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7915 S. Emerson Avenue, Suite 192, Indianapolis, IN 46237-9708 877-450-8774
________________________________________________________________________
Expert Aviation Consulting LLC Page 1 of 1
Steven C. Ellis
Experience: 1988 to Present: United Airlines Pilot.
O'Hare International Airport, Chicago, Illinois.
Captain, Airbus 320/319. Captain, B737.
First Officer, B737,B757,B767
Flight Engineer, McDonnell Douglas DC10.
Member of the Airline Pilots Association (ALPA). From 1994 thru 2004, served on the ALPA
National ground and in-flight icing projects.
Duties included representing ALPA in various U.S. and international in-flight icing efforts.
Highlights include being directly involved with the FAA and the National Transportation Safety
Board (NTSB) in regulation rewriting, and AIM (Airman's Information Manual) rewriting as a
result of the American Eagle crash of flight 4184 on October 31, 1984, and the crash of Comair
flight 3272 on January 9, 1997.
Other highlights concern representing ALPA at the international meetings of SAE (Society of
Automotive Engineers) from 1994 thru 2004. These are ground icing issues. At the SAE G-12
meeting in Frankfurt, Germany (May, 2002), I made a presentation concerning the temperature
drop that can occur on the lifting surfaces of an aircraft during takeoff. (see temperature drop 2
PowerPoint attachment). As a result of this presentation, the G-12 group assigned one of its
standing committees to investigate the temperature drop. I represented ALPA on this committee,
which included officials from the FAA, and Transport Canada, and engineers from every major
aircraft manufacturer in the free world. (Boeing, Airbus, Embraer, Cessna, etc.). The work of this
committee confirmed the temperature drop, and a presentation was made to an AIAA (American
Institute of Aeronautics and Astronautics) conference in 2005. I am credited in this paper for
bringing the topic to the attention of the experts who could properly investigate it. (see AIAA-
2005-0654 attachment).
Additional highlights include working with various entities within United Airlines to improve inflight
and ground icing knowledge and procedures. In this capacity, I have written significant
portions of the icing sections of the Flight Operations Manual (FOM), which governs flight
operations at United. This work also resulted in significant changes to the icing sections of the
Airbus Airplane Flight Manual (AFM) at United, which is the manual by which flight crews
operate the Airbus in icing conditions for united.
I've also written several articles concerning icing for United's internal safety publication, the
SAFETY LINER.
1977-1988: Corporate pilot.
Duties included flying turboprop aircraft (Piper Cheyenne) throughout the United States and
Canada for a manufacturing firm in Wisconsin. This was a single pilot, all weather operation,
which contributed significantly to my practical in-flight and ground icing experience and
knowledge. It was in this capacity that I first witnessed slush freezing on the lifting surfaces of
aircraft during takeoff.
1974-1977: Flight instructor and Air Freight pilot
1973-1974: Helicopter Pilot, Lambair Ltd., Thompson, Manitoba, Canada
1969-1973: Helicopter Pilot, United States Army and Wisconsin National Guard.
NEW TRENDS IN WELDING IN THE AERONAUTIC INDUSTRY
Patricio F. Mendez†‡, Thomas W. Eagar†
†Massachusetts Institute of Technology, Cambridge, MA 02139, USA
‡Exponent, Inc., Natick, MA 01760, USA
Abstract
In the two years since the last conference, welding in the aeronautic industry continued to
experience exciting developments. Rivets are being replaced at a fast rate by welds. One of the
welding processes used, friction stir welding (FSW), has far surpassed the expectations of two years
ago by being the main joining process in a new commercial jet and for replacing variable polarity
plasma arc (VPPA) welding in aerospace applications. Laser welding of airplanes is now a reality
with the Airbus A318 and 380 scheduled for production. Electron beam welding of titanium for
military airplanes is also happening with the approval of the first production series of 13 F-22’s.
Welding is experiencing a resurgence after a long time in which it was almost absent in airplanes.
Key processes to watch are friction stir welding as it expands its role in civil aircraft and aerospace
applications. Laser welding and friction stir welding are likely to be competing processes, and it is
uncertain what equilibrium these process are going to reach.
"New Trends in Welding in the Aeronautic Industry," P.F. Mendez and T.W. Eagar,
2nd Conference of New Manufacturing Trends, Bilboa, Spain, November 19 - 20, 2002.
 
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