New Program in Western New York Aims to Accelerate Growth for Small and Medium-Sized Manufacturers

AMPPD blog2Most small and medium-sized manufacturers recognize that to achieve growth, it is important to stay ahead of the innovation curve, to continue to improve efficiencies, and to keep investing in advanced technology. Yet, many companies lack the bandwidth and budget necessary to address these things as quickly or easily as they’d like – particularly in an organization where it is necessary to wear a lot of hats.

To help these manufacturers address the technology innovation and advancement issues that are so key to staying competitive, Buffalo Manufacturing Works (operated by EWI) has joined forces with Insyte Consulting and Next Street to introduce a new program in Western New York called Shift. Shift provides valuable consulting services to small and medium sized manufacturers at no cost to them, to help them:

  • Assess innovation readiness
  • Evaluate business risks and opportunities
  • Review production processes with an on-site engineering consultant
  • Learn about new technologies and best practices
  • Boost competitiveness with the help of a professional business team

Want to learn more?

See how the Shift process works
Ready to get started now? Register today.

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How to Develop Additive Manufacturing Process Parameters for Your Product

AMPPD blog1There is no “machinist handbook” for creating products with metal additive manufacturing (AM). With seven distinct AM process categories, an expanding base of compatible materials, and a wide range of process inputs, there is no one-size-fits-all way to figure out the right process parameters for a part.

How can manufacturers get the help they need to determine the best process parameters for their metal 3D printing applications? EWI is pleased to offer its new Additive Manufacturing Process Parameter Development service to help clients formulate unique process parameter sets for their products.AMPPD blog2

How does it work? The EWI team uses a step-by-step approach to help you select the optimal parameters:

  • Set your product requirements and understand the trade-offs
  • Select your AM process
  • Modify your design for the process
  • Select and qualify your feedstock
  • Select your process parameters and understand the trade-offs
  • Validate your process parameters
  • Help you identify a partner to print at scale (if required)

Why EWI? As a leading AM technology developer for more than a decade, the EWI team is uniquely qualified to offer AM Process Parameter Development services. Our expertise covers all seven ASTM F42 process categories and is backed by state-of-the-art AM equipment in our laboratories. EWI has operated the broad-based Additive Manufacturing Consortium since its founding in 2010, and has recently been awarded the ASTM AM Center of Excellence in partnership with Auburn/NASA.

Do you need help developing AM process parameters for your application? Click here now to contact our team or get more information, or contact John Conway at jconway@ewi.org.

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EWI Welcomes New Member Gyeongbuk Technopark

GTechnopark 1Gyeongbuk Technopark serves as a hub of industrial growth and support for small and medium enterprises in the province of Gyeongbuk, South Korea. In addition to their current R&D, corporate support services, and startup support, Gyeongbuk aims to create new manufacturing industries while advancing business operations in cooperation with the region’s universities and research institutions.

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“EWI Awards” presented to students at Ohio Academy of Science’s State Science Day

EWI was once again excited to sponsor the “EWI Award” for outstanding student projects in the field of materials science and engineering at the Ohio Academy of Science’s State Science Day competition on May 12, 2018. The annual event, held this year at The Ohio State University’s French Field House (near EWI headquarters in Columbus), brings together students with top science and engineering projects from all over the state.

EWI volunteers evaluated approximately 120 projects this year in two grade categories, 7th– 9th, and 10th-12th. In addition to receiving the EWI Awards, the high school awardees receive college scholarships from the State of Ohio.

The 1st prize winner in the high school division was Isabelle Davis, a tenth grader from St. Vincent-St. Mary High School in Akron. Isabelle’s project examined 3-D printing of combinations of polymers. Second and place winners were Swati Bhageria (Sycamore High School, Cincinnati) and Grace Elhindi (Beaumont School, Cleveland Heights).

Audrey Margaret Zorman, a ninth grader from Beaumont School (Cleveland Heights), won 1st prize in the junior high division. Her project involved electrically conductive polymers for use in wearable electronics. Rayanne Mustapha (Bounty Collegium, Sylvania) and Molly Noel Groeschen (St. Columban School, Loveland) placed second and third, respectively.

State Science Day judgesEWI principal engineer and judging chairperson, Bill Mohr, thanked each of his EWI volunteer judges “for dedicating their time and effort to an event that helps inspire and reward the next generation of engineers and scientists.” EWI judges included: Hilary Johnson, Charlie Drews, Lance Cronley, Seth Shira, and Lindsey Lindamood, as well as three other volunteers who have judged before: Barb Christel, Joshua Emerick and Greg McMahon.

For more information, including a complete roster of participating students and sponsored awards, please visit www.ohiosci.org/ssd/.

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Warm Forming of High-Strength Aluminum Automotive Structural Parts — New Paper

Warm-forming success story HKThe automotive industry faces increased challenges to produce vehicles that meet the demands of the consumer while improving performance, fuel consumption, and emissions. Lightweighting structural components with sheet metal made of materials like high-strength aluminum (HSA) can help meet new standards and requirements.

EWI Forming Center and 12 industry partners recently completed a joint industry project to test and engineer forming solutions for automotive lightweighting. The project goal was to develop advanced and practical warm forming technology for high-strength aluminum (HSA) automotive structures. The project focused on an economical method of warm forming aluminum. The team’s work produced new design guidelines for a cost-effective warm-forming solution for aluminum alloys.

Hyunok Kim, Director of the EWI Forming Center, has written a new paper, Warm Forming of High-Strength Aluminum Automotive Structural Parts: A Success Story, describing the work and outcome of the joint industry project. To read the paper, click here.

To learn more about the activities of the EWI Forming Center, visit ewi.org/ewi-forming-center or contact hkim@ewi.org.

Project team at EWI Forming Center

Project team at EWI Forming Center

EWI Forming Center

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EWI Welcomes AAM to Membership

AAM

AAM has joined EWI as a new member. Headquartered in Detroit, the company operates at more than 90 facilities in 17 countries providing design, engineering, validation and manufacturing of driveline, metal forming, powertrain, and casting technologies for automotive, commercial and industrial markets.

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EWI Capabilities to Support the Midstream Pipeline Industry — New Paper

Burst test specimenSince our founding in 1984, EWI has supported the midstream pipeline industry through developing nondestructive examination tools, specialized testing and computer modeling approaches to support construction, repair, and integrity assessment of critical pipeline systems, materials engineering, and welding process expertise.

EWI Senior Technology Advisor Tom McGaughy has written EWI Capabilities to Support the Midstream Pipeline Industry which outlines recent work to improve methods for predicting failure of corroded pipelines. This paper highlights advanced computer modeling and full-scale testing efforts that have reduced the scatter and bias in current failure prediction methodologies.Burst test digital image scan

To view EWI Capabilities to Support the Midstream Pipeline Industry, click here.

To learn more about EWI’s work in the oil and gas industry, visit ewi.org/industries/oil-gas.

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Ultrasonic Metal Foil Additive Manufacturing Explained

Ultrasonic metal foil additive manufacturing is a technology that was pioneered by Fabrisonic, an affiliate of EWI. It uses ultrasonic welding to build up metal parts layer by layer – a low-temperature, solid-state process that can produce 3D-printed parts as large as 6’ x 6’ square.

Recently, Fabrisonic President Mark Norfolk gave a terrific explanation of ultrasonic additive manufacturing (UAM) and its advantages in an interview at the RAPID + TCT 3D printing event in Fort Worth, Texas.  A short video of his conversation with James Anderton can be viewed on engineering.com.

Norfolk Rapid interview Ultrasonic Metal Foil Additive Mfg

To learn all about the UAM process and its advantages, watch the interview now.

To reach Mark Norfolk at Fabrisonic, contact mnorfolk@fabrisonic.com.

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EWI Welcomes Federal-Mogul as New Member

Federal-Mogul logoEWI is pleased to welcome Federal-Mogul LLC as a new member. The global supplier of products and solutions to manufacturers of automotive, light commercial, heavy-duty and off-highway vehicles, as well as in power generation, aerospace, marine, rail and industrial, operates with two business divisions. Federal-Mogul Powertrain focuses on original equipment powertrain products for automotive, heavy-duty and industrial applications, and Federal-Mogul Motorparts sells and distributes a broad portfolio of products in the global vehicle aftermarket, while also serving original equipment manufacturers with vehicle products including brake friction, chassis, wipers and other components.

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Advancements in EWI DeepTIG™ for Higher Productivity GTAW – New Paper

EWI DeepTIG™, developed through the Navy ManTech Program in the 1990s, increases productivity during gas tungsten arc welding (GTAW) by enabling simplified joint preparations and reduced number of passes. It is classified by the American Welding Society as a penetration enhancing flux with many user benefits. GTAW welds made with EWI DeepTIG are typically produced in a single pass on square groove butt-joints with base material thickness up to 3/8-in thick.Image for blog

For some time, EWI DeepTIG has been available in specialized flux formulas for carbon steel, stainless steel, and nickel-based alloys. Now, a more user-friendly version of the product, EWI DeepTIG wire, is also available and can be used like any other welding filler metal. The advantage is that penetration can be increased 250%-300% compared to conventional welds made with solid wire.

EWI DeepTIG wire has been validated by work that EWI has performed for the National Shipbuilding Research Program (NSRP) to improve the productivity of pipe welding in U.S. shipyards. This work is discussed in a new paper by EWI Senior Engineer Nick Kapustka, Advancements in EWI DeepTIG™ for Higher Productivity GTAW.

To view this paper, click here.

To order or learn more about EWI DeepTIG products, contact nkapustka@ewi.org.

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