New Guide Highlights Successful Integration of Automated Inspection for Manufacturers

AUTOMATED INSPECTION FOR GREATER MANUFACTURING PRODUCTIVITY_Page_1Companies that incorporate automated inspection into their manufacturing processes see benefits that include increased accuracy, faster response times, and reduced risk. Now, with new developments in technology innovation, these benefits are achievable across a wider range of applications.

EWI’s new eguide, Advancements in Automated Inspection: Three Case Studies, explores three such breakthrough applications in automated inspection. Topics of these success stories include:

  • Automated inspection process development
  • Multi-sensor integration
  • Automated data analysis

Download the eGuide

If you would like to learn how EWI can help your company be more competitive with customized machine vision solutions, contact Ron Brown at 716.710.5530 or rbrown@ewi.org.

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Welcome to New EWI Member Optonicus

Capture1We are pleased to announce that Optonicus is a new member of EWI. The company, headquartered in Dayton, Ohio, is focused on the research, development, and marketing of intelligent optical systems used by commercial and government organizations. The company’s INFOCO product family of intelligent fiber collimators and arrays is used to improve performance for atmospheric imaging, laser communications, laser target tracking, directed energy, and remote sensing applications.

 

 

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STC Projects in 2017 — Focus on Inspection of Dissimilar Metal Welds

STCThe EWI Strategic Technology Committee for Oil & Gas (STC) is beginning a new project to evaluate the relative accuracy and reliability of nondestructive evaluation methods for the inspection of dissimilar metal welds (DMWs). This work is important as the oil and gas industry is increasing its use of corrosion-resistant alloys. While radiographic testing can reliably detect volumetric flaws, its ability to detect sharp flaws such as hot cracks is dependent on their orientation. Phased-array automated ultrasonic testing systems offer improved flaw detection and sizing accuracy; however, the process requires more skilled personnel and its use with DMWs can be challenging.

Xsection nickel-based-alloy girth weld on clad pipeAdditional upcoming projects include assessment of the brittle fracture resistance properties of welds in seamless pipe operating just below the system’s design temperature, and the creation of guidelines for engineering critical assessment (ECA). The latter will include outlines of various ECA approaches as well as guidance on how to effectively implement results.

To learn more about current STC projects, download the recently published report, “EWI Strategic Committee for Oil & Gas: Research for 2017.”

For more information about EWI’s work with the oil and gas industry, click here.

 

 

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Medina is Co-author of New Book on Metals Additive Manufacturing

Capture1Congratulations to EWI Technology Leader Frank Medina on the publication of  the new book ADDITIVE MANUFACTURING OF METALS: THE TECHNOLOGY, MATERIALS, DESIGN AND PRODUCTION.  Co-authored by a team of additive manufacturing (AM) specialists from both academia and industry, this comprehensive volume is designed to serve as both a textbook for students and a resource guide for practitioners.

frank-medina-speakingFrank Medina, world-renown for his expertise on the subject, currently manages AM activities at EWI and serves as the director of the AMC, a national consortium of industry, government, academic, and non-profit research organizations.

For more information about the book, visit click here. To learn more about EWI ‘s program, visit ewi.org/technologies/additive-manufacturing.

 

 

 

 

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A New In-process Monitoring Technique for Laser Powder Bed Fusion

Figure 1: Post process scans of parts with notches simulating tight cracks and holes simulating porosity

Figure 1: Post process scans of parts with notches simulating tight cracks and holes simulating porosity

An EWI innovation team led by  Evgueni Todorov has successfully developed, integrated, and demonstrated a prototype electromagnetic/eddy current (EC) system for layer-by-layer monitoring of  metal additive manufacturing (AM) processes. This system can be adapted to monitor any metal AM process where the material is deposited using a layer-by-layer technique. This technology was developed as part of a research effort to demonstrate the application of electromagnetic and eddy current techniques at all fabrication stages of AM, including (1) evaluation of feedstock (e.g. powder), (2) real-time monitoring during fabrication, and (3) post-process examination of built parts. The demonstration was conducted using EWI’s open-architecture laser powder bed fusion (L-PBF) AM test bed, which was built with funding from the National Institute of Standards and Technology (NIST) to develop, optimize, and test new techniques and tools for real-time process monitoring of L-PBF.

Figure 2: Post process scans of parts with notches simulating lack of fusion with depths of 0.04 mm and 0.12 mm.

Figure 2: Post process scans of parts with notches simulating lack of fusion with depths of 0.04 mm and 0.12 mm.

During the demonstration, process parameters were changed to create discontinuities within the build structure. The system reliably detected and imaged intended and unintended discontinuities and irregular surface conditions using a layer-by-layer approach. Subsurface discontinuities were also detected. This technology has great potential for the development and implementation of real-time AM process control.

To learn more, contact Evgueni Todorov, NDE Technology Leader, at etodorov@ewi.org.

 

 

 

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Liebherr Mining Equipment Joins EWI as New Member

Capture1We are pleased to welcome Liebherr Mining Equipment Newport News Co. to EWI membership. Founded in 1995, this division of the international Leibherr Group manufactures large machines for the extraction of raw materials in open-cast mining environments.

 

 

 

 

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Development of Intelligent Servo-Controlled Forming Technology — New Paper

EWI forming centerDesigners are adopting new high-performance alloys to create innovative and reliable products while simultaneously reducing cost; however, forming these unique materials can be challenging. As a result, U.S. manufacturers require new forming approaches to stay globally competitive. To address this need, the EWI Forming Center is developing an intelligent servo-controlled forming process that integrates nondestructive evaluation (NDE) techniques, real-time data acquisition, visual monitoring, and computer-aided engineering (CAE) simulation to develop a process-optimizing control algorithm. This new process is expected to yield multiple benefits, including increased productivity, real-time parameter adaptation to material property variations, and an improved understanding of the formability limits of these new alloys.

kim-cropHyunok Kim, Director of the EWI Forming Center, has written The Development of Intelligent Servo-Controlled Forming Technology to discuss the EWI Forming Center’s work to develop an intelligent servo-controlled forming process that will leverage nondestructive evaluation (NDE) techniques, real-time data acquisition, visual monitoring, and computer-aided engineering (CAE) simulation to develop a process-optimizing control algorithm. To read the paper, click here.

For learn about EWI’s activities in materials forming, click here.

For more information about the EWI Forming Center, click here.

 

 

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Innovate and Succeed with EWI’s Advanced Manufacturing Implementation Strategy

Is your company looking to advance its manufacturing processes to become more competitive? Do you want to integrate new technologies but aren’t sure how to get started?

EWI is pleased to present a new offering to our customers, the Advanced Manufacturing Implementation Strategy service. This comprehensive program, also known as AMIS, helps forward-looking manufacturers evaluate their current operations, identify their innovation goals, and develop a systematic plan to achieve success in a rapidly changing economy.

amis3AMIS was created in direct response to our clients’ requests for external, unbiased advisement on incorporating technology intelligence into their business planning efforts. An AMIS engagement starts with our team spending time on your production floor conducting an assessment of your operation. Using all the information gathered on-site, we thoroughly analyze your current state before returning to conduct a visioning exercise with your team. The reality of the current state and the aspirations of your future are brought together in the third phase of the project – a full gap assessment with suggested ways to address opportunities and challenges. The  project culminates with the delivery of a roadmap — a written blueprint with key technology recommendations (including the anticipated impact of each one) and a proposed implementation timeline.

EWI is uniquely qualified to provide this advising-to-implementation service to manufacturers. For more than 30 years, we have been one of the top industrial consultancy organizations helping manufacturers optimize operations, improve products and processes, develop and deploy cutting-edge technology, and compete effectively in an increasingly competitive global market. We offer premium custom solutions to deliver game-changing results to companies throughout the world.

For a detailed description of EWI’s Advanced Manufacturing Implementation Strategy, visit ewi.org/AMIS. If you are interested in initiating an AMIS engagement today, contact Michael Ulbrich at mulbrich@ewi.org.

 

 

 

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Advanced X-ray Inspection Techniques for Electronic Devices — New Paper

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Digital radiography and computed tomography (CT) are powerful imaging tools that allow manufacturers to assess the quality of their products after final assembly. Bak USA, a manufacturer of ruggedized laptops and tablets, engaged EWI with a need to understand which technology would be most appropriate to assess the final build quality of their hardened hand-built products. EWI used both techniques to analyze a tablet with manufactured defects representative of the most common issues seen during quality checks, as well as a defect-free device. Based on these analyses, EWI recommended a real-time nondestructive evaluation technique that will allow Bak to ensure that their products will consistently meet their stringent quality standards.snip Kitt Lee

EWI Associates Alex Kitt and Chris Lee have written “Advanced X-ray Inspection Techniques for Electronic Devices” to discuss the challenges, analyses, and recommendations  in this case. To read the paper, click here.

To learn about EWI’s work in digital radiography and CT, contact Alex Kitt at akitt@ewi.org.

To find out how EWI can help your company develop and implement a strategic roadmap to improve your operations and advance your products, click here for information about our Advanced Manufacturing Implementation Strategy program.

 

 

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