Archive for the ‘Welding Engineering’ Category

My name is Connor, and I have been working as an intern in the Welding Engineering department at The Ohio State University this summer. I am currently a student at Metro Early College High School.

During the school year, I had an internship at Battelle under a Materials Engineer/Tribologist there, Dr. Merriman, and he was the one who originally got me interested in Materials and Welding Engineering — before him, I didn’t even know it was a field of engineering. I then found out about the internship opportunity the Welding Engineering department offered through my FIRST Robotics Team’s Coach, Dr. Bruening. I was very interested because I had previously been exposed to this field of engineering.


After some interviewing, I got the position and started working under two graduate research associates, Jansen Lenzo and Michael Orr. I have been studying solidification cracking in nickel and cobalt based alloys in addition to high manganese steel. Day to day I bounce between preparing metal samples, working with microscopes, compiling data and observations, and studying/discussing welding engineering concepts. Before this internship, I was dead set on doing Aerospace Engineering, because for the last two years I have been the Lead Designer/CAD Guru on my Robotics Team. But, welding engineering has proven to be a grand slam of every field of science I have come to enjoy.

I really love my job, the community at the welding engineering department is fantastic and the experience and information I have gathered here is invaluable. Michael and Jansen are real all-star mentors and it has been awesome to have two people so dedicated to promoting my ambitions and accelerating my career. I would recommend this opportunity to any other young engineer.

Go Buckeyes!


Welding Engineering senior Jacob spent his summer at an internship with a medical device company.  Here is his report.

Greatbatch MedicalOver the summer of 2013, I participated in a welding engineering internship program in Buffalo, New York, with Greatbatch Medical.  The scope of products there range from batteries used in medical devices, drilling rigs, in NASA designs, to catheters and orthopedic implants. In the Buffalo facilities, batteries, capacitors, medical devices, and feedthroughs are the main focus.

Welding processes incorporated here are ultrasonic, laser, and small scale resistance welding.  Additionally, some brazing has been applied to certain projects.  Materials used in the various products include titanium, molybdenum, aluminum, stainless steel, nickel, platinum, gold, and lithium.

For my major project I was able to work on a scanning electron microscope (SEM) for microstructure analysis and composition mapping.  I found the exposure to these exotic materials and complex processes very interesting.  My co-workers were both knowledgeable and very friendly, helping me through whatever was necessary in my projects.


Dan is a 2013 OSU Welding Engineering graduate who moved to Ft. Collins, Colorado, to start his Welding Engineering career at Wolf Robotics.  There, he joins recent OSU WE alumni Jared and Adam.

The transition from being a student to becoming an engineer has been pretty sweet. It was weird, at first, having all this free time with no WolfRoboticshomework or studying. I am glad I chose Wolf Robotics to be the place to start my career.

The people here are all pretty great, and I seem to fit in fine. The majority of my time has been spent training to ready me for on-site support at John Deere in Dubuque, Iowa. I have been sent to Lincoln Electric twice now for their Fanuc Robotics training classes. For my on-site support I am being relocated to Iowa for six months. The relocation is kind of a pain, but I’m excited to get the hands-on experience in a production atmosphere.

In addition to getting ready for relocation I am part a team putting together a capstone project for this year’s OSU Welding Engineering seniors. It is interesting being on the sponsor side of things and getting to see how much really goes into these projects. This is another experience I am glad to be a part of.

Dan loving the Colorado life

Dan loving the Colorado life

Moving to Colorado has also been pretty awesome. Having spent my entire life on the east side of the country, it has been a real eye-opener to what else is out there. Fort Collins is way smaller then Columbus, but there is always something to do.

I have been taking the dogs on hikes and swimming in the river, riding my bicycle all over, and when I just want to relax there are like 13 breweries in this town.

I’m Erik, a third-year Welding Engineering major at OSU.  This summer I worked for GE Energy in Greenville, South Carolina, which manufactures gas turbines for power plants, ranging in size from 107 tons (85 megawatts) to 314 tons (256 megawatts).

The GE Greenville campus houses the manufacturing, engineering, and testing of their products.  I worked in a section of manufacturing known as the “pipe shop” cutting, bending, welding, and x-raying all the pipe that goes on a turbine for cooling systems (both air and oil), manifolds that carry fuel, and any other piping needed.

One of Erik’s hobbies is building and flying model planes.

I also helped out in an area known as “Unit to Base,” the final step in assembly.  We put the turbine on a base and all of the piping, wiring, tubing, and monitoring devices on the unit.  The manufacturing floor is absolutely amazing.  At any given time you can see all of the rotors assembled and getting ready to be run up to a few hundred rpm’s for balancing or final machining, a 300 ton turbine being moved through the air by cranes over to being prepped to ship, or countless CNC and EDM machines on the floor doing machining on exotic alloys.

There were a total of 96 interns at GE Energy in Greenville this summer, with a little less than half being engineering/manufacturing interns.  The biggest thing I learned is that Ohio State alumni are everywhere!  I thought coming down here I would be lucky to run into one or two alumni, but it turns out there are a lot. There is even a bar and grille in Greenville that has an entire half of the restaurant reserved for every OSU football game —  and it mostly fills up!

Chris worked 4 co-op rotations with GE Aviation

Hi, I’m Chris, and I am a senior in Welding Engineering at OSU this year.

This summer I worked for GE Aviation in Cincinnati, Ohio, in my fourth co-op rotation.   I worked with a group called Rotating Parts Lean Lab.  In other words, I worked on projects that  involved developing new manufacturing processes to produce rotating parts for aircraft engines.

Since I am a welding engineer, I spent most of my time working with Linear Friction Welding and Inertia Welding. The coolest part of my co-op is that I got to run the machines that made the welds.  Not often does an intern get to run machines that make parts worth more than $200,000 (of course I had an engineer watching me the whole time).  I learned  lots of interesting things, mostly about solid-state processes.

I spent most of my time refining process parameters and looking at the microstructure of welds.  I now have a very good knowledge of what good Inertia and Linear Friction welds look like.  The worst part of my job was when my interesting projects were in process outside my area, and I had to do regular desk work like everyone else.

GE is a big company, so there were a lot of interns from different colleges and majors around me.  This gave me a chance to talk and meet with a wide variety of people.  Being from the only accredited Welding Engineering program in the country, I was asked a lot of questions about my major.  I also got to work with other OSU Welding Engineering alumni.

It sometimes surprised me how much everyone wanted to help me learn.  Even when they were busy, I could ask mostly anyone and they would explain the project or just answer a question I had.

I don’t think that I could find a better place to learn and grow as a student than at GE Aviation.  Hopefully I’ll have a chance to go back full-time when I’m done with school, because I’d love to continue to work there.

While our students are busy with summer jobs, internships, and classes, here are a few things going on in the department this summer.

First, it’s Ohio State Fair time, and OSU’s Welding Engineering students who worked on the Moonbuggy project partnered with the College of Engineering to get an interactive engineering display at the Technology and Engineering Showcase in the Youth Center (Lausche Building). Stop by until August 7.

OSU's Moonbuggy at the Ohio State Fair

In addition, the department acquired a new “toy” that will be used in classes and welding demonstrations to show a type of solid state welding called “cold pressure welding.”    The hand-held device welds wire pieces together without the use of heat.  Forcing two wires through a die several times, exposes pure areas of metal (copper, in this video) to come in close contact with each other, so that metallic bonding occurs.

In this video, visiting high school teachers learn about materials and solid state welding at an ASM Materials Teachers camp held in the department this summer.


This summer

OSU Welding Engineering students are interning at: Murray Energy, Sterling Process Eng., GE Energy, Edison Welding Institute, GE Aviation, General Dynamics-NASSCO, General Motors, Swagelok, Duke Energy, Miller Electric, Lincoln Electric, Special Metals, Techniche Universitat Bergakademie Freiberg.

OSU Welding Engineering summer interns are averaging: $17.58/hour

Posted by Megan, Academic Advisor for Welding Engineering.

One of my duties as academic advisor is to recruit new students to the Welding Engineering major. It’s a little like selling shoes; we know you need shoes, and you want to buy a pair, but we bet you’ve never seen this kind!

Welding Engineering is sort of the Rodney Dangerfield of Engineering…. “We don’t get no respect.”
The misconception that we train welders keeps students (and their parents) from giving us a second look when seeking an Engineering major at OSU.

I call it the “cocktail party” problem:
“So, I hear your son is going to OSU. What’s his major?”
“(Fill in the blank) Engineering.”
“Oh, that’s wonderful!” As long a the blank is something they’ve heard of before.

Parents don’t want to deal with:
“So, I hear your daughter is going to OSU. What’s her major?”
“Welding Engineering.”
“Oh.” lengthy pause  “Your daughter is going to be a welder? How do you feel about that?”

We know there’s nothing wrong with being a welder. Companies are begging to hire well-trained welders!
It’s just not what we do at OSU Welding Engineering!  We educate Welding Engineers who learn the science behind the welds. They understand, design, and create new processes for welding, so that welders can do their jobs with the multitude of materials, conditions, and budgets that industry throws at them.  Our Welding Engineering graduates get jobs, and are well-paid.  Nothing disrespectful about that!

Next weekend, we’re selling our shoes, er, major, at our OSU Welding Engineering Open House.  That morning, Welding Engineering juniors and seniors will host their families and alumni, while the seniors show off their final projects.  Later that afternoon, invited high school juniors and seniors and OSU Engineering students who are still looking for an engineering home, will tour our beautiful facilities and see the remarkable things our Welding Engineers do.

Slowly, but surely, we’ll convince prospective students and their parents to try on our unique line of shoes.  They’ll be walking around getting all kinds of respect.

Senior students in the Ohio State Welding Engineering program are required to finish their year with a year-long senior capstone project.  The projects are usually done in teams, with the support from companies such as John Deere, Lincoln Electric, Caterpiller, General Electric, etc.   Here, seniors Dorian, Brian, and Paul show their advisor how a small robot welder works.

Paul explains:

We are studying the effects of shielding gas combinations on the weld properties.  We are testing four different gases, each primarily argon mixed with different levels of carbon dioxide or oxygen.

There are two different types of metal and three thicknesses of each steel being tested.  The main goal is to find the shielding gas combination that gives the best properties of the weld.

The use of a robot is essential in creating consistent welds and eliminating human error.

As seen in the video, a simple horizontal fillet weld is being made.  The testing with the robot just began and the exact parameters aren’t dialed in yet, which can be seen/heard in the video.  The robot is an education robot cell from Lincoln Electric and is very useful for small scale testing such as what we’re doing or for learning robotic welding in classrooms.

Hi, my name is Lucas Crumley, and I’m a 4th year student in Welding Engineering.

Instead of talking about my classes, I want to tell you about my job as an Engineering Ambassador. As an ambassador, I give tours to prospective high school students, but instead of covering all of campus like the University Ambassadors, I get to focus on the best part of campus: the College of Engineering!

On my tours, I show students some of the labs and classrooms that Engineering students at Ohio State typically use in their first year. I also talk about my specific experiences in classes, dealing with professors, campus life, and how and why I ended up coming to Ohio State, studying Welding Engineering.

Each ambassador is required to be able to talk about all of the Engineering Majors offered at Ohio State, but we have the freedom to promote our own majors specifically.

If you are a prospective high school student, I highly encourage you to take one of our tours because you not only get to learn about why Ohio State is an AWESOME university to attend, you get to hear our stories, experiences, and tips while seeing all that the College of Engineering has to offer.

So if you do come for a visit and attend our college overview and tour, you might get the joy of having Kristen Hammer, the only other Welding Engineering major Ambassador, or me as your tour guide – especially if you say that you want to study Welding Engineering.