda Aluminum, Sebree Reduction Facility, 1978–1980

Professional Affiliations

American Society for Materials (member and past chapter chairperson)

American Welding Society (member and past chapter chairperson)

The American Boat and Yacht Council (member)

American Society for Testing & Materials (member)

CREDENTIALS & PROFESSIONAL HONORS

  • M.B.A., Business Administration, Nova University, 1985
  • B.S., Metallurgical Engineering, University of Missouri, Rolla, 1977

LICENSES & CERTIFICATIONS

U.S. Coast Guard Captain’s License, 50 Gross Tons, 1985

Licensed Professional Engineer, Florida, #41264, 1988

American Welding Society Certified Welding Inspector (CWI), 1994

NACE Protective Coatings and Linings, 1994

American Boat & Yacht Council (ABYC) (Marine) Accident Investigation, 1998

American Boat & Yacht Council (ABYC) Metal Corrosion in Boats, 1999

National Association of Fire Investigators Certified Fire and Explosion Investigator (CFEI), 2002

National Association of Fire Investigators Certified Vehicle Fire Investigator (CVFI), 2009

Certified English XL Tribometrist (CXLT), 2002, 2008, 2013

American Boat & Yacht Council (ABYC) Technical Certification-Diesel Engines, 2013

American Boat & Yacht Council (ABYC) Technical Certification-Diesel Engines, 2014

American Boat & Yacht Council (ABYC) Technical Certification-Marine Electrical, 2015

American Boat & Yacht Council (ABYC) Master Technician Certification, 2015