About Us

About Michael Pfeifer, Ph.D., P.E.

Metallurgical Engineering Consultant • Failure Analysis Expert • Metallurgy Trainer

Michael Pfeifer is President of Industrial Metallurgists, a leading engineering consultancy that specializes in metallurgical engineering for product design, manufacturing, and root cause analysis of product failures.

With over 30 years of hands-on experience, Michael has been helping clients world-wide with design and manufacturing decisions and problems. He also is a failure analysis expert for forensic engineering investigations, and provides metallurgy expert witness services when needed. 

Michael has worked on every aspect of product development and manufacturing. A metallurgy background coupled with extensive design and manufacturing experience enables him to quickly understand your situation, work with you to make a plan, help you get the information you need, and help you use the information to get to the best outcome.
Michael Pfeifer talking with a client

Services Provided

  • Materials selection & design. Tailoring metals and alloys and optimizing components to meet performance, reliability, and cost requirements.
  • Failure analysis & expert witness testimony. Investigating product, equipment, industrial, and structure failures and providing clear, authoritative testimony when disputes arise.
  • Manufacturing process optimization. Advising on production processes for quality improvement and cost reduction.
  • Metallurgy training for non-metallurgists. Offering on-site or virtual courses on metallurgy fundamentals, metallurgical engineering principles, and best practices for engineering teams.

Education and Background

Michael received a B.S. and M.S. in Metallurgical Engineering from University of Illinois and a Ph.D. in Materials Science and Engineering from Northwestern University.

Industry experience includes automotive, aerospace, hardware, tools, medical and dental devices, plumbing, industrial equipment, machinery, electronics, and many more.

Alloy experience includes carbon steel, low-alloy steel, tool steel, stainless steel, aluminum alloys, copper alloys, brass and bronze, and super alloys.

Coating experience includes electroplated, PVD, galvanized, powder coated, and thermal sprayed.

Michael also wrote a book - Materials Enabled Designs. It teaches how to select materials that optimize product performance, reliability, and cost. He applies these concepts to metallurgy consulting projects.

Why Choose Michael Pfeifer as Your Metallurgical Engineering Consultant?

Metallurgical Knowledge
We have experience with a wide range of alloys and coatings, their properties, and how they behave during use. Combined with our engineering experience, we can help optimize component designs, manufacturing processes, and quickly determine the root cause of product failures and quality problems.

Industry Experience
Dr. Pfeifer has extensive experience with all aspects of the product life cycle - design, manufacturing, product testing, supplier evaluation, and failure analysis. Clients cover a wide range of industries and products - automotive, aerospace, medical devices, appliances, metal suppliers, industrial equipment, and many more.

Failure Analysis Expertise
As a failure analysis expert, Dr. Pfeifer conducts investigations to determine root causes of material or component failures. His reports and testimony not only clarify how and why a failure occurred but also help clients implement corrective actions to prevent future incidents.

Ways I work with clients

Consulting Metallurgist

I work as a consulting metallurgist and advisor to help clients with decisions and problems related to metals - component design, cost reduction, supplier evaluation, improve manufacturing quality, and more. I work as part of a client's engineering team, working together to identify options and find solutions that make business sense. I provide metallurgy expertise and they provide knowledge of their product and expertise in their field of engineering. This support model is especially useful for businesses looking to optimize resources while still adhering to the highest engineering standards.

Root Cause Analysis 

Effective root cause analysis of component failures and quality problems begins with a thorough failure analysis of the failed component or the item with the quality problem. Through metallurgical evaluations, we identify the metallurgical reason for the problem and use the information to help clients determine the root cause and corrective actions to prevent similar failures or quality problems in the future.

Metallurgist Expert Witness

As your metallurgist expert witness, I offer specialized insight into metal failure investigations for product liability cases. By applying in-depth metallurgy knowledge and engineering experience, a metallurgist expert witness can help courts or arbitrators make well-informed decisions. This critical guidance can significantly impact the outcome of legal proceedings where the performance and integrity of metal components are under scrutiny.

Metallurgist Training

We offer metallurgy training geared to design, quality, and manufacturing engineers who are non-metallurgists. We offer on-demand courses, webinars, and on-site training. We teach practical metallurgy concepts that will help engineers deal with real-world situations so they can be more effective when dealing with decisions and problems related to metals and have more productive conversations with customers, suppliers, and colleagues about metals.

We offer discounts and customized training for groups.

Fractured fastener hydrogen embrittlement

Industrial Metallurgists, LLC

Providing metals engineering expertise for failure analysis and forensic investigations of metal components and products.
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