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Daniel B. McCray

Group Leader, Aerospace Materials Sustainment - Senior Research Engineer

University of Dayton Research Institute: Nonstructural Materials


Email: Daniel McCray
Phone: 937-656-6009
Website: Visit Site
WPAFB Bldg 652 Rm 155


Dan McCray has over 20 years of experience conducting projects related to material and processing (M&P) issues with structural adhesive bonding, prebond surface preparation, polymer matrix composites, and aerospace specialty materials. Dan specializes in addressing M&P issues encountered during original manufacture or repair of aerospace structures. He has extensive experience evaluating physical, mechanical, and electrical properties of materials, optimizing processing techniques, and transitioning these technologies to aircraft manufacturers and maintainers. Dan has authored over 100 technical papers/reports and regularly presents at technical conferences and meetings. Dan regularly chairs technical sessions related to the topics of adhesive bonding and composite materials at various conferences and currently serves as the Technical Co-Chair of the High Temperature Polymeric Laminate (HIGH TEMPLE) Workshop, an annual meeting devoted to discussing advances in high temperature polymers, composites, and their applications.

Dan currently manages UDRI’s Aerospace Materials Sustainment Group, composed of 16 researchers focused on developing M&P solutions for a variety of aerospace applications. The AMS Group is based in several laboratories and facilities at Wright-Patterson Air Force Base and exceeded $5M in revenue for the first time in history in GFY19. Dan’s primary responsibility within UDRI’s AMS Group is to serve as Program Manager for the Composites, Adhesives, Specialty Technologies, and Elastomers Research (COASTER) program with Air Force Research Laboratory. The COASTER program is a seven-year, $43M contract aimed at developing polymer-related M&P technologies and transitioning those technologies to end users within the U.S. Air Force, Department of Defense, aerospace industry, and beyond.


  • Structural Adhesive Bonding: Evaluation of structural adhesive materials, material properties, and development of prebond surface preparations
  • Polymer Matrix Composites: Evaluation of composite materials, material properties, process development and optimization, and test methodologies
  • Characterization of Aerospace Specialty Materials: Evaluation of nonstructural aerospace specialty materials found on the outer mold line of aerospace vehicles, including specialty coatings, boot materials, gap fillers, conductive materials, etc.
  • Aircraft Repair Development: Development of repair methodologies encompassing a variety of aerospace M&P that can be performed in field or depot maintenance environments


  • M.S., Materials Engineering, University of Dayton
  • B.S., Materials Science and Engineering, Wright State University
  • A.S., Engineering Science, Sinclair Community College


  • University of Dayton Research Institute Exceptional Performance Award, 2015
  • University of Dayton Wohlleben-Hochwalt Outstanding Professional Research Award, 2004-05


  • HIGH TEMPLE Workshop
  • Society for the Advancement of Materials and Process Engineering (SAMPE)
  • Tau Beta Pi, The Engineering Honor Society
  • Alpha Sigma Mu, The International Professional Honor Society for Materials Science and Engineering