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RESEARCH EXPERIENCE
As a research engineer, Mr. Hornbach conducted many residual stress programs for the automotive,
aerospace, nuclear, and power generation industries. He developed several novel services for the laboratory,
including a mechanical ring-core residual stress method for coarse grain stainless steel weldments, finite
element methods of predicting residual stress, and developing techniques for non-destructive subsurface
residual stress measurement by x-ray diffraction.
As the laboratory supervisor, he managed the day-to-day activities of the residual stress laboratory. In
addition to managing the laboratory, he was the project manager for several programs involving the
development of the LPB™process for aerospace and medical applications. As the manager of these
programs, he oversaw the design of the compressive residual stress, measurement of the residual stress,
and validation of the fatigue strength improvement via testing, finite element and fracture mechanics. As
Director of the Lab Operations, he is responsible for the overall operations of Lambda's testing facilities,
including the x-ray diffraction laboratory and the fatigue and corrosion characterization laboratory.
ENGINEERING SOCIETY AFFILIATIONS
Mr. Hornbach is a member of SAE, ASM, ASTM, and ASME. He serves as a member of the ASTM Committee
E28.13 on Measurement Methods for Residual stress and SAE Committee A-5 Aerospace Landing Gear
Systems.
PUBLICATIONS
D. Hornbach, P. Prevey, M. Piche, D. Rivest, “The Influence of Surface Enhancement by Low Plasticity
Burnishing on the Corrosion Fatigue Performance of 7475-T7351 and 2024-T351”, pp 381-387, Proceedings of 2008 10th International Conference On Shot Peening, Tokyo, Japan, Sept. 15-18.
D. Hornbach, P. Prevey, “Reducing Corrosion Fatigue and SCC Failures in 300M Steel Landing Gear Using
Low Plasticity Burnishing”, Paper No. 07ATC-104, Proceedings of 2007 SAE AeroTech Congress & Exhibition, Los Angeles, CA, Sept. 17-20, 2007, No. 270
D. Hornbach, E. Loftus, “Application of Low Plasticity Burnishing (LPB) to Improve the Fatigue Performance of
Ti-6Al-4V Femoral Hip Stems”, Journal of ASTM International, Vol. 3, No. 5, No. 263
D. Hornbach, P. Prevey, M. Blodgett, “Development of Nondestructive Residual Stress Profile Measurement
Methods – The Integral Method”, Proceedings of the Review of Progress in Quantitative Nondestructive Evaluation, Vol. 24, July 25-30, 2004, Golden, CO.
D. Hornbach, P. Prevey, “The Effect of Prior Cold Work on Tensile Residual Stress Development in Nuclear
Weldments,” Proceedings: 2001 ASME Pressure Vessels and Piping Conference, July 22-26, 2001, Atlanta, GA, No. 225
D. Hornbach, P. Prevey, “Tensile Residual Stress Fields Produced in Austenitic Alloy Weldments,”
Proceedings: Energy Week Conference, Book IV, January 28-30, Houston, TX, ASME International, 1997, No. 217
R. McGregor, D. Hornbach, U. Abdelsalam, P. Doherty, "Experimental Residual Stress Evaluation of Hydraulic
Expansion Transitions in Alloy 690 Steam Generator Tubing," Proceedings of the Seventh International Symposium on Environmental Degradation of Materials in Nuclear Power Systems, Breckenridge, Colorado, August 7-10, 1995, No. 216
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