EWI, Buffalo Manufacturing Works Featured in 3D METAL PRINTING Magazine

3d-metal-printingAn article in the Summer 2017 issue of 3D METAL PRINTING, “Spearheading AM Technology & Powder R&D,” shines the spotlight on Buffalo Manufacturing Works and the groundbreaking work being accomplished there by EWI’s additive manufacturing specialists. The AM team, under the guidance of EWI Technology Leader Frank Medina, plays a leading role in developing in qualifying new metal powders and developing build parameters for manufacturers using the technology. To read the article about this and other innovations in AM technology being developed at Buffalo Manufacturing Works, click here.squarish logo bmw

For more information about EWI’s full suite of AM capabilities and services, contact Frank Medina, Technology Leader, at fmedina@ewi.org.






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Use of Design of Experiments (DOE) Methods in Materials Joining Research

Design of Experiments (DOE) methods have been used as a tool for industrial research for many decades. These methods allow empirical correlation between defined input data factors and any number of responses from the process of interest.  For example, in resistance spot welding input parameters might be current, weld time, and force. Responses would then be weld diameter, nugget penetration, joint shear strength, etc.  The experimental designs themselves are essentially input factor combination arrays. These arrays are used to map process response using relatively simple linear equations. Designs are selected to provide differing resolution of the resulting correlations between input and response factors. Designs commonly include two levels of each factor. These are configured so there are equal numbers of high and low levels for each factor included. Analysis of these designs is based on averaging the response from two data subsets (high and low for each factor) and comparing the results statistically. An example is shown in Figure 1 below. Correlation is established by comparing means and standard deviations for these two data sub-sets. This allows identification of any correlation as well as an average response magnitude. EWI has used these methods in hundreds of programs to assist in interpreting process capability. EWI’s methodology includes first establishment of the most efficient experimental design, data collection, normalization of the resulting datasets, regression curve fitting, and development of process robustness plots.  An example process robustness plot for capacitive discharge welding of an automotive suspension component is provided in Figure 2.

DOE for Joining - figures _Gould

The plot shows changes in weld strength as a function of power supply type as well as process and manufacturing factors.  The response is optimized to the values on the right side of the plot.  Of note, the application represented is sensitive to only changes in the power supply type (here from a CD to a frequency converter system)  All other factors have very limited influence on joint strengths.  The plot indicates a process that would be quite robust in a manufacturing environment.

At EWI, the techniques have been used to investigate applications incorporating the breadth of process technologies available at EWI, as well as a comparable number of material systems.  The techniques remain a powerful research and development tool, particularly for complex applications with a wide range of input factors and physical experimentation might be costly.

Jerry Gould, EWI Technology Fellow for Resistance and Solid-state Welding, can be reached at jgould@ewi.org.




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Increasing Weld Penetration with Unique Process Can Improve GTAW

Ian Harris, EWI Technical Director of Aerospace Solutions, recently published an article titled Detailing DeepTIG: How Increased Weld Penetration Can Improve GTAW ResultsCo-authored with Yehuda Baskin and Philip A. Baskin, the article appears in the July-August 2017 issue of Practical Welding Today.

detailing-deeptig-1500900990A patented process called EWI DeepTIG uses specialized metal oxides to increase weld penetration in gas tungsten arc welding (GTAW). It uses proprietary oxide formulations which, when applied to the surface of the workpieces to be joined, increases weld penetration and consequently enhances process productivity. It has been shown to improve weld penetration in GTAW by up to 300 percent.

To learn about the benefits and applications of EWI DeepTIG for GTAW, click here to read the full article.

EWI’s Ian Harris can be contacted at iharris@ewi.org.





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New article: Understanding Collaborative Robot Safety

Ron and CobotThe introduction of collaborative robots (cobots) into the marketplace brings new standards for safe interaction with this new robotic technology.   Cobot safety starts with understand the collaborative application and what technology is required to meet the safety needs.  Once the technology is determined then a methodical risk assessment is done and the correct standards are followed to reduce the safety risk in the work cell.

A new article by EWI Senior Engineer Mike Garman, Understanding Collaborative Robot Safety, provides an overview of what standards apply to collaborative robots, an example of the risk based assessment process flow and a brief summary of the new collaborative robot technical specifications that will help ensure the safe deployment of this new technology.

To download Understanding Collaborative Robot Safety, click here.

Mike Garman can be reached at mgarman@ewi.com.






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Servotronics is New EWI Member

ServotronicsEWI is pleased to welcome new member  Servotronics, Inc. Based in Elma, NY, the company manufactures, designs, and develops high-quality components, systems, and sub-systems. The products include servocontrol valves, torque motors, actuators, pressure regulators, metallic seals, and many other products which are used in applications for space, military, and commercial aircraft; helicopters; ground vehicles; test equipment; medical devices; and precision controls of all types.




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EWI’s Jerry Gould to speak at GALM on August 23rd

headshot gouldJerry Gould, EWI Technical Fellow for Resistance and Solid-state Welding, will be a featured speaker this month at the 6th Annual Global Automotive Lightweight Materials (GALM) Summit in Detroit. His presentation, Joining As An Enabling Technology For the Manufacture of New Generation Lightweight Automotive Structures, will cover the following:

  • Technical challenges in welding of new generation materials for vehicle construction
  • Capable processes for dissimilar materials joining
  • Methods of assessing joint structural performance
  • Process instrumentation and strategies for quality assurance

Jerry has been on the senior technical staff at EWI since 1985. His major area of expertise is resistance spot welding of sheet steels. His research has focused on all aspects of resistance and friction based technologies, with particular interest in application to lightweight materials structures. Jerry is also a member of the LIFT (Lightweight Innovations for Tomorrow) technical leadership team, and currently serves as LIFT’s Pillar Leader for Joining and Assembly.

GALMIf you are attending the 6th GALM Summit, you are invited attend Jerry’s presentation on Wednesday, August 23, at 2:25pm. A Q&A session will follow at 2:45.

To learn more about EWI’s activities and innovations for lightweighting, please visit come to see us at Booth 38, Ballroom B, at the GALM Exhibitors Showcase. Jerry and EWI Director of Marketing & Product Development Jon Jennings will be happy to speak with you. To set up a meeting with Jerry or Jon prior to the GALM Summit, contact jgould@ewi.org or jjennings@ewi.org.





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