Michael L. Santella
Development Staff Member
Materials Joining Group
Materials Science & Technology Division
Oak Ridge National Laboratory
P.O. Box 2008
Oak Ridge, TN 37831-6096
Phone: (865) 574-4805
Fax: (865) 574-4928
e-mail: santellaml@ornl.gov

 

 

 

 

 


Research Interests:

Dr. Santella has a broad expertise in materials joining, and he is widely recognized for his research and developments related to welding of intermetallic alloys and to brazing of ceramics. Mike's background is also somewhat unique in that early in his career he actually worked as a welder. His work on welding encompasses alloy development for welding filler metal alloys, the relationships of alloy properties to weld cracking phenomena, simulation of thermal stress distributions during welding, dissimilar metal welding, phase transformations in steels during welding and heat treating, weld microstructure characterization, and weldment properties and their relationship to welding process parameters. His brazing and soldering work has emphasized wetting phenomena, residual stress issues in ceramic-to-metal joints, microstructure development at bonded interfaces, and mechanical properties.

Education:

  • 1981 PhD., Metallurgical Engineering, University of Pittsburgh
  • 1979 M.S., Metallurgical Engineering, University of Pittsburgh
  • 1972 B.S., Industrial Engineering, Pennsylvania State University

Professional Experience:

  • 1983 - Present, Development Staff Member, Oak Ridge National Laboratory
  • 1982 - 1983, Staff Member, Olin Corporation, Metals Research Laboratory
  • 1981 - 1982, Research Faculty, University of Pittsburgh
  • 1974- 1976, Welding Engineer, Pittsburgh Des Moines Steel Company
  • 1973 - 1974, Welding Engineer, Chicago Bridge & Iron Company

Honors & Professional Activities:

  • ASM International
  • American Welding Society
  • 1989 Charles H. Jennings Award for a technical publication
  • Member of C3 Committee on Brazing and Soldering
  • Peer Review Panel for Weld~ng Journal
  • 1995-1996 Northeast Tennessee Section Chairman
  • Adjunct Facilty of the University of Tennessee
  • Science and Technology of Joining
  • Editorial Board
  • The Minerals, Metals & Materials Society (TMS)
  • 1993- 1997 Accreditation Board for Engineering and Technology Evaluator
  • 1995 Organizer for Joining of Refractory Metals and Materials Symposium
  • 1999 Nikon International Small World Competition Honorable Mention

Patents:

  • "Method for Producing a Metal Alloy Strip," by M. J. Pryor and M. L. Santella, U. S. Patent No. 4,648,437.
  • "Method for Producing a Metal Alloy Strip," by M. J. Pryor and M. L. Santella, U. S. Patent No. 4,663,242.
  • "Iron-Nickel Alloys having Improved Glass Sealing Properties," by E. Shapiro and M. L. Santella, U. S. Patent No. 4,711,826.
  • "Nickel Aluminide Alloys with Improved Weldability," by M. L. Santella and G. M. Goodwin, U.S. Patent No. 5,413,876.
  • "Intermetallic Alloy Welding Wires and Method for Fabricating the Same," by M. L. Santella and V. K. Sikka, U. S. Patent No. 5.525,779.
  • "Filler Metal Alloy for Welding of Cast Nickel Aluminide Alloys," by M. L. Santella and V. K. Sikka, U.S. Patent No. 5,725,693.
  • "Weldable Nickel Aluminide Alloy," by M. L. Santella and V. K. Sikka, patent application filed, l999.
  • "Method of Aluminizing Metal Alloys by Weld Overlay using Aluminum and Aluminum Alloy Wire," by M. L. Santella, V. K. Sikka, and S. Viswanathan, patent application filed, 1999.
  • "Ductile Filler Metal Alloys for Welding Nickel Aluminide Alloys," by M. L. Santella, J. D. McNabb, and V. K. Sikka, patent application filed, 1999.
  • "Iron-Chromium-Silicon Alloys for High-Temperature Oxidation Resistance," V. K. Sikka, J. D. Vought, C. R. Howell, and M. L. Santella, patent application filed, 1999.
  • "Improving the surface properties of aluminum alloys by weld overlay cladding," M. L. Santella, C. A. Blue, J. D. McNabb, and V. K. Sikka, invention disclosure filed, 2000.

Selected Publications:

  • "Thermodynamics of Ti in Ag-Cu Alloys," J. J. Pak, M. L. Santella, and R. J. Fruehan, Metallurgical Transactions B, vol. 21B, 1990, pp. 349-355.
  • "Microstructure of Alumina Brazed with a Silver-Copper-Titanium Alloy," M. L. Santella, J. A. Horton, and J. J. Pak, Journal of the American Ceramic Society, vol. 73, 1990, pp. 1785-1787.
  • "Fundamental Metallurgical Considerations in Brazing and Soldering," Michael Santella, published in The Metal Science of Joining, The Metallurgical Society, Warrendale, Pennsylvania, 1992, pp. 61-65.
  • "Factors in Sub-Solidus Heat-Affected Zone Cracking," M. C. Maguire, M. L. Santella, and B. K. Damkroger, published in The Metal Science of Joining, The Metallurgical Society, Warrendale, Pennsylvania, 1992, pp. 41-48.
  • "A Review of Techniques for Joining Advanced Ceramics," M. L. Santella, Ceramcc Bulletin, vol. 71(6), l992, pp. 947-954.
  • "Weld Solidification Cracking in Cast M3AI Alloys," M. L. Santella, Scripta Met. et Mat., 28 ( 11), pp. 1305-1310 (1993)
  • "Brazing of Titanium-Vapor-Coated Zirconia," M. L. Santella and J. J. Pak, Welding Journal, 72 (4), pp. 165-s-172-s (I993).
  • "Flexure Strength of Ti-Vapor-Coated Silicon Nitride Braze Joints," M. L. Santella, published in DE-Vol. 79, Reliab~lity, Stress Analysis, and Failure Prevention Aspects of Composite and Active Materials, American Society of Mechanical Engineers, 1994, pp. 43-54.
  • "Analysis of Weld Solidification Cracking in Cast Nickel Aluminide Alloys, M. L. Santella and Z. Feng, published in Trend;s in Welding Research, Proceedings of the 4th International Conference, ASM Intemational, 1996, pp. 609-614.
  • "An Overview of the Welding of Ni3AI and Fe3AI Alloys," M. L. Santella, published in International Symposium on Nickel and Iron Aluminides. Processing, Properties, and Applications, ASM International, 1997, pp. 321-328.
  • "Processing, Properties, and Applications of Ni3AI-based Alloys," V. K. Sikka, M. L. Santella, and C. T. Liu, published in Recent Advances in Metallurgical Processes, Volume 1, New Age International Ltd., New Delhi, 1997, pp. 607-618.
  • "Wetting of Iron Aluminide Alloys by Ag, Au, and Cu," M. L. Santella and A. B. Patterson, Materials Science & Engineering, vol. A258, 1998, pp. 270-275.
  • "Influence of microstructure on the properties of resistance-spot welds," M. L. Santella, S. S. Babu, B. W. Riemer, and Z. Feng, pp. 605-609, Proceedings of the 5th International Conference on Trends in Welding Research, ASM International, Materials Park, OH, 1999.
  • "An Empirical Model of the Effects of Pressure and Temperature on the Electrical Contact Resistance of Metals," S. S. Babu, M. L. Santella, Z. Feng, and B. W. Riemer, accepted for publication in Science and Technology of Welding and Joining, 2000.

Recent Presentations:

  • ''Analysis of Weld Solidification Cracking in Cast Nickel Aluminide Alloys, M. L. Santella and Z. Feng, 4th International Conference on Trends in Welding Research, Gatlinburg, TN, June 7, 1995.
  • "The Importance of Interfaces in the Brazing Process," M. L. Santella, 117th Meeting of the Japanese Institute of Metals, Honolulu, Hawaii, December 14, 1995.
  • "Analysis of Weld Solidification Cracking in Cast Nickel Aluminide Alloys," M. L. Santella and Z. Feng, 117th Meeting of the Japanese Institute of Metals, Honolulu, Hawaii, December 15, 1995.
  • "Designing Ceramic-to-Metal Braze Joints for Engine Applications," M. L. Santella and B. W. Riemer, 27th AWS Brazing and Soldering Conference, Chicago, April 24, 1996.
  • "Welding and Weld Overlays of Nickel and Iron Aluminides," M. L. Santella, ASM-TMS Materials Week, Cincinnati, OH, October 8, 1996.
  • "Wetting Behavior of Iron Aluminides," M. L. Santella and A. B. Patterson, TMS Annual Meeting, San Antonio, TX, February 18, 1998.
  • "Mechanical Properties of a Nickel Aluminide Weldment," M. L. Santella, R. W. Swindeman, and R. J. Barkman, 5th International Conference on Trends in Welding Research, Pine Mountain, GA, June 4, 1998.
  • "Microstructure Development in Resistance Spot Welds," M. L. Santella, S. S. Babu, Z. Feng, and B. W. Riemer, 5th International Conference on Trends in Welding Research, Pine Mountain, GA, June 5, 1998.
  • "Development of M3AI Alloys with Emphasis on Welding," M. L. Santella, V. K. Sikka, and J. D. McNabb, University of Tennessee Graduate Seminar, Knoxville, TN, October 12, 1999.
  • "Mechanical Behavior Evaluation of Nickel Aluminide Weldments," M. L. Santella, V. K. Sikka, R. W. Swindeman, and R. J. Barkman, AWS Annual Meeting, Chicago, IL, April 26, 2000.
  • "An Evaluation of Automated Ball Indentation for Measuring the Tensile Properties of Solder Alloys," M. L. Santella, T.-Y. Pan, F. W. Gayle, and F. Haggag, 129th TMS Annual Meeting, Nashville, TN, March 15, 2000.

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