Manufacturing Success Stories: Shift Program Marks Its First Anniversary

Shift,
a program based at EWI’s Buffalo Manufacturing Works,
is designed to help small and medium-sized manufacturers improve their
operations and competitiveness by identifying and investing in critical
technology. Having just completed its first full year, Shift has
already made a significant impact on manufacturing community in Western New
York state. The program has helped manufacturers not only implement new
technology into their operations, but also examine their business holistically
with an eye toward the future.

In the past year, Shift has engaged with more than 80 small and medium-sized enterprises to make them more strategic and confident about their future success. You can hear directly from leaders of some of these companies in this short video.

To learn how Shift can help your business succeed and grow in today’s competitive landscape, visit shiftmfg.com. To register for an initial, no-cost Shift business assessment, click here now.

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New paper — GMAW-P Welding of Copper-nickel Pipe Joints for Shipbuilding Applications

Virtually all ship designs utilize copper-nickel alloys for applications such as fire mains and other seawater/freshwater piping, tanks, and structures such as rope guards and fairings. The manual gas tungsten arc welding (GTAW) process that is typically used to weld copper-nickel pipe joints has relatively low productivity due to slow travel speeds and low deposition rates. The implementation of pulsed gas metal arc welding (GMAW-P) can yield significant productivity benefits for semi-automatic, mechanized, and robotic applications through faster travel speeds and increased deposition rates.

EWI has recently demonstrated the feasibility of semi-automatic and robotic GMAW-P for all-position welding of copper-nickel pipe joints for welding in both the pipe shop and onboard the ship. Engineering Group Leader Nick Kapustka and Business Development Director for Government Programs Paul Blomquist present this work in a new paper, GMAW-P Welding of Copper-nickel Pipe Joints for Shipbuilding Applications. The findings show that by combining advanced GMAW welding systems with optimized welding procedures, the barriers that have historically limited the use of the GMAW-P process for copper-nickel pipe joints were overcome, with significant gains in productivity.

To view/download GMAW-P Welding of Copper-nickel Pipe Joints for Shipbuilding Applications, click here.

To contact the authors of this paper, email nkapustka@ewi.org or pblomquist@ewi.org.

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New Paper – Joining Challenges in the Manufacture of Motors for Electric Vehicles – Stator Winding Assemblies

Stator windings in traction motors for electric vehicles are created by joining multiple short copper wire sections. Current joining approaches for these multiple copper wire sections lack the productivity for high volume manufacturing, require an increased amount of copper for assembly, and risk reduced joint strength due to softened copper from extended thermal cycles.

In his new paper, Joining Challenges in the Manufacture of Motors for Electric Vehicles – Stator Winding Assemblies EWI Technology Fellow Jerry Gould discusses two emerging technologies for stator winding assembly: resistance-forge and capacitor discharge welding.

To learn how these emerging technologies can increase productivity, reduce thermal cycles, and increase strength in joining for stator windings, download the paper here.

To learn more about
EWI’s work in resistance welding for vehicle electrification, please contact
Jerry Gould at jgould@ewi.org.

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ASTM International Additive Manufacturing Center of Excellence to Host First Workshop

The ASTM International Additive Manufacturing
Center of Excellence will host its first workshop on Monday, March 25 at the
Auburn Marriott Opelika Resort & Spa at Grand National in Alabama, USA. The
workshop immediately precedes the biannual meeting of ASTM International’s
committee on additive manufacturing technologies (F42).

“There is a critical demand from industry and
others involved in additive manufacturing technologies to understand the entire
value chain as well as how standardization is helping ensure quality and
reliability,” said Dr. Nima Shamsaei, Auburn University. “This workshop helps
meet that need.” 

Specifically, the workshop will focus on key
steps in the value chain, including:

  • Feedstock,
  • Design,
  • Materials and processing,
  • Post-processing,
  • Non-destructive evaluation and inspection,
  • Qualification and structural integrity, and
  • Standardization and certification

The 12 interactive sessions – led by key
experts – will help address the growing needs of key industries such as
aerospace, defense, medical, and auto. Discussions will also address some of
the gaps in standardization and workforce development related to additive
manufacturing technologies. 

“The workshop emphasizes the role and value
of standardized practices in accelerating product qualification and
certification for additive manufacturing,” said Dr. Mohsen Seifi, ASTM
International’s director of global additive manufacturing programs. ”Notably,
participants will learn about the latest standards development activities as
well as the center’s efforts to support targeted R&D projects that help
address those gaps.”  

This event is designed by center of
excellence partners including: Auburn University, manufacturing technology
innovator EWI, NASA, the UK-based Manufacturing Technology Centre, the National
Institute for Aviation Research, and the National Additive Manufacturing
Innovation Cluster (Singapore). Several organizations such as America Makes,
Innovate UK, and CECIMO (Europe) have provided support for this event. The
workshop is also sponsored by LPW/Carpenter Additive, EOS, and SLM
Solutions.  

To register for the workshop and for more
details, visit http://www.amcoe.org/workshop. On March 1, registration
increases from $300 ($250 for ASTM International members) to $400 ($350 for
members). For more information, contact event chairs Shamsaei (shamsaei@auburn.edu) and Seifi (mseifi@astm.org). 

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