Academic Credentials
  • M.S., Mechanical Engineering, University of Missouri, Rolla, 2010
  • M.S., Metallurgical and Materials Engineering, University of Texas, El Paso, 2001
  • B.S., Metallurgical and Materials Engineering, University of Texas, El Paso, 1999
Licenses & Certifications
  • Professional Engineer, Texas, #98330

Mario R. Guerra, M.S., P.E., is a metallurgical and corrosion engineering expert with over 20 years of experience in failure analysis, corrosion evaluations, welding engneering and materials selection. He specializes in downhole integrity, HPHT (high-pressure, high-temperature) materials qualification, fracture mechanics, and sour service evaluations across the energy industry. Additionally, he has applied his metallurgical and corrosion engineering expertise to the aerospace and heavy manufacturing industries.

Throughout his career, Mr. Guerra has provided critical consulting and expert analysis for operators, equipment manufacturers, and law firms. His project experience spans deepwater Gulf of America HPHT completions, unconventional shale well casing integrity, and carbon capture (CCS/CCUS) materials challenges. He resolves complex integrity issues involving tubular failures, sulfide stress cracking (SSC), hydrogen stress cracking (HSC), and downhole corrosion.

Throughout his work, Mr. Guerra integrates metallurgical laboratory testing with computational and operational well design experience and fracture mechanics. He brings deep technical expertise in understanding how to integrate advanced material testing methodologies and environmental material degradation mechanisms into fitness for service critical assessments. His hands-on fitness for service laboratory capabilities includes the design of standard and customized mechanical testing.

Prior to consulting, Mr. Guerra held senior engineering roles at premier industrial firms. He was a Senior Facilities Engineer at Marathon Oil Company managing the materials and welding engineering QA group for deepwater subsea developments; a Senior Metallurgical & Welding Engineer at GE Oil & Gas (Vetco Gray) designing materials and welding specifications for land and subsea equipment applications; and a Materials, Processes & Physics Engineer at Boeing supporting NASA's International Space Station program.

An active contributor to the engineering community, Mr. Guerra has presented at ASM IMAT, SPE, and ShaleTech on casing failures and CCS materials challenges, and published peer-reviewed research on friction stir welding of aluminum alloys. Additionally, he is an experienced expert witness, having provided trial and deposition testimony on metallurgical failures, welding defects, and product liability disputes.