Summer with Cessna

Rachel also visited the Rocky Mountains.  This is NOT Wichita!

Rachel visited the Rocky Mountains while she was part of the way there. This is NOT Wichita!

Reporting from Wichita is MSE junior Rachel who tells us about her summer internship working with Cessna Aircraft .

Rachel CessnaI am doing a materials internship this summer in Wichita, Kansas at Cessna Aircraft (now part of Textron Aviation), in the metals group of the Materials and Processes Engineering division.  My internship requires me to inspect returned parts and parts from the production line, and to write condition reports on the pieces. I spend a lot of time in the lab, often getting dirty, and am consistently busy. I have been fortunate to be able to observe the entire production line, from raw material to finished airplane, for both Cessna and Beechcraft aircraft.

There is something special about working for an airplane manufacturer. No matter how tired, hungry, or ready to go home I am, it is awe-inspiring to walk through the hangar and see the lines of planes in production, and to realize that, in some way, no matter how small, I am a part of it.

Rachel Ground SchoolAs for the rest of the summer, I also look forward to Engineering Fastener Training, Private Pilot Ground School, and a trip to San Francisco and Yosemite.

Research internship in Germany

Colin, an OSU MSE junior, spent this past summer as an intern for Bodycote Kolsterising.  Here is some information about his work, though he doesn’t say anything about the lederhosen!

Bodycote is an engineering firm that specializes in low temperature diffusion of carbon into stainless steel.  I worked at the regional plant in London, Ohio, during the summer of 2012, and was asked to return for the summer of 2013.  Thus, during the summer of 2013 I went to Germany as an intern and researcher for Bodycote Kolsterising.

Colin at the Bodensee, also known as Lake Constance.

Colin at the Bodensee, also known as Lake Constance.

My goal as researcher for Bodycote was to find a better cleaning method for Kolsterised samples.  After Bodycote’s proprietary Kolsterising process, the stainless steel is left with a dull brown coloring, instead of the shiny metallic luster normally associated with stainless steel.  Bodycote has an in-house cleaning process that was yielding unsatisfactory results. It was my task to remedy this.

I first arrived in Landsberg Am Lech, Germany, where I spent a week studying the current cleaning process at the Kolsterising plant.  I spent the remainder of the summer in Konstanz, where I performed independent research within the Department of Materials Research at HTWG Konstanz, under the guidance of Dr. Paul Gumpel.  I was responsible for the design, data collection, and analysis of my testing.  After five weeks of testing, I had created my own cleaning process that showed promising results.  During the remaining 5 weeks, I optimized and analyzed the results of my cleaning process.

Colin rocking the Bavarian party attire

Results indicated that the new process created optically cleaner parts that were more corrosion-resistant than the current cleaning process.  At the end of my stay, I presented my findings to the VP and European sales of Bodycote who are now trying to implement my cleaning process into their plants.

MSE Honda Internship and Winner

Summer internship report from Kelvin, MSE 3rd-year.

I spent the past few months interning at Honda R&D Americas Inc. in Marysville, Ohio, and my experience was great. Honda produces primarily automobiles, motorcycles, and ATVs. The work I do involves the quality of paints applied to the vehicles.

Dr. Nitin Padture and Kelvin

I learned the many meticulous tests that go into choosing paint (base, coat, and primer) from suppliers for current and future vehicles. Before a paint combination can be put into mass production, it must meet all durability and quality requirements set by Honda. Selected paints must be able to withstand the daily abuse of a car such as acid rain and pelting of small rocks. I also aided associates with projects outside of my main research area when possible. This involved going to factories to run tests, preparing test samples, or shipping items to suppliers. Some of the most interesting things I did involved taking measurements in essentially a car oven/freezer at -30°C and 80°C.

I stayed at an off-campus apartment at Ohio State this summer, which gave me a 45-minute drive to work. I could arrive anytime from 6:00-10:00 AM, so the long window of clock-in time definitely helped for the mornings I hit snooze for an hour or two past my expected departure time. I had a few hours of time to myself after work so I decided to take up softball with our department team. I am not necessarily a baseball fan but softball was enjoyable. Most of my co-workers were under 30 years old and this made it extremely easy for me to get along with them.

This summer internship has provided me with valuable work experience that will be useful as I continue at OSU and after graduation. It gave me a taste of what the real world will be like after college. I would encourage all to take an internship if they have the chance. It will pay off greatly in the future.

NOTE: Kelvin was on the winning team for the Materials category in the Honda iDream student competition this summer.  He is pictured here with his faculty and project advisor Prof. Nitin Padture.


Summer Internship to Co-op

From Mike K., junior in Materials Science and Engineering.

Summer 2010 found me at The Timken Company in Canton, Ohio,  interning in tech service for steel for automotives.  I led a Lean Six Sigma project to reduce customer claims on tube defects called wavy OD and hooked ends, and on the effect two straighteners have on these defects.
My responsibilities required me to  go to the plant and measure the straightness of 2 orders of tubes after they came off each of the straighteners.  I found only a borderline significance between the straighteners, but I found a huge variation between the readings an inspector takes on the same area of the tube, which can lead to a good part being scrapped or a bad part being shipped.
Also as part of tech service, I traveled with my mentor to customers around Ohio and Kentucky, helping out the Value Added Supply Chain group in finding potential suppliers to machine parts for an automotive customer.

My summer internship ended last week, and now I’m in Oshkosh, Wisconsin, where I’ll be co-oping for Oshkosh Corporation in their Global Tech Center until next September.  I will continue to blog about my experiences there.  (ed. note: see posts from Joel at Oshkosh Corp).

Man of Steel… products

From Joel, MSE Senior

Time has flown and there are only 6 weeks left till classes start again!

Joel at the Charter Steel shipping yard

This summer I have been interning at Charter Steel in Cuyahoga Heights, Ohio (of Charter Manufacturing) which produces round bar, rod, and wire steel products.   Sizes range from 7/32 up to 1-9/16 inches and almost all common grades of steel are produced.

I work with the Quality and Technical Manager for the rolling mill. The two major projects I work on involve improving the yield of product as it rolls through the mill, and organizing and consolidating the cooling practices that the steel undergoes. These projects will reduce downtime for the company, and increase revenue of the final product.

Making the Slinky

We melt scrap with an Electric Arc Furnace (EAF) and strand-cast ~34-foot long billets that are 7×7 inches in cross-section. The billets are reheated in the rolling mill (where I work) and then rolled down from square cross-section to their final diameter.  A series of consecutive rolls (31 intotal) reduce the billet size. One 34-foot billet can produce up to 4-5 miles of steel rod. One billet weighs about 2.5 tons and is wrapped at the end of the rolling mill, much like a slinky.  One ring overlaps the next, which overlaps the next. The “coil” of rings is wrapped into a tight package which is then shipped to customers via truck or train. Common product uses include roller bearings, springs, welding wire, fasteners/bolts, and rebar for concrete.

 

Freshly-made Coil

Charter Steel ordered a set of uniforms and steel-toed boots for me so that I fit in with the hourly crews. I often get free lunch and I have taken a few business trips to customers’ facilities. It is a very laid back atmosphere at Charter, but everyone is a very hard worker when they need to be. There have been a few times throughout the summer where I actually had to pull out my old MSE 205 book to review some things with my boss.  It felt good to get some use out of my college knowledge.

Graduation looms at the end of fall quarter for me, but after this second internship, I feel better prepared for the real world. Now all I have to do is find a job….

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