Engineering Welding
Resume:
Daniel R.E. Foster
******.***@***.***
Current Address:
Permanent Address:
Columbus, OH 43221
Swedesboro, NJ 08085
OBJECTIVE
Career opportunity to apply research skills in materials joining, additive manufacturing and characterization in
order to design, innovate and problem solve critical engineering challenges.
EDUCATION
The Ohio State University, Columbus, OH
Doctor of Philosophy in Welding Engineering GPA: 3.84 Anticipated Graduation Date: May.
2014
Dissertation: “Thermal and Mechanical Characterization of Ultrasonic Additive Manufacturing”
The Ohio State University, Columbus, OH
Master of Science in Welding Engineering GPA: 3.86 Graduation Date: Aug. 2008
Thesis: “Resistance Spot Welding of Dissimilar Metals”
The Ohio State University, Columbus, OH
Bachelor of Science in Welding Engineering GPA: 3.28 Graduation Date: Jun. 2007
RESEARCH PROJECTS
Thermal and Mechanical Characterization of Ultrasonic Additive Manufacturing
• PhD dissertation investigating in-situ along with post consolidation mechanical and
thermal property changes due to the creation of layered metal matrix composites using
ultrasonic energy
• Developed a non-destructive process monitoring technique that can be used to determine
bond quality in-situ in aluminum alloys
• Investigated mechanical and thermal anisotropy due to interfacial bonding defects
Resistance Spot Welding of Dissimilar Metals
• Master of Science thesis investigating material and mechanical properties of resistance spot
welds between super austenitic stainless steel (Al-6XN) and nickel alloys (Hastelloy C-22 and
Inconel 625)
• Developed optimum process parameters as well as performed mechanical and
metallurgical characterization dissimilar welds
Through Transmission Laser Welding of Polypropylene Nanocomposites
Daniel R.E. Foster Page 1 of 4
******.***@***.***
Welding Engineering Program
Dept. of Materials Science & Engineering
The Ohio State University
• Senior project research sponsored by Edison Welding Institute investigating laser welding
(using scanning Nd:YAG laser) of polypropylene nanocomposites for packaging
applications.
• Won 3rd Place in the American Welding Society’s National Undergraduate Research Poster
Competition
Microlaser Welding of Polypropylene Nanocomposites
• NSF (Nationional Science Foundation) sponsored Summer Research for Ohio State
University Welding Engineering Department in exploring the possibilities of using low
power laser welding (diode laser) in producing micro sized hermetically seals between a
polypropylene nanocomposite film substrate for packaging applications
Hybrid Laser Welding of Polymers
• SROP (Summer Research Opportunities Program) sponsored research for Ohio State
University Welding Engineering Department in exploring the applications and feasibility of
hybrid laser welding using a Ti:Sap femtosecond laser and a ytterbium fiber laser to weld
clear plastics
JOURNAL PUBLICATIONS
• D.R. Foster, G.A. Taber, S.S. Babu, G.S. Daehn, In-situ Velocity Measurements of
Ultrasonic Additive Manufacturing Using a Photonic Doppler Velocimeter, Science and
Technology of Welding and Joining (Accepted)
• D.R. Foster, S.S. Babu, M.J. Dapino, Elastic Constants of Ultrasonic Additive
Manufactured Al 3003-H18, Ultrasonics, 53 (2013) 211-218
• D.E. Schick, S.S. Babu, D.R. Foster, M.J. Dapino, M. Short, J.C. Lippold, Transient
Thermal Response in Ultrasonic Additive Manufacturing of Aluminum 3003, Rapid
Prototyping Journal, 17 (2011) 369 - 379.
• M.R. Sriraman, M. Gonser, D.R. Foster, H T. Fujii, S.S. Babu, Matt Bloss, Thermal
Transients During Processing of 3003 Al-H18 Multilayer Build by Very High Power
Ultrasonic Additive Manufacturing, Metallurgical and Materials Transactions B, 43 (2012)
133-144
CONFERENCE PRESENTATIONS & INVITED TALKS
D.R. Foster, Process Monitoring Of Ultrasonic Additive Manufacturing, Invited Talk at the Air
Force Research Laboratory, Wright-Patterson Air Force Base Nov 2013, Dayton, Ohio
D.R. Foster, S.S. Babu, G.S. Daehn, In-situ Velocity Measurements of Ultrasonic Additive
Manufacturing Using a Photonic Doppler Velocimeter, Materials Science and Technology 2012
Conference and Exhibition, Oct. 2012, Pittsburgh, Pennsylvania
D.R. Foster, S.S. Babu, G.S. Daehn, In-situ Velocity Measurements of Ultrasonic Additive
Manufacturing, Solid Freeform Fabrication Symposium 2012, Jul. 2012, Austin, Texas
S.S. Babu, A.G. Troug, S. A. Channagiri, D.R. Foster, X-Ray Tomography of Very High Power
Ultrasonic Additive Manufactured builds, Solid Freeform Fabrication Symposium 2012, Jul.
2012, Austin, Texas
D.R. Foster, S.S. Babu, M.J. Dapino, Elastic Constants of Ultrasonic Additive Manufactured Al
3003-H18, Materials Science and Technology 2011 Conference and Exhibition, Oct. 2011,
Columbus, Ohio
Daniel R.E. Foster Page 2 of 4
******.***@***.***
Welding Engineering Program
Dept. of Materials Science & Engineering
The Ohio State University
D.R. Foster, S.S. Babu, G.A. Taber, G.S. Daehn, Low Velocity Photonic Doppler Velocimeter
Measurements, 6th Annual Photonic Doppler Velocimeter Conference, Sept. 2011, Livermore,
California
SKILLS
Knowledgeable of industry standards and codes including ASTM, AWS (In-depth knowledge of D1.1),
API and ISO
Experienced in shielded metal arc welding, gas metal arc welding, flux core arc welding, gas
tungsten arc welding, robotic welding, resistance spot welding, laser welding, polymer welding,
ultrasonic spot welding and ultrasonic inspection
Proficient in metallography (mounting, polishing, optical microscopy and scanning electron
microscopy)
Adept in mechanical testing (tensile, shear, bend and resonant frequency testing)
Proficient with COMSOL, ANSYS and ABAQUS Finite Element Analysis (FEA) software
Skilled with CAD modeling (SolidWorks) and CAM coding (CamWorks)
Skilled with vibrometry and high velocity measurements using a Photonic Doppler Velocimeter (PDV)
Proficient in focusing, aligning, and calibration of laser optics systems
Well versed with Microsoft Office Suite, Matlab, Mathcad and Labview
HONORS AND ACTIVITIES
NASA’s Ohio Space Grant Consortium Fellowship recipient (09/09-09/12)
Nationional Science Foundation’s Graduate STEM Fellow in K-12 Education (GK-12 program)
Fellowship recipient (09/08-08/09)
Ohio State Graduate Enrichment Fellowship recipient (09/07-08/08)
3rd Place in the American Welding Society’s National Undergraduate Research Poster
Competition (10/07)
Member of ASME, AIST and American Welding Society (AWS)
MEP (Minority Engineering Program) Academic Year Award Recipient (09/06)
Participant in Ohio State’s NSEC (Nanoscale Science and Engineering Center) Research program
(06/06- 09/06)
Participant in Glenn-Stokes Research Internship Program (06/05- 09/05) and (06/06- 09/06)
Participant In SROP (Summer Research Opportunities Program) (06/05- 09/05) and (06/06- 09/06)
Builder’s exchange Scholarship recipient (09/06)
OSU Welding Engineering Jackson Scholarship recipient (09/05)
American Welding Society’s Donald Hasting scholarship recipient (09/05)
Recipient of The Ohio State National Buckeye Plus Scholarship (09/02- 08/06)
Member of Ohio State Black Graduate and Professional Caucus (09/07- Present)
Member of National Society of Black Engineers (NSBE) (09/02- Present)
EXPERIENCE
Graduate Fellow and Graduate Research Associate for OSU Welding Engineering Program researching,
“Thermal and Mechanical Characterization of Ultrasonic Additive Manufactured Components” (09/08-
Present)
Graduate Fellow for OSU Welding Engineering Program researching “Resistance Spot Welding of
Dissimilar Metals” (09/07- 08/08)
Daniel R.E. Foster Page 3 of 4
******.***@***.***
Welding Engineering Program
Dept. of Materials Science & Engineering
The Ohio State University
Undergraduate Research Associate for OSU Welding Engineering Program researching “Microlaser
Welding of Polypropylene Nanocomposites” (06/06- 09/06)
Undergraduate Research Associate for OSU Welding Engineering Program researching “Hybrid Laser
Welding of Plastics” (06/05- 09/05)
TEACHING EXPERIENCE
Graduate Teaching Assistant
Welding Engineering 4102 & 7102 (Welding Metallurgy II (SS, Al, Ni, Cu & Ti alloys))
Welding Engineering 4012 & 7012 (Resistance Welding Processes)
Welding Engineering 4201 & 7201 (Engineering Analysis for Design and Simulation)
Elementary School Teaching
o Developed innovative science lesson plans and hands-on experiments to advance science
education in Columbus City Schools as part of NSF’s GK-12 program
o Taught 3rd grade science classes at Lincoln Park Elementary School
o Trained other graduate students in developing lesson plans, classroom management, and creating
hands-on science experiments
o Led professional development meetings with a focus on producing interactive science lessons
and hand-on activities for 3rd grade teachers
Daniel R.E. Foster Page 4 of 4
******.***@***.***
Welding Engineering Program
Dept. of Materials Science & Engineering
The Ohio State University
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