THEODOROS KOUTSOUKIS

theodoroskoutsoukis@gmail.com, info@metalsconsulting.com, +1 (774) 329-0353

Metallurgical Engineer, Ph.D.

SUMMARY

Metallurgical Engineer with expertise in physical metallurgy and materials science. Broadly based theoretical and hands-on experience in materials characterization and properties, alloy and process development, electron microscopy and micro-analysis. In-depth knowledge in a variety of alloy systems, metallurgical processes, and additive manufacturing. Proven ability to lead, manage and deliver projects within strict time deadlines and budget constraints, without sacrificing quality and creativity. A mature personality, with flexibility to adapt to challenging engineering environments, able to handle challenging client relationships and develop junior staff.

PROFESSIONAL EXPERIENCE

Metallurgical Engineer, IPG Photonics, Oxford, MA, USA.                                                                                                                                       Dec 2016 – present

 Consultant, IPG Photonics, Oxford, MA, USA.                                                                                                                                                         Aug 2015 – Dec 2016

Independent Editor for Scientific Manuscripts                                                                                                                                                       Oct 2015 – present

  • Editing, proofreading and consulting for technical scientific manuscripts, focus on engineering fields, that aim to be published in international scientific journals.

KEY roles:

  • Edit scientific manuscripts in order to be prepared for publication
  • Revise/consult on manuscripts that needed revision

KEY results:

  • Has offered his editing and consultation services to over 200 clients. Most clients are returning clients.

Research Scientist, Worcester Polytechnic Institute, Worcester, MA, USA.                                                                                                        Aug 2013 – Aug 2015

  • Specialized in casting of aluminum alloys (Mechanical Engineering, Metals Processing Institute, Advanced Casting Research Center Team). Hired to assist in an ongoing R&D project, focusing on alternative solutions for the Al-Si eutectic system, widely used in the industry, with significant results. Worked with all levels of management and client teams to drive collaboration and forward momentum toward the completion of project milestones and the attainment of client goals.

KEY results:

  • Identified the limitations of the Al-Si eutectic system and suggested the alternative Al-Ni, Al-Fe and Al-Fe-Ni eutectic systems as viable solutions for higher strength aluminum alloys
  • Played a significant role in achieving the modification of the microstructures of the Al-Ni, Al-Fe and Al-Fe-Ni eutectic systems
  • Relied on as one of the Institute’s primary assistants on various projects of post graduate students and lab management
  • 3 Conference Presentations

Assistant Professor, King Saud University, Riyadh, KSA.                                                                                                                                        Sep 2012 – Aug 2013

  • Hired as the principal researcher of the Dental Biomaterials Research and Development Chair (School of Dentistry). Worked on the R&D of dental biomaterials, focusing on Co-Cr dental alloys, also including casting techniques (lost wax method), additive manufacturing (SLS), CAD-CAM, scientific manuscripts and reports preparation and revision, INSTRON training and verification (Electropuls E3000 and INSTRON 5965).

KEY results:

  • Played an instrumental role in maintaining the collaboration between KSU and University of Athens
  • Contributed significantly in increasing the ranking of the Department within the University
  • Provided practical solutions for dental restoration failures, improving cost and properties of materials
  • Identified knowledge gaps in designing and manufacturing of dental alloys and proposed solutions
  • Contributed as a reviewer in dental scientific journals and reports
  • 4 Publications in International Journals

Research Associate, University of Athens, Athens, Greece                                                                                                                                    Apr 2011 – Sep 2012

  • Worked as a researcher (Department of Biomaterials, School of Dentistry) in various projects with dental alloys, including characterization of cast dental alloys (Ti-based, Co-Cr, Ni-Cr, etc.), casting (lost wax method), microscopy (SEM, EDS, XRD), Laser Beam Welding (Nd:YAG Laser) and failure analysis projects.

KEY results:

  • Provided practical solutions for dental restoration failures, reducing cost and improving properties of materials
  • Relied on as a consultant in various projects on dental biomaterials
  • Contributed as a reviewer in dental scientific journals

Military Service, Hellenic Army, Veroia, Greece                                                                                                                                                      Aug 2010 – Mar 2011

  • Served the Hellenic Army in the 3rd Decree of Army Aviation Helicopters, as a Master Sergeant. Was responsible to design the daily sharing of the responsibilities of 90+ privates, including securing, maintaining and safety assignments of the base. Co-training for one month with the Hellenic Army Special Forces (Green berets). Developed management, leadership, multi-tasking and decision making skills. Earned honors for outstanding performance at military drills.

KEY results:

  • Suggested an improved plan for enhanced security of the base, later adapted by the highest rank officers

Internship via ERASMUS,

Ecole de Mines de Nancy, Institut Jean Lamour, Nancy, France                                                                                                                            Oct 2009 – Apr 2010

  • Trained in TEM and accomplished the characterization of various secondary phases and creation of TTP diagrams for S31254 and S32654 steel grades, for the first time that these diagrams were drawn. Also developed skills in TEM characterization.

KEY results:

  • Offered in the scientific community by providing novel TEM results
  • 2 Publications in International Journals
  • 2 Conference Presentations

Technical Advisor,

Hellenic Union of Mining and Metallurgical Engineers, Athens, Greece                                                                                                                Jun 2006 – Mar 2008

  • Performed a market study and statistical analysis of mining and metallurgical issues, including data collection of all the Hellenic Mining and Metallurgical Engineers in one volume.

KEY results:

  • Assisted in creating the first yearbook of the Union

Marketing Agent,

Hellenic Telecommunications Organization, Athens, Greece                                                                                                                                 Oct 2006 – Jun 2007

  • Worked as telemarketing agent as a group leader, with the assignment to increase the customers’ pool of the company.

KEY results:

  • Contributed in the increase of the profits of the company with outstanding performance

EDUCATION

Doctor of Philosophy (Ph.D.) in Metallurgical Engineering, 2011

National Technical University of Athens, Athens, Greece.

Dissertation: Microstructural – Property Relationships in Superaustenitic Stainless Steels

Bachelor of Science (BS) in Mining and Metallurgical Engineering, 2005

National Technical University of Athens, Athens, Greece. (GPA: 7.23/10)

Ph.D. Candidate & Teaching Assistant,

National Technical University of Athens, Athens, Greece                                                                                                                                             Sep 2005 – Aug 2010

  • Worked on the characterization of superaustenitic (S31254, S32654) and novel superferritic stainless steels. Trained in various metallurgical processes (i.e. welding, cold rolling). Assisted in teaching activities of courses: Basics in Metals I, Basics in Metals II, Phase Transformations, Welding Technology of Metals, Metal Designing. Became efficient in analytical methods, heat treatments and mechanical testing and developed teaching, management, leadership and mentoring skills.

KEY results:

  • Created the TTP curves for S31254 and S32654 steel grades
  • Produced valuable knowledge on the behavior of the materials, not clear until then
  • Relied on as one of the department’s primary trainers of undergraduate and post graduate students
  • 5 Publications in International Journals
  • 13 Conference Presentations
Internship, HALCOR Metal Works SA, Department of Casting, Athens, Greece | Jul 2003 – Aug 2003
  • Worked for the Quality Control Department of HALCOR (bulk and long products of copper, copper alloys and zinc alloys) and specimen inspection of copper slabs. Performed the initial alloy characterization on a novel Zn-based alloy that the company produces until present.

KEY results:

  • Relied on as one of the company’s assistant in the quality control of produced slabs
  • Played a key role in developing the novel Zn-based alloy
Internship via IAESTE,
  • University of Mining and Metallurgy, Faculty of Mining, Krakow, Poland.                                                                                                                      Sep 2002 – Oct 2002
    • He studied the importance of rock bolting in underground mines.

    KEY results:

    • Relied on as one of the team’s assistant in improving the performance of rock bolting
Internship, METKA Group, Volos, Greece | Jul 2001 – Aug 2001
  • Worked for the Quality Control Department of HALCOR (bulk and long products of copper, copper alloys and zinc alloys) and specimen inspection of copper slabs. Performed the initial alloy characterization on a novel Zn-based alloy that the company produces until present.

KEY results:

  • Relied on as one of the company’s assistant in the quality control of produced slabs
  • Played a key role in developing the novel Zn-based alloy

HONORS & AWARDS

2nd Prize (“Thomaideio Award”) for the Best PhD Thesis of Year 2011, in National Technical University of Athens

Scholarship by National Technical University of Athens (N.T.U.A.) for PhD research (2007-2010)

N.T.U.A. award for presenting a novel scientific paper within 2008 in an international conference (2008)

N.T.U.A. award for presenting a novel scientific paper within 2006 in an international conference (2006)

Scholarship by the IMC16 Conference Secretariat, covering the costs of registration fees for presenting two papers at the conference (2006)

  • SME (Society of Manufacturing Engineers) Member (April 2016)
  • ASM (American Society for Metals) Central Mass Board Secretary (September 2016)
  • ASM (American Society for Metals) Central Mass Board Member (September 2015)
  • ASM Member (September 2014)
  • The Minerals, Metals & Materials Society (TMS) Member (September 2014)
  • Alpha Sigma Mu (ΑΣΜ), International Professional Honor Society for Materials Science and Engineering (April 2014)
  • Sigma Xi (ΣΧ), Scientific Research Society (April 2014)
  • Technical Chamber of Greece, (March 2005)
  • Greek Union of Mining and Metallurgical Engineers (March 2005)
  • Hellenic Metallurgical Society (November 2004)
  • Koutsoukis and Makhlouf M. Makhlouf, “Rendering Wrought Aluminum Alloys Castable by Means of Minimum Composition Adjustments”, International Journal of Cast Metals Research, (Jan 2017), DOI 10.1080/13640461.2017.1287645.
  • Koutsoukis and Makhlouf M. Makhlouf, “Alternatives to the Al-Si Eutectic System in Casting Aluminum Alloys,” International Journal of Metalcasting, 10(2) (2016), DOI 10.1007/s40962-016-0042-6.
  • Koutsoukis and Makhlouf M. Makhlouf, “Alternatives to the Al-Si Eutectic System in Casting Aluminum Alloys,” AFS Transactions, paper No. 15-089, Apr (2015).
  • Koutsoukis and Makhlouf M. Makhlouf, “An Alternative Eutectic System for Casting Aluminum Alloys: I. Casting Ability and Tensile Properties,” Light Metals 2015, TMS Annual Meeting (2015), 277-282.
  • Koutsoukis and Makhlouf M. Makhlouf, “An Alternative Eutectic System for Casting Aluminum Alloys: II. Modification of the eutectic Morphology,” Light Metals 2015, TMS Annual Meeting (2015), 283-288.
  • Koutsoukis, Y.S. Al Jabbari, S. Zinelis, “Selective laser melting technique of Co-Cr dental alloys: A review of structure and properties and comparative analysis with other available techniques”, Journal of Prosthodontics, 24 (2015), 303-312.
  • S. Al Jabbari, T. Koutsoukis, X. Barmpagadaki, E.A. El-Danaf, R.A. Furnelle, S. Zinelis, “Effect of Nd:YAG Laser Parameters on the Penetration Depth of a Representative Ni-Cr Dental Casting Alloy”, Lasers in Medical Sciences, 30(2) (2015), 909.
  • S. Al Jabbari, T. Koutsoukis, X. Barmpagadaki, S. Zinelis, “Metallurgical and interfacial characterization of PFM Co-Cr dental alloys fabricated by Casting, Milling or Selective Laser Melting”, Dental Materials, 30 (2014), No 9, e79-e88.
  • Al Jabbari, S. Al Taweel, M. Al Rifaiy, M. Al-Qahtani, T. Koutsoukis, S. Zinelis, “Effects of surface treatment and artificial aging on the shear bond of orthodontic brackets bonded to four different provisional restorations”, Angle Orthodontist, 84(4) (2014), 649.
  • Koutsoukis, A. Redjaimia, G. Fourlaris, “Phase transformations and mechanical properties in heat treated superaustenitic stainless steels”, Materials Science and Engineering: A, 561 (2013), 477-485.
  • Koutsoukis, A. Redjaimia, G. Fourlaris, “Characterization of precipitation sequences in superaustenitic stainless steels”, Solid State Phenomena, 172-174 (2011), 493.
  • Koutsoukis, K. Konstantinidis, E.G. Papadopoulou, P. Kokkonidis, G. Fourlaris, “Comparative study of precipitation effects during aging in superaustenitic and superferritic stainless steels”, MST, 27(5) (2011), 943.
  • Koutsoukis, E.G. Papadopoulou, S. Zormalia, P. Kokkonidis, G. Fourlaris, “Precipitation sequences in cold deformed superaustenitic stainless steels”, MST, 26(9) (2010), 1041.
  • Koutsoukis, S. Zormalia, P. Kokkonidis, E. Papadopoulou, P. Tsakiridis, G. Fourlaris, “Effect of Cold deformation upon ageing of superaustenitic stainless steels”, Advanced Materials Research, 89-91 (2010), 301.
  • Koutsoukis and Makhlouf M. Makhlouf, “Alternatives to the Al-Si Eutectic System in Casting Aluminum Alloys,” AFS Metalcasting Congress, paper No. 15-089, Apr (2015).
  • Koutsoukis and Makhlouf M. Makhlouf, “An Alternative Eutectic System for Casting Aluminum Alloys: I. Casting Ability and Tensile Properties,” The 115th TMS Annual Meeting, Orlando, Florida, Mar (2015).
  • Koutsoukis and Makhlouf M. Makhlouf, “An Alternative Eutectic System for Casting Aluminum Alloys: II. Modification of the eutectic Morphology,” The 115th TMS Annual Meeting, Orlando, Florida, Mar (2015).
  • Koutsoukis, Makhlouf M. Makhlouf, “Alternative Eutectic Systems for Aluminum Casting Alloys”, Advanced Casting Research Center semiannual meeting, WPI, Worcester, MA, USA, Dec (2014).
  • Koutsoukis, Makhlouf M. Makhlouf, “Alternative Eutectic Systems for Aluminum Casting Alloys”, Advanced Casting Research Center semiannual meeting, WPI, Worcester, MA, USA, Jun (2014).
  • Koutsoukis, Makhlouf M. Makhlouf, “Alternative Eutectic Systems for Aluminum Casting Alloys”, Advanced Casting Research Center semiannual meeting, WPI, Worcester, MA, USA, Dec (2013).
  • Zinelis, Y. Al Jabbari, T. Koutsoukis, X. Barmbagadaki, G. Eliades, “Porcelain fused-to-cast/milled and SLM Co-Cr alloys: The effect of a bonder”, IADR Continental European Division (CED) annual meeting, Sep (2013).
  • Koutsoukis, A. Redjaimia, G. Fourlaris, “A complete study of microstructure – mechanical properties relationship in superaustenitic stainless steels”, 4th Pan-Hellenic Conference of Metallic Materials, Thessaloniki, Greece, Nov (2010).
  • Koutsoukis, A. Redjaimia, G. Fourlaris, “Characterization of precipitation sequences in superaustenitic stainless steels”, PTM2010, Avignon, France, Jun (2010).
  • Kokkonidis,E.Papadopoulou, T.KoutsoukisE.Kyriakopoulou, P.TsakiridisG.Fourlaris, “Microstructure-mechanical property relationships in a TRIP 800 Steel”, Euromat 2009, Glasgow, UK, Sep (2009).
  • Papadopoulou,P. TsakiridisP. KokkonidisE. Kyriakopoulou, T. KoutsoukisG. Fourlaris, “Formability-texture characteristics in novel Ti-V IF strip steels”, Euromat 2009, Glasgow, UK, Sep (2009).
  • Koutsoukis, S. Zormalia, P. Kokkonidis, E. Papadopoulou, P. Tsakiridis, G. Fourlaris, “Effect of cold deformation upon ageing of superaustenitic stainless steels”, THERMEC2009, Berlin, Germany, Aug (2009).
  • Kokkonidis, E. Papadopoulou, A. Rizos, T. Koutsoukis, G. Fourlaris, “Microstructure – mechanical property relationships in a 250 maraging steel” , EMC2008, Aachen, Germany, Sep (2008).
  • Zormalia, T. Koutsoukis, E. Papadopoulou, P. Kokkonidis, G. Fourlaris, “Effect of ageing in cold rolled superaustenitic stainless steels” , EMC2008, Aachen, Germany, Sep (2008).
  • Koutsoukis, K. Konstantinidis, P. Kokkonidis, E. Papadopoulou, G. Fourlaris, “Precipitation reactions in superferritic stainless steels”, EMC2008, Aachen, Germany, Sep (2008).
  • Koutsoukis, K. Konstantinidis, G. Fourlaris, “A comparative study of precipitation effects during ageing of superaustenitic and superferritic stainless steels”, 6th European Stainless Steel Conference, Helsinki, Finland, Jun (2008).
  • Koutsoukis, K. Konstantinidis, G. Fourlaris, “A comparative study of precipitation effects in superaustenitic and superferritic stainless steels”, 3rd Pan-Hellenic Conference of Metallic Materials, Patras, Greece, Dec (2007).
  • Parissis, T. Koutsoukis, G. Fourlaris, “A microstructure – mechanical properties study in a superaustenitic stainless steel coated with hydroxyapatite by laser gladding”, 1st Hellenic Society for Biomaterials, Athens, Greece, Oct (2006).
  • Koutsoukis, G. Fourlaris, “Microstructure – mechanical property relationship in superaustenitic stainless steels”, IMC16, Sapporo, Japan, Sep (2006).
  • Koutsoukis, G. Fourlaris, “Precipitation reactions in superaustenitic stainless steels”, IMC16, Sapporo, Japan, Sep (2006).

CITATIONS

More than 200 citations in International Journals

REVIEWER FOR SCIENTIFIC JOURNALS

Metallurgical and Materials Transactions A

Dental Materials (Elsevier)

Journal of Dental Biomechanics (Sage Publications)

Recent Patents on Mechanical Engineering (Bentham Science Publishers Ltd.)

LANGUAGES

Greek

Native language

English

Fluent

German

Very Good