Aerospace, Electrical, IT, Mechanical Engineering Internship 2025 - Tunnel 9

Job Title: Aerospace, Electrical, Mechanical Engineering Internship 2025 - Tunnel 9

Location: White Oak, MD

Function/Branch: Engineering / Tunnel 9

Directorate: Test Operations

Position Type: Casual

Pay Type: Non-Exempt

Grade: A04 - A05

Starting Hourly Rate: $29.42 - $38.48 (*This position qualifies for H&W fringe, as defined in the DoL SCA Wage Determination.)

Overview

Beyond New Horizons, LLC (BNH) has an exciting opportunity for Aerospace, Electrical, and Mechanical Engineering Interns, supporting TOS II, at Tunnel 9 in Silver Spring, MD.

Job Summary

Tunnel 9 is a Geographically Separated Unit (GSU) of a larger organization known as AEDC. Tunnel 9 provides aerodynamic simulation critical to hypersonic system development and hypersonic vehicle technologies at speeds from Mach 7 to Mach 18. Tunnel 9 is the highest Reynolds number, largest scale ground test facility in the world capable of simultaneously collecting continuous pitch polar static force and moment, pressure and heat transfer data during each run.

The BNH Internship Program offers 10-12 week full time summer internship opportunities for undergraduate and graduate students pursuing degrees in engineering. As part of the internship, you are paired with experienced engineers and scientists who serve as your mentor(s) in completing assigned projects gaining valuable experience in your field of study while contributing to the Air Force and BNH mission. You will be required to present a briefing to senior management on work accomplished, lessons learned, and further recommended actions.

Job Duties:

The Tunnel 9 internship is structured such that you are assigned multiple tasks to complete throughout the summer to provide exposure to the variety of types of work conducted at AEDC Tunnel 9. Assignments performed by BHN interns will address true engineering challenges and further the mission of the Air Force and BNH.

Examples of types of tasks interns have worked previously or are planned for this summer include: (these are examples, not an exhaustive list):

Operate and conduct tests in Tunnel 9's R&D Mach 3 tunnel.
• Installation of test article hardware & instrumentation into Tunnel 9 in support of active customer Mach 7-18 testing.
• Validation of test article data acquisition system set-up configuration and nomenclature.
• Pre-test instrumentation integrity checks and model hardware changes between runs.
• Continued development of Temperature Sensitive Paint & IR Thermography.
• Diagnostics and instrumentation development of fast response piezoelectric force balance development and balance calibration software.
• Support of test article boundary layer transition measurements and analysis.
• Develop graphical user interfaces for processing, analyzing, and decoding test article & tunnel facility data.
• Modify or develop hardware and software interfaces between data sources and computer hardware used in integrated data acquisition and processing systems.
• Repair of malfunctioning test article instrumentation.
• Create and modify electrical schematics using AutoCAD.
• Research power load bank systems to determine feasibility of use in emergency generator systems.
• Assist in the field implementation, validation and verification of new or recently modified measurement, data acquisition, and/or controls systems.
• Improve/Add limit indicator to networks and facility HMI screens utilized by operators in the facilities.
• Analyze current optical measurement system and provide recommendations for upgrade of existing analog drive motors with more modern stepper motor technology.
• Modify or develop PLC ladder logic or HMI screens for facility control systems.
• Configure and program Digital Servo Amps or other control system hardware for facility control systems.
• Develop improved system controller interfaces.
• Perform system integration, checkouts and troubleshooting, redline drawings, and improve clarity and quality of work instructions for test cell systems.
• Research and prepare technical documentation and recommendation for operationally feasible dewpoint measurement hardware.
• Develop portable electronic device used for timing and calibration of high-speed camera systems.
• Create 3D models of sub-system components in PTC Creo.
• Design and 3D print fixtures for alignment, installation, and gauge inspections. Design of large hardware carts for assembly work.
• Improve and document 3D printing methods for more accurate prints.
• Refine Heat Transfer Code to work more seamlessly with ANSYS/Creo.
• Material, structural, and thermo-structural analysis using ANSYS.
• Desing hardware for the test cell and test article support for customer testing.
• Update statistics probability failure of High Pressure (20-60,000psi) Vessels.
• Build a servo valve model in MATLAB Simulink.
• Perform field verification of hydraulic units' drawings and perform engineering check of controls schematics.

Minimum requirements for consideration:

• Must be currently enrolled in university and pursuing a degree in aerospace, aeronautics, electrical, mechanical, or mechatronics engineering from an accredited engineering college or university.
• Satisfactory completion of at least two years of study as a full-time student in one of the above listed disciplines at the time the internship begins (at least sophomore status / 45 credit hours completed by May 2025).
• Graduate students are also welcome to apply.
• Minimum GPA of 2.75.
• Resumes must include degree program, projected graduation date, and GPA in order to be considered.
• Ability to work 40 hours each week for 10 to 12 weeks from May to August. This is a full-time position.
• Must have reliable transportation to transport to drive to site (not commuter-friendly).
• Must be a U.S. citizen.
• Ability to obtain security clearance.

Preferred qualifications

• Positive attitude and willingness to receive feedback.
• Self-driven with the ability to seek out requirements with minimal direction.
• Demonstrated intellectual curiosity.
• Demonstrated ability to communicate effectively.
• Desire to work on a team with energy and commitment to the work assigned.
• Adaptable and willing to stretch technically and learn new things.
• Experience with PTC Creo, AutoCAD, ANSYS, Excel, MATLAB, and/or 3D printers.
• Ability to read, create, and modify mechanical drawings and/or electrical schematics.
• Experience with reading wire tables and cable instrumentation.
• Knowledge or experience in PID design.
• Interest in supporting our nation's defense.
• Current security clearance

Who We Are

Beyond New Horizons (BNH) is a fully populated joint venture of Astrion and Fluor Federal Services, Inc. formed to provide unmatched Test Operations and Sustainment services for the Arnold Engineering Development Complex.

We chose our name to serve as an enduring reminder of our commitment to AEDC's rich aerospace research and development legacy anchored in AEDC's Toward New Horizons founding study and the unprecedented opportunities to greatly expand AEDC's capabilities and capacity Beyond those existing today. Leveraging the capabilities of our parent companies, BNH specializes in testing and evaluation for military and space systems combined with proven capability in large-scale Government program management, integration, engineering, and construction services for specialized and technically advanced high-hazard facilities.

Join our Team!

BNH is an Equal Employment Opportunity/Affirmative Action Employer. We provide equal employment opportunities to all employees and applicants for employment and prohibit discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws.