7451 Oakmeadows Drive Worthington, Ohio 43085 | (614) 847-9410

Company Profile & History

MicroWeld Engineering, Inc. is a small privately held business located in Worthington, Ohio. We have been in the same location since 1988.
Our customers range from aerospace suppliers and jet engine manufacturers to local customers specializing in unique markets. We have a full aerospace certified quality assurance program that includes all necessary quality documentation, travelers, shop routers, NIST tracability, inspections, and welder certs to meet any tough standards you demand. The impeccable quality we hold ourselves to is the life blood of our company.

We began life as a company in the late 1980's. A few engineers recognized a need in the welding community that was not being addressed. This need was for an economical cutting tool for manufacturing airplanes. The good cutters worked but were very expensive. Less expensive cutters didn't leave the surface finish or have the work life that was desired.

These engineers got together, formed a company, and developed a welding system, procedures, and tooling for turning cheap cutters into great cutters. This new system, all controlled by a computer, very precisely welded great material on the edges of large cutters. After grinding them back to their original size, these cutters outlasted and outcut the brand new expensive cutters. This is how our company began it's life.

As our customers were, primarily, aerospace manufacturers, we got the opportunity to see other needs in this exciting jet engine world. One of the needs we saw was for another welding process. A welding process that would be very unconventional as it had to weld on materials that were considered to be "unweldable". These alloys, used in the hottest sections of today's jet engines, would always crack after welding them with any conventional welding process including high tech LASER or Electron Beam welders. Called grain boundary liquation micro-cracking in the heat affected zones, these cracks are very small. However, they will grow to bigger cracks when the engines are put into service. This is unacceptable. Ergo, this family of jet engine superalloys was considered to be unweldable.

We tackled the challenge. By 1990, we had developed a prototype welding process. Still unnamed, it worked. There were still some glitches particularly with it's slow welding speed, but it worked. This process, which we call MicroMIG, has become our bread and butter. Upon successful completion of our initial development program, this process was tested and approved for repairing gas turbine engine flight hardware. MicroMIG-repaired turbine engine components have been flying in military and commercial engines since the early 1990's.

Since the early 1990's, we have constantly made improvements to our MicroMIG(TM) process by both increasing it's welding speed and in developing methods and tools for welding in some very difficult places on complicated parts. Today, there are no areas on most gas turbine engine vane rings or other very complex components that we cannot weld because of accessibility constraints.

In the early 1990's, we developed an offshoot to our MicroMIG process that we called T-REX. As the name implies, T-REX is used for adding strength to a surface. This strength comes in the form of a very hard layer that can exceed Rc70. The surface finish is also unique. We figured out how to weld these hard layers down while leaving a surface that can be as smooth as emery cloth or as rough as course sandpaper. This opened the door for new applications that, even today, are not fully exploited. We are constantly finding new ways to help our customers with this unique welding process.

Due to the entrepreneurial way we approach old problems with new solutions, we were asked to assist in a unique welding problem for our defense industry. Our newest fighters, the YF22, have nozzles in their tails that direct the flow of the engine exhaust up and down. That's right, the hot exhaust gasses are directed not just rearward but at rearward angles up or down to help with the planes maneuverability. The mechanism to do this is called a Vectored Thrust Nozzle (VTN) and has a very unique lining to protect it from the fiery flames of the exhaust gasses.

We developed the welding procedures using a fairly conventional process, called micro-plasma arc welding process (M-PAW), to successfully weld the lining pieces together. Our procedures worked so well, that we were asked to help with another, more unconventional, welding problem for the same VTN assembly. This last chunk of our assistance was part of a classified program (part of the secrets of why our YF22 worked so well) so we cannot share details with you. Suffice it to say that our assistance was so appreciated that we were asked to fabricate the actual large automated welding systems for both of the welding processes that were to be used to make the YF22's liners including all the tooling to hold all the pieces during welding.

We were a small company, and a project of this size was big, financially. So we teamed up with a large welding systems integrating company. Together, we produced the welding systems. MicroWeld Engineering manufactured the computer controls, wrote the software, manufactured the tooling, and integrated the computers and software into the large mechanical frames, motors, and welding packages provided by the systems house. For years, these machines made assemblies for our armed forces F/A 22 fighter planes.

Since our inception, we have helped companies solve welding problems. Using our very unconventional MicroMIG or T-REX processes or our more conventional Gas Tungsten Arc Welding (GTAW) and Micro-Plasma Arc Welding (M-PAW) systems, we have saved our customers tens of millions of dollars. Our unique technologies have been instrumental in salvaging thousands of very expensive parts while assisting in the production of new parts and assemblies that continue to operate today. We are recognized as a welding engineering company with very unique expertise and technology. If you've got a tough welding challenge, a mismachined expensive part or assembly, an unweldable alloy that needs repaired, or just need a another pair of very experienced eyes to offer a new solution, give us a call. We'd love to help!