Dr. Gregory Smith is a Materials Scientist, licensed Professional Engineer (including New York, Connecticut, New Jersey, Massachusetts, and Maryland), and AMPP Certified Coatings Inspector (NACE CIP Level 2). Dr. Smith has a B.E. in Engineering Science, a B.S. in Marine Sciences, and a Ph.D. in Material Science and Engineering from Stony Brook University, State University of New York. Dr. Smith has experience in the analysis and forensic investigation of failures and other technical issues related to mechanical equipment, products, components, and systems. Dr. Smith’s experience has included a focus on both research and development and practical engineering-related failure analysis, statistical process control, process and design engineering, and mechanical/thermal testing. He has over 10 years of experience working with surface engineering and protective coatings for corrosive, marine, and other harsh environments and for general corrosion protection, involving paints, polymers, and cladding.

Dr. Smith has experience with and has inspected various aerospace-, sea-, and land-based power generation systems heavy machinery equipment, chemical processing equipment, boilers, furnaces, water heaters, HVAC systems and components, valves/actuators, heat exchangers, plumbing, piping, and fire suppression system failures (including valves, unions, fittings, couplings, sprinklers, piping and joints in copper, brass, steel, stainless steel, PEX, PVC/CPVC, and other materials), weld failures, metallurgical, and fire protection system failures. He combines both his background in materials science and mechanical engineering to provide an in-depth analysis of complex system and component failures.

Dr. Smith began working as a process engineer with a start-up firm developing characterization tools and sensors for process measurement of thermal spray deposition activities. This included advancing a DARPA-funded non-distributive evaluation (NDE) inspection program using flash infrared thermography (FIT) to identify and visualize defects below spray-coated Navy ship decks using a digital image correlation algorithm that he developed.

He extended his NDE coating inspection focus internationally at GKN Aerospace Engines Sweden, where he implemented an eddy current-based thickness probe for contact thickness measurement of complex geometry ceramic thermal barrier coating (TBC) layers applied to a range of FeCrAlY and NiCoCrAlY metallic bond coats and Fe, Ni, and Ti-based substrates. Additionally, Dr. Smith supported statistical process control and process engineering for commercial aerospace-, land-, and sea-based power generation gas turbines in the development of test reduction plans, to reduce QC/QA test burdens, and supported failure analysis on critical systems.

Dr. Smith’s materials graduate work focused on mechanical property characterization of thermal spray and cold spray coating systems. Externally facing, he heavily supported an Army Futures Command program developing temperature-resistant diesel piston coatings for improved power generation on track vehicles. Additionally, he supported process parameter development and mechanical testing for aerospace original equipment manufacturer (OEM) components, such as Al2O3 clearance coatings in turbine compressor sections and WC-CoCr and CrC-NiCr hard-chrome alternative materials in landing gear struts, where resistance to fatigue and impact-based damage was a primary concern.
As a Materials Research Engineer for the US Navy, Dr. Smith supported shipyards, warfare centers, regional maintenance centers, and Navy technical authorities on a wide range of corrosion-related mitigation and prevention efforts. He was recognized as an expert in surface preparation, non-skid materials, and research and development within NAVSEA 05P Coatings and Corrosion Control technical pyramid and directly supported updates to NAVSEA Standard Item 009-32 and 009-124 to improve technology transfer to shipboard and fleet operation. Dr. Smith worked with a range of polymeric and thermal spray coatings systems under MIL-PRF-32577, -23236, and -24667, and with a range of aluminum, stainless steel, CuNi, Inconel, and high-yield carbon steel material components. Additionally, he is certified as a NACE/SSPC Level 1 Coatings Inspector.

Dr. Smith is an active member of ASM’s Thermal Spray Society sub-committee and involved in the publication and peer-review of the Journal of Thermal Spray Research papers. He additionally mentors and supports graduate students at his alma mater and participates as a member of the Department of Materials Science and Engineering’s Industrial Advisory Board (IAB) as well as an active member of the Long Island, New York, ASM Professional Society Chapter.

Dr. Smith has testified in multiple depositions and arbitrations regarding the origin and cause of mechanical and materials failures.

• Engineering Science, B.S.: State University of New York, Stony Brook (2013)

• Marine Sciences, B.S.: State University of New York, Stony Brook (2013)

• Professional Engineer (P.E.): New York Engineering No. 107451; New Jersey Engineering No. 24GE05941200; Connecticut Engineering No. PEN.0036905, Maryland Engineering No. 62040, Massachusetts Engineering No. 58785

• Materials Science and Engineering, Ph.D.: State University of New York, Stony Brook (2018)

• PADI Advanced Open Water Diver

• Association for Materials Protection and Performance (AMPP) Basic Coatings Inspector / CIP Level 1 Certification (formerly NACE/SSPC) CIP Level 1: N-82104

• Liddell, H., Erickson, L., Tagert, J., Arcari, A., Smith, GM., Martin, J., “Mode Mixity and Fracture in Pull-off Adhesion Tests,” Eng. Fract. Mech., 281 (2023).

• Smith, GM., et al., “Discernment of Adhesion/Cohesion Character of Cold Spray and Thermal Spray Particle Bonding to Drive Improvement of Structural Integration of Corrosion Repair Coatings”, Navy Memorandum Report., 6130-20-10,210. (2021).

• Brown, RF., Smith, GM., Potter, J., Eden, TJ., “Ultrasonic Consolidation Post Treatment of Composite CuNi Cold Spray Coatings: A Mechanical and Microstructure Assessment”, J. Therm. Spray Technol., 30, 2069–2082. (2021).

• Gingrich, E., Tess, M., Korivi, V., Schihl, P., Saputo, J., Smith, GM., Sampath, S., Ghandhi, J., “The Impact of Piston Thermal Barrier Coating Roughness on High Load Diesel Operation”, Int. J. Engine Res., 3, 890–910. (2021).

• Weathers, B., Smith, GM., Miller, C., Zuk, D. “Test Method for Constrained Compressive Properties of Rubber and Rigid Cellular Plastics”, Technical test method assessment, NAVSEA PMS 450. (2020).

• Brown, RF., Smith, GM., Potter, J., Eden, TJ., “Parameter Development via In-Situ Residual Stress Measurement and Post-deposition Analysis of Cold Spray CuNi Coatings”, J. Therm. Spray Technol., 29, 1876–1891. (2020).

• Saputo, JC., Smith, GM., Lee, H., Sampath, S., Gingrich, E., Tess, M., “Thermal Swing Evaluation of Thermal Barrier Coatings for Diesel Engines”, J. Therm. Spray Technol., 29, 1943–1957. (2020).

• Liddell, H., Smith, GM., Erickson, L., “Extraction of Mode Mixity and Other Fracture Data from Crack Paths in Pull-Off Adhesion Tests”, 43rd An. Meet Adh. Soc., (2020).

• Smith, GM., et al., “Observation of Residual Stress and Fatigue Behavior of SI-TS Nickel Coatings”, J. Therm. Spray Technol., Spec. Issue on Res. Stress., 29, 1229–1241. (2020).

• Abbas, M., Smith, GM., Munroe, P., “Microstructural investigation of bonding and melting-induced rebound of HVOF sprayed Ni particles on an aluminum substrate”, J Surf. Coat. Technol., 402, 126353 (2020).

• Abbas, M., Smith, GM., Munroe, P., “Microstructural characterization of HVOF-sprayed Ni on polished and oxidized stainless steel substrates”, J. Therm. Spray Technol., 29, 1093-1110. (2020).

• Abbas, M., Smith, GM., Munroe, P., “Microstructural Evolution and Bonding of HVOF Sprayed Ni Particles on Both Mild and Stainless-Steel Substrates”, Surf. Coat. Technol., 394, 125909 (2020).

• Smith, GM., et al., “On the System and Surface Performance of Thermally Sprayed Carbide Coatings Produced Under Controlled Residual Stresses”, Surf. Coat. Technol. 387, 12536 (2020).

• Smith, GM., Smith, A., Sampath, S. “Fracture Toughness of Thermal Spray Ceramics: Measurement Techniques and Processing Dependence”, J. Therm. Spray Technol. 27, 1076–1089 (2018).

• Luo, X., Smith, GM., Sampath, S. “On the Interplay Between Adhesion Strength and Tensile Properties…Part I and Part II”, J. Therm. Spray Technol. 27, 296 –318 (2018).

• Smith, GM., et al., “Orientation Dependent Thermal and Mechanical Properties of Plasma Sprayed Ceramics”, J. Am. Cer. Soc., 101 (2018).

• Smith, GM. and Sampath, S., “Sustainability of Metal Structures Via Spray Clad Remanufacturing”, TMS JOM., 70, 512–520 (2018).

• Smith, GM., Higgins, O., Sampath, S. “In-Situ Observation of Strain and Cracking in Coated Laminates by Digital Image Correlation”, Surf. Coat. Technol. 328 (2017).

• Wang, Q., Seshadri, R.C., Smith, GM., Sampath, S., “Sliding Wear Behavior of Air Plasma Sprayed Al2O3 Coatings Sealed with Aluminum Phosphate”, Tribol. Int. 116 (2017).

• Smith, GM., et al., “Eddy Current Measurement Technique for Bi-Layer Thermal Barrier Systems”, ITSC 2015—Proc. Int. Therm. Spray Soc. (2015).