THOMAS B. MILLS
Dr. Mills has over 15 years of experience developing advanced structural integrity methods, with particular emphasis on structural effects of corrosion/fatigue and the interaction of residual stress fields with fatigue. He is an expert failure analyst (including scanning electron and optical microscopy) and has two decades of experience deciphering failures of laboratory and in-service components. Dr. Mills also has extensive hands-on experience with material testing systems as well as mechanical testing and corrosion standards.
Present Position & Responsibilities
2002 Analytical Processes / Engineered Solutions (APES), Inc., St. Louis, MO
· Consulting Engineer: Integrate and implement analytical engineering tools. Develop new structural models for corrosion for implementation into fracture-mechanics-based philosophies. Conduct detailed fractographic analyses and crack-history construction of failed components using optical and scanning electron microscopy. Design experimental programs to test and validate new hypotheses about behaviors of material and structural systems.
2000-2002 Principal Engineer for Structural Corrosion, Aerostructures Technologies, P/L, Melbourne, Victoria, Australia
· Research Engineer: Designed and executed numerous research programs to include corrosion damage into traditional damage tolerance assessment for aircraft. Work focused on exfoliation and pitting in aluminum alloys and pitting in high-strength steels, particularly for the RAAF’s Sole Operator Program for the F-111 strike aircraft. Developed artificial corrosion protocols for pitting in high-strength steel. Incorporated pitting damage into full-scale fatigue tests of F-111 wing structure. Conducted extensive failure analysis for laboratory and in-service aircraft components.
1997-2000 Air Force Research Laboratory, Wright-Patterson AFB, OH
· Research Engineer: Designed and executed numerous research programs to determine effects of corrosion on aircraft structure. Served as technical expert on several high-profile USAF programs. Conducted research into bonded-composite repair of metallic structures. Installed several bonded composite repairs on cracked wings of USAF aircraft as part of bonded-repair technology demonstration. Coordinated several international-level research activities and participated in six-month scientist exchange with Australian Defence Science and Technology Organisation in 1999.
1992-1997 University of Utah
· Graduate Research Assistant: Gained familiarity with ASTM testing standards and use of closed-loop, servo-hydraulic material testing equipment. Conducted thesis research into effects of exfoliation corrosion on fatigue in aluminum. Conducted research into the involvement of corrosion and fretting fatigue on aircraft accidents and incidents. Taught undergraduate-level material test laboratory classes. Selected to participate two summers (1995 and 1996) in the AFOSR Graduate Student Summer Research Program at Wright-Patterson AFB, OH during which guided and executed corrosion/fatigue research programs for the USAF.
University of Utah
Doctor of Philosophy, Mechanical Engineering January 1997
· Thesis: “The Combined Effects of Prior-Corrosion and Aggressive Chemical Environments on Fatigue Crack Growth Behavior in Aluminum Alloy 7075-T651”
Master of Science, Mechanical Engineering June 1995
· Thesis: The Effects of Exfoliation Corrosion on the Fatigue Response of 7075-T651 Aluminum Plate”
· Coursework in graduate school emphasized corrosion effects on structure, fatigue and damage tolerance, and metallurgy.
University of Missouri—Kansas City
Bachelor of Science. Mechanical Engineering December 1991
1. S. Prost-Domasky, C. L. Brooks, T. B. Mills, and K.T. Honeycutt. Incorporating Laser Peening Residual Stress into a Holistic Life Assessment Approach. Presented at the Eleventh International ASTM/ESIS Symposium on Fatigue and Fracture Mechanics, Anaheim, California, May, 2011.
2. Scott Prost-Domasky, Thomas Mills, Kyle Honeycutt, and Craig L Brooks. “Incorporating Laser Peening Residual Stress into a Holistic Life Assessment Approach” Presented at the USAF Aircraft Structural Integrity Program Conference (ASIP 2010), San Antonio, Texas, December, 2010.
3. T. Mills, S. Prost-Domasky, K. Honeycutt, and C. Brooks. Corrosion and the threat to aircraft structural integrity. In Corrosion Control in the Aerospace Industry, Woodhead Publishing, 2009
4. Thomas Mills. Structural Health Monitoring for Corrosion. Presented at 2009 Aging Aircraft Conference, Kansas City, Missouri, April 2009.
5. D. Forsyth, Thomas Mills, and Rock Rushing. Development and Use of Standard Environmental Exposure Spectra for Validation of Health Monitoring. Presented at the 2008 USAF Aircraft Structural Integrity Program Conference (ASIP 2008), San Antonio, Texas, December 2008.
6. Thomas B. Mills, Kyle T. Honeycutt, Scott A. Prost-Domasky, and Craig L. Brooks. Corrosion modeling and life prediction supporting structural prognostic health management. Presented at 2007 International Committee of Aeronautical Fatigue (ICAF 2007) Symposium, Naples, Italy, May 2007.
7. C.L. Brooks, S.A. Prost-Domasky, K.T. Honeycutt, T.B. Mills, and N. Young. Fretting fatigue model. AFRL-VA-WP-TR-2006-3080, Final Report for 01 May 2003 – 30 April 2006, SBIR Phase II Report, May 2006.
8. Thomas Mills and Craig L. Brooks. Surface integrity effects on aircraft durability application for legacy systems such as the C-130. Presented at the Canadian Aeronautics and Space Institute 52nd AGM and Conference, Toronto, Canada, 2005.
9. Thomas B. Mills, Kyle T. Honeycutt, Craig L. Brooks, P. Khan Sharp, Chris Loader, and Bruce Crawford. Development and Demonstration of an Holistic Structural Integrity Process using the Initial Discontinuity State Concept for 7050-T7451 Aluminum. Presented at the 2004 USAF Aircraft Structural Integrity Program Conference (ASIP 2004), Memphis, TN December 2004.
10. Craig L. Brooks, Scott A. Prost-Domasky, Kyle T. Honeycutt, and Thomas B. Mills. Predictive modeling of structure service life. In ASM Handbook Volume 13A, Corrosion: Fundamental, Testing and Protection, October 2003, pp. 946-958.
11. Kyle T. Honeycutt, Craig L. Brooks, Scott A. Prost-Domasky, and Thomas B. Mills. Holistic life assessment methods” Presented at the Canadian Aeronautics and Space Institute 50th AGM and Conference, 16th Aerospace Structures and Materials Symposium, Montreal, Canada, April 2003.
12. C.L. Brooks, S.A. Prost-Domasky, K.T. Honeycutt, T.B. Mills, and N. Young. Fretting fatigue model. AFRL-VA-WP-TR-2003-3012, Final Report for 01 February 2002 – 30 November 2002, SBIR Phase I Report, February 2003. 55 pages.
14. T. Mills, K. Honeycutt, C. Brooks, I. Hammad, and D. Peeler. Managing damage in the wing: modeling the interaction of exfoliation with static and fatigue loads. Presented at the Sixth Joint FAA/DoD/NASA Conference on Aging Aircraft, San Francisco, California, September 2002.
15. T. Mills, P. K. Sharp, C. Loader, “The Incorporation of Pitting Corrosion Damage into F-111 Fatigue Life Modeling,” DSTO-RR-0237, DSTO/AMRL, June 2002.
16. P. K. Sharp, T. Mills, and G. Clark, “Modeling of Fatigue Crack Growth from Pitting and Exfoliation Corrosion”, Proceedings of the 20th Symposium of the International Committee on Aeronautical Fatigue, Toulouse, France, 2001.
17. P. K. Sharp, T. Mills, and G. Clark, “Aircraft Structural Integrity: The Impact of Corrosion,” ICF 10, Hawaii, 2001.
18. S. G. Russo, P. K. Sharp, R. Dhamari, T. Mills, B. R. W. Hinton, K. Shankar, and G. Clark, “Effect of the Environment and Corrosion on the Fatigue Life of a Simulated Aircraft Structural Joint,” IMPLAST 2000.
19. P. K. Sharp, T. Mills, S. Russo, G. Clark, L. Qianchu, “Effects of Exfoliation Corrosion on the Fatigue Life of Two High-Strength Aluminum Alloys,” 4th Joint DoD/FAA/NASA Conference on Aging Aircraft, St Louis, May 2000.
20. J. D. Baldwin, T. Mills, and C. A. Paul, “Statistical Analysis of Fatigue Behavior of Aluminum Alloys in the Presence of Prior Corrosion,” Fatigue in New and Aging Aircraft, R Cook, P Poole (eds.), Proceedings of the 19th Symposium of the International Committee on Aeronautical Fatigue, Edinburgh, Scotland, 18-20 June 1997.
21. D. W. Hoeppner, L. Grimes, A. Hoeppner, J. Ledesma, T. Mills, and A. Shah, “Corrosion and Fretting as Critical Aviation Safety Issues: Case Studies, Facts, and Figures from U.S. Aircraft Accidents and Incidents,” Proceedings of the 18th Symposium of the International Committee on Aeronautical Fatigue, Melbourne, Australia, 1-5 May 1995.