Autumn and Winter Quarters have passed since our last update. Time sure flies when….. you’re taking classes!

Since then, Welding Engineering students attended FABTECH 2011 in Chicago, participated in a Lincoln Electric welding bootcamp, graduated 5, and now are getting ready for the April 27 Welding Engineering Open House and The Great Moonbuggy Race 2012.

Moonbuggy Captains Jared and Issac sent in a few photos to show what the team is up to.

Isaac tig welds the suspension tabs onto the frame.

Jared, Isaac, and Ben discuss some welding on the suspension tabs.



The challenge for the team, of course, involves more than welding. Students design, build, budget, purchase, market, and race the buggy. Check back later in April for Moonbuggy updates from Huntsville.

NASA – The Great Moonbuggy Race


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.

If the bachelor’s degree isn’t enough, there also are the master’s and PhD programs in Welding Engineering.

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.

OSU Welding Engineering students prepare for the 2011 NASA Moonbuggy competition in April.
See story in the Lantern:

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.