Kevin Sisco

Background

About Kevin Sisco

Materials scientist and engineer specializing in alloy design, solidification science, and additive manufacturing. My work focuses on developing new aluminium alloys for high-temperature applications by controlling solidification phase selection and directing microstructure evolution. I have developed advanced phase selection modeling techniques for complex alloy systems, providing new pathways to design materials with tailored properties. I have also worked with the design, production, and large-scale powder fabrication of thirteen novel aluminium alloys specifically engineered for additive manufacturing. These alloys were created to overcome long-standing challenges such as solidification cracking and keyhole porosity. Additionally these materials leveraged new design strategies and additive manufacturing to create reliable performance at temperatures between 200 and 450°C. Beyond alloy development, my contributions include advancing real-time defect detection technologies for metal additive manufacturing and supporting the creation of in-situ monitoring tools that have helped shape new industry qualification standards for critical components. My research has been recognized with an R&D 100 Award and has resulted in multiple patents, peer-reviewed publications, software innovations, and methodologies. I am passionate about combining fundamental research with industrial application to accelerate innovation in advanced materials, manufacturing technologies, and the future of engineered systems.