Materials Engineering Internship/Co-Op (Spring 2019)

Job description

Description

The Role

The purpose of the Tesla Materials Engineering organization is to facilitate the Tesla mission of accelerating the world to sustainable transportation via identification, development and insertion of advanced materials and processes while supporting other Tesla Engineering and Manufacturing functions with materials expertise.

The Tesla Materials Engineering team is seeking Interns who can work independently and bring a great attitude and technical acumen to the group.

This role is available across various Tesla locations, including headquarters in Palo Alto, CA, the factory in Fremont, CA, and Gigafactory 1 in Sparks, NV – must be able to relocate for the duration of your internship.

Team Overviews

Mechanical Fasteners

Responsibilities: Design and test mechanical fasteners, rivets and clips for vehicle and power systems. Supporting supply chain with sourcing and qualification. Assist manufacturing with quality control and trouble shooting. Identify, develop and implement new fasteners and manufacturing processes for cycle time improvements and cost reductions.

Qualifications: Mechanical or Materials Engineering degree. Required coursework includes structural analysis (statics, dynamics, mechanics of materials) and machine design. Experience with 3D CAD tools (Catia, SolidWorks, AutoCad, NX, ProE, etc.). Enjoys hands on engineering, turning wrenches and putting things together. Basic knowledge of bolted joint design, such as ability to translate joint design loads to bolt torque requirements.

Welding Internship

Responsibilities: Provide consultation to design engineering on proper joining process selection given both structural performance as well as manufacturing requirements. Establish test plans for developing joint design data used to validate structural performance via numerical simulation. Develop, author and publish specifications that ensure joining processes used in production will deliver the performance anticipated and validated in the design.

Desired profile

Requirements: Mechanical, Welding or Materials Engineering degree. Experience joining the following materials: Aluminum Sheet, Extrusions, and Castings (1xxx, 3xx, 5xxx, 6xxx and 7xxx), Automotive Sheet Steels (low carbon, HSLA, Dual Phase, Hot Press and Martensitic) at a minimum. Additional experience joining electrical grade coppers and other electronic components would be an additional plus, but not required. Industrial experience with the following joining processes: Arc (MIG/CMT) and Resistance Spot at a minimum. Additional experience with advanced joining processes such as Laser and Friction Stir would be strongly preferred. Hands on process development experience, including process parameter identification, tooling, equipment, automation, etc. necessary to meet design requirements. Experience with the use of computational tools for weld process development and prediction of joint structure/quality/performance characterizes would be preferred. Experience evaluation weld quality metallurgical and demonstrated skills relating process, microstructure and properties. Has developed joint structural design values, authored welding process specifications and performed process qualifications. Familiarity with WPS’s and PQR’s. Demonstrated skills in statistical analysis of data and root-cause analysis. Strong ability to collaborate across multi-disciplined groups along with exceptional organizational skills and communication (verbal and written).

Structural Metals Internship

Responsibilities: Materials selection, Specification, development, modeling, testing and qualification for structural metallic materials used in Body and Closures such as 5xxx/6xxx Aluminum Sheet & Extrusions and Mild to Ultra High Strength Steel Sheet. This will involve sourcing samples, selecting test methods, coordinating testing, and analyzing results. Will work with design engineering on material selection and specification with CAE (FEA) on material modeling, Supply Chain for Sourcing and Qualification, Vehicle Test for physical validation as well as Manufacturing for process development and trouble shooting. Materials Engineering/Metallurgy: Leading characterization and optimization of new metals.

Qualifications: Degree in Materials Science and Engineering; Preferred Physical Metallurgy focus and advanced studies (MS or PhD). Knowledge of process-structure-property relationships in structural aluminum and/or steel alloys. Phase and TTT/CCT diagrams, heat treatment, aging curves, dislocation theory and strengthening mechanisms. Understands effects of materials on process (e.g. stamping, welding, extrusion, casting, etc.) and vice versa. Basic understanding of structural design needs and corresponding material selection drivers (load vs stress relationships for axial vs bending) as well as mechanics of materials (elastic-plastic deformation). Knowledge of common test methods for characterizing materials, such as tensile testing, hardness, microscopy, etc. Experience using computational materials engineering tools in an applied manner is preferred.

Electrical Metals Internship

Responsibilities: Materials selection, testing, development and validation for powertrain and battery materials. Will be working with design engineering, test groups and CAE (FEA) on property characterization and material modelling. Will lead building a comprehensive database of properties for Material modeling for electrical and magnetic materials.

Qualifications: Degree in Materials Science and Engineering; Preferred Metallurgy (MS or PhD). Candidate must have fundamental understanding of process-structure-property relationships in aluminum, copper, and/or iron based alloys. Should have a good knowledge of electronic and magnetic properties of materials (Conductivity, B-H Curves etc), as well as a reasonable understanding of physical properties and mechanical testing of materials (tensile testing, hardness, etc). Familiar with Integrated Circuit devices (MOSFET, bipolar transistor), soldering process, and microelectronic packaging. Familiarity with MATLAB is desired. Ability to present deliverables by designing experiments, characterizing materials, and analyzing results in a fast-paced environment.Good interpersonnel skills and ability to quickly adapt.

Castings Internship

Responsibilities: Will be supporting the Materials & Processes Engineering team at Tesla’s Aluminum High Pressure Die Casting Facility in Lathrop, CA. Areas of focus include aluminum melting, high pressure die casting process and tooling, and heat treating. Specific activities will include process improvement projects, issue resolution and root cause corrective action.

Qualifications: Materials or Mechanical Engineer (any level, BS, MS or PhD) with emphasis in as many of the following areas as possible: metals, aluminum alloys, casting, manufacturing processes, tool design, equipment design/automation, mechanical testing, casting simulation, computational material modeling and microstructure analysis.

Structural Adhesives Internship

Responsibilities: Position will support development and validation of structural adhesives and paint systems for the vehicle body structure and door closures.

Typical tasks include preparing test samples, coordinating testing with internal and external test sources, personally executing tests, benchmarking various adhesives and/or coatings, performing failure analysis on adhesives and/or coatings, collecting, analyzing, and presenting data to peers and management, researching potential solutions to problems.

Qualifications: Pursuing a degree, Materials Science, Materials Engineering, Polymer Science, Polymer Engineering, Chemical Engineering, Mechanical Engineering. Focus on adhesives is preferred. Good understanding of polymer fundamentals, and principles of adhesion. Experience with paints or coatings a plus. Experience characterizing the following material properties: Rheology, Lap shear adhesion performance, T-Peel adhesion performance, Wedge impact adhesion performance, Cross hatch adhesion performance, Corrosion performance, Familiarity with the following polymer/adhesive families: epoxies, urethanes, acrylics, silicones. Experience with standard test procedures (ASTM, ISO, DIN, SAE etc.). Strong hands-on problem-solving skills. Experience with tools, mechanical equipment, test equipment.Ability to thrive in an environment of constant change.

Power Electronics Internship

Responsibilities: Position will support development and validation of polymeric materials and adhesives for battery module and power electronics systems. Typical tasks include: Preparing test samples, coordinating testing with internal and external test sources, personally executing tests, benchmarking various materials, maintaining a database of materials used in the vehicle, supporting injection molding trials and process development, performing failure analysis on materials, collecting and analyzing data from material suppliers, collecting, analyzing, and presenting data to peers and management, researching potential solutions to problems

Qualifications: Pursuing a degree in Materials Science, Materials Engineering, Polymer Science, Polymer Engineering, Chemical Engineering, Mechanical Engineering. Good understanding of electrical, physical, and chemical characteristics of materials. Experience characterizing the following material properties: Tensile/Elongation, Impact performance, Rheology, Dielectric properties, Arc Tracking behavior, Thermal and electrical conductivity/resistance, Adhesion, Flammability resistance, UV stability, Creep Resistance, Hydrolytic Stability. Familiarity with the following polymer/elastomer/adhesive families: Polyamides, polyesters, polycarbonates, polyolefins, silicones, polyurethanes, TPEs, epoxies, urethanes, acrylics, silicones. Experience with standard test procedures (ASTM, ISO, DIN, SAE etc.). Strong hands-on problem solving skills. Experience with tools, mechanical equipment, test equipment. Ability to thrive in an environment of constant change.

Plastics/Polymers Internship

Responsibilities: Position will support development and validation of polymeric materials for vehicle interior and exterior systems. Typical tasks include: preparing test samples, coordinating testing with internal and external test sources, personally executing tests, benchmarking various materials, maintaining a database of materials used in the vehicle, supporting injection molding trials and process development, performing failure analysis on materials, collecting and analyzing data from material suppliers, collecting, analyzing, and presenting data to peers and management, researching potential solutions to problems

Qualifications: Pursuing a degree in Materials Science, Materials Engineering, Polymer Science, Polymer Engineering, Chemical Engineering, Mechanical Engineering. Good understanding of polymer fundamentals. Experience characterizing the following material properties: Tensile/Elongation, Impact performance, Rheology, UV stability, Creep Resistance. Familiarity with the following polymer/elastomer families: Polyamides, polyesters, polycarbonates, polyolefins, acrylics, polyurethanes, TPEs, Experience with standard test procedures (ASTM, ISO, DIN, SAE etc.). Experience with injection molding process development. Strong hands-on problem solving skills. Experience with tools, mechanical equipment, test equipment. Strong inter-personal skills and ability to motivate others to meet project goals and timing, Strong project management skills, database experience a plus, Ability to thrive in an environment of constant change.

Battery Module, Battery Pack, and Power Electronics Internship (Gigafactory 1)

Responsibilities:

Position will support material failure analysis, material process development, and material validation of polymeric materials and adhesives for battery module, battery pack and power electronics systems at the Tesla GigFactory in Sparks, NV (Reno). Typical tasks include: Performing failure analysis on materials. Preparing test samples, coordinating testing with internal and external test sources, and personally executing tests. Characterizing optimal processing conditions and parameters for adhesives. Collecting and analyzing data from material suppliers, Collecting, analyzing, and presenting data to peers and management, Researching potential solutions to problems.

Qualifications:

Pursuing a degree in Materials Science, Materials Engineering, Polymer Science, Polymer Engineering, or Mechanical Engineering with a Materials or Processing Focus. Good understanding of electrical, physical, and chemical characteristics of materials. Experience characterizing the following material properties: Tensile/Elongation, Impact performance, Rheology, Dielectric properties, Arc Tracking behavior, Thermal and electrical conductivity/resistance, Adhesion, Flammability resistance, UV stability, Creep Resistance, Hydrolytic Stability. Familiarity with the following polymer/elastomer/adhesive families: Polyamides, polyesters, polycarbonates, polyolefins, silicones, polyurethanes, TPEs, epoxies, urethanes, acrylics, silicones. Experience with standard test procedures (ASTM, ISO, DIN, SAE etc.). Strong hands-on problem solving skills. Experience with tools, mechanical equipment, test equipment. Ability to thrive in an environment of constant change. Experience in a manufacturing environment.

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