EWI Welcomes New Member NWMO

NWMO 1We are pleased to introduce The Nuclear Waste Management Organization (NWMO) as a new EWI member. The Canadian organization is responsible for designing and implementing Canada’s plan for the safe, long-term management of used nuclear fuel. NWMO has provided technical expertise in support of Ontario Power Generation’s (OPG) efforts to obtain regulatory approvals for a proposed deep geologic repository (DGR). The organization’s vision is the long-term management of Canada’s nuclear waste in a manner that safeguards people and respects the environment, now and in the future.



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EWI Validates New NanoSteel Alloy for Resistance Spot Welding

Dissimilar weld joint between NXG 1200 and DP 980

Dissimilar weld joint between NXG 1200 and DP 980

NanoSteel, which develops advanced high-strength steels (AHSS) for manufacturing, has a new alloy, NXG™ 1200, designed to address the need for weight reduction and safety enhancement in the automotive market. Recently, EWI helped NanoSteel evaluate and validate the weldability of this new sheet steel both to itself and to other commonly used sheet steels.

EWI Senior Engineer Dave Workman has written “Resistance Spot Welding of NanoSteel NXG™ 1200 to Other Materials,” which highlights EWI’s evaluation of this new material and it’s successful validation. To read the full story, click here.

To learn more about EWI’s testing and evaluation services, contact info@ewi.org.




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Ultrasonic-Assisted Drilling of 4340 Alloy Steel — New Article

Tough and resistant to fatigue, 4340 is a high-strength alloy steel that is widely used in the automobile and aerospace industries. Due to its properties, drilling 4340 alloy steel, especially at high material removal rates, has challenges that include heavy thrust force and torque which directly affect tool life, surface roughness, and dimensional accuracy of drilled holes. Therefore, to improve productivity of the drilling process using faster feed rates, these challenges must be addressed.

EWI UAD module

EWI UAD module

 With deep expertise and capabilities in high-power ultrasonics, EWI has developed an industrially hardened, ultrasonic-assisted drilling (UAD) system which applies high-frequency (20 kHz) vibrations at amplitudes of 2-20 µm to the drill tip in the feed direction. This system, which is fully compatible with CNC systems, is able to work with a drill at a shank diameter of up to 20 mm for a variety of materials from aluminum to Inconel and composites.

Studies conducted by EWI’s Amin Moghaddas, Matt Short, and Karl Graff  have demonstrated notable improvements in productivity using the EWI UAD system on 4340 alloy steel. The findings are reported in a new article, Ultrasonic-Assisted Drilling of 4340 Alloy Steel.

To download the article, click here.

To learn more about EWI’s high-power ultrasonic capabilities, contact Matt Short at mshort@ewi.org.

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Advanced Materials Joining and Forming Forum for Auto Industry Hosted Recently by EWI

On October 19, EWI hosted an industry-wide workshop in Detroit to discuss current technical challenges in materials joining and metal forming.  The underlying theme for the workshop was the recently completed NIST-funded Comprehensive Advanced Materials Joining and Forming Technology Roadmap, developed in concert with several joining and forming experts. One objective of the workshop was to gain additional insight from auto industry experts on how relevant the findings from the national roadmap are to current joining and forming needs. A second objective was to identify potential pre-competitive technology development initiatives in joining and forming that would address current needs and provide the U.S. auto industry with new capabilities to enhance productivity, reduce costs, improve reliability and performance, or to achieve other critical business goals.McGaughy Gould Kim

The workshop was moderated by Tom McGaughy, Jerry Gould and Hyunok Kim of EWI. McGaughy opened the workshop by presenting the background to the national roadmap project, outlined the activities that were carried out to identify cross-industry needs in joining and forming, and then briefly discussed seven joining and forming technical priorities that the roadmap indentified as having significant impact on the global competitiveness of U.S. manufacturing operations, including:

  • Development of an advanced distortion control weld system
  • Development of next generation materials formulation and high temperature weld prediction tools
  • Development of advanced high productivity fusion processes
  • Development of joining processes for hybrid materials (mixed metals, ceramics to metals, metal matrix composites to plastics, etc.)
  • Implementation of advanced measurement, prediction and control technologies in forming processes
  • Development of practical warm & hot forming technology for aluminum, titanium and nickel alloys and advanced high strength steels
  • Development of advanced technologies for near net-shape lightweight forgings

Following the background presentations, an open group discussion took place to discuss the roadmap priorities and their relevancy to current automotive challenges. Going forward, EWI seeks to collaborate with the automotive industry on addressing these challenges.

For more information about this initiative, contact Jerry Gould at jgould@ewi.org.




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First Solar joins EWI as new member

First solarWe are pleased to welcome First Solar, Inc., to EWI membership. The company’s North American manufacturing facility is located in Perrysburg, OH. First Solar has developed, financed, engineered, and constructed many of the world’s largest grid-connected photovoltaic (PV) power plants in operation today.




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New Paper — Hybrid Ultrasonic Spot Welding of High Strength Materials

The idea that resistance and ultrasonic processes can be combined into an effective joining method has been around for more than 20 years, but has never been commercialized. With the increasing demand for  lightweight materials in planes and vehicles, however, the resistance-and-ultrasonic concept is under reconsideration. Studies now indicate that this hybrid method could be a superior way to join high strength steels and high strength aluminums efficiently and safely.

EWI recently completed a study comparing the hybrid process to ultrasonic metal welding, focusing on joining aluminum 6061 to itself. Using a prototype ultrasonic-resistive welding apparatus, the hybrid process achieved higher strength welds compared to ultrasonic welding alone. The results of this research are discussed in a new paper by Applications Engineer Lindsey Lindamood, Hybrid Ultrasonic Spot Welding of High Strength Materials. 

To download the paper, click here.

To learn more about EWI’s work on joining high strength materials, contact Lindsey Lindamood at llindamood@ewi.org.

US alone

US plus resistance

SEM images of aluminum welded using 1750W ultrasonic power. The left image had no applied current, while the right image had 10kA applied current.





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EWI Celebrates Manufacturing Day 2017

EWI held two special programs on October 6 to mark Manufacturing Day 2017, a nationwide day of events that highlight the importance of manufacturing in the American economy and workplace.

mfg day Ohio new press ribbonIn the morning, several officials from the State of Ohio visited EWI’s Columbus facility to dedicate our newly installed, 330-ton servo press. In attendance were Stephen White, District Director for U.S. Senator Rob Portman; Rob Nichols, District Director for U.S. Congressman Pat Tiberi; and Mike Dittoe, Chief of Staff for Ohio House Speaker Cliff Rosenberger. The acquisition of the Aida press was made possible through a $1.5 million award from the state’s capital budget fund last year.

mfg day PAST 1Later that afternoon, we were pleased to co-sponsor an event with two local organizations who share our mission to advance American manufacturing through innovation and education. EWI teamed up with Rogue Fitness at the PAST Innovation Lab to talk to students interested in pursuing careers in STEM (science, technology, engineering, or math) fields when they graduate. The Innovation Lab is a state-of-the-art, educational prototyping center that offers unique, hands-on learning opportunities for students of all ages. The event participants, ages 8-18, enjoyed talking to Heimdall Mendoza, an engineer in EWI’s Additive Manufacturing group; and mfg day PAST 2Nick Garcia, Senior Designer at Rogue Fitness, an EWI member company known for its Crossfit equipment.

To see more photos of EWI’s Manufacturing Day events, visit our Facebook page, facebook.com/ewiinnovation.






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OMEGA is New EWI Member

Omega-Engineering-logoWe are pleased to welcome OMEGA Engineering of  Sunbury, OH, to EWI membership. This Ohio branch of OMEGA Engineering, Inc. (Norwalk, CT) supplies pressure and load transducers. Since OMEGA’s inception in 1962, the company has grown from manufacturing a single product line of thermocouples to offering more than 100,000 state-of-the-art products for measurement and control of temperature, humidity, pressure, strain, force, flow, level, pH and conductivity.




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EWI Forming Center Workshop Highlights Advancements, New Capabilities

IMG_2024 - zoomThe annual EWI Forming Center Workshop was held on October 5 at EWI headquarters in Columbus, Ohio. Industry leaders convened to share knowledge and discuss applications, advances, and challenges related to sheet metal forming.

The event, geared largely towards the automotive industry, featured presentations from Honda, Aida, KTH, AK Steel, AMAG, Fuchs, AutoForm, and others. Topics ranged from warm forming high-strength aluminum alloys to the lubrication in forming lightweight sheet materials. Approximately 75  participants attended the workshop.

Forming demo team - zoomThe event culminated with a EWI Forming Center open house featuring live demonstrations. Of particular interest was EWI’s new, 330-ton servo forming press, which was recently funded by a $1.5 million grant from the State of Ohio. The Forming Center team showcased the press’s cold forming capabilities to the visitors. Other demonstrations included warm forming of high strength aluminum alloys, and 3D scanning of formed parts with ATOS for springback measurement.

To learn more about the EWI Forming Center, click here.

For more information on EWI’s forming capabilities,visit ewi.org/technologies/forming.




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