Academic Credentials
  • Ph.D., Metallurgical and Materials Engineering, Michigan Technological University, 1998
  • M.S., Metallurgical Engineering, Michigan Technological University, 1995
  • B.S., Metallurgical Engineering, Michigan Technological University, 1993
Licenses & Certifications
  • Professional Engineer, Maryland, #38382
Academic Appointments
  • Research Affiliate, Mechanical Engineering, Massachusetts Institute of Technology
Professional Honors
  • Iron and Steel Society's Young Leaders Award, 1997-1998
  • DeVleig Academic Fellowship, 1997
  • Department of Defense Research Fellow, 1994-1997
  • Forging Industry Education and Research Foundation's Forging Achievement Award, 1992
Professional Affiliations
  • Materials Research Society, 2001-present
  • Electrochemical Society, 1999-present
  • Tau Beta Pi, 1992-present
  • Alpha Sigma Mu, 1991-present
  • ASM/TMS, 1991-present

Dr. Horn consults in the areas of metallurgy and electrochemistry and frequently addresses issues related to corrosion analysis, battery manufacturing, and battery science. In the field of metallurgy, he consults on topics related to failure analysis, corrosion, material degradation, and material selection. 

In the field of battery technology, Dr. Horn's work addresses a broad range of issues including material selection and testing, cell design, cell manufacturing, performance degradation, accelerated life testing, and due diligence technology evaluation. He has extensive experience developing characterization techniques for understanding discharge reactions and degradation mechanisms in a wide range of battery systems including lithium-ion, lithium-primary, nickel-metal hydride, nickel cadmium, lead-acid, and alkaline primary cells.

Prior to joining Exponent, Dr. Horn held positions as a Principal Scientist at Physical Sciences Inc. (PSI), and as a Staff Technology Engineer at Energizer/Eveready Battery Company. At PSI, Dr. Horn designed, developed, and tested high-energy and high-power electrodes for lithium-ion batteries. At Energizer, Dr. Horn was responsible for the Microscopy and Materials Group, where he conducted failure analysis studies to solve problems related to battery failures and battery manufacturing issues.

Dr. Horn is a Research Affiliate at the Massachusetts Institute of Technology, where he collaborates with researchers in the Electrochemical Energy Laboratory on projects related to electric vehicles and new gas diffusion electrodes for metal-air batteries and fuel cells.