Since introducing its new VDA tight radius testing capability with digital image correlation (DIC) in Winter 2021, the EWI Forming Center has conducted further research test applications of the test on a variety of high-strength materials.
A recent study evaluated test switch-off criteria and applied the results in finite element analysis (FEA). This work is covered in a paper by Applications Engineer Tom Feister, Application of VDA Tight Radius Bend Testing. You may view the paper – for free – by completing the form on this page.
If you are interested in this or other testing capabilities of the EWI Forming Center, please contact Hyunok Kim at [email protected].
Complete this form to download the paper:
The original presentation of this capability, VDA Tight Bend Radius Testing with Digital Image Correlation, can be accessed by clicking here.
To view the paper, please submit the form above.
Want to contact an EWI expert about a project? Call 614.688.5152 or click here.
EWI has recently developed a new method for joining thick steel plate by combining the hybrid laser arc welding and the submerged arc welding processes. The new approach is an improvement over earlier methods on many fronts, and further research is planned to test different materials and thicknesses.
This project is discussed in Co-processing of HLAW & SAW to Enhance Productivity in High Strength Steel Joints by EWI Senior Technology Leader Alber Sadek. You are invited to download this paper, at no charge, by completing the form on this page.
For more information about this work, you may contact Alber directly at [email protected].
Complete this form to download the paper:
To view the paper, please submit the form above.
Want to contact an EWI expert about a project? Call 614.688.5152 or click here.
Recently, EWI conducted a study in which ultrasonic vibrations were applied to the wire drawing process to improve both final wire quality and process performance.
This investigation demonstrated positive results in several areas including wire roughness, dimensional accuracy, microstructure, draw force, and strength. It also reduced the number of die passes required to complete the process.
EWI ultrasonics engineers Amin Moghaddas and Tim Frech discuss this work in Application of Power Ultrasonic Vibrations to Improve Productivity and Quality in Wire Drawing Process. You are invited to download this paper today by completing the form on this page.
If you would like explore the use of this technology for your wire drawing application, contact [email protected].
Complete this form to download the paper:
To view the paper, please submit the form above.
Want to contact an EWI expert about a project? Call 614.688.5152 or click here.
Welding of dissimilar polymers is becoming more commonplace in manufacturing. There are several key reasons for this trend. First, many new plastics are being used in environments where adhesives cannot be easily applied. Typical examples include medical products for which finding adhesives that pass FDA regulations and join materials with low surface energy (like polyolefins) is very challenging.
Dissimilar polymers are also joined in many highly engineered applications which require unique and often expensive materials for their very specific engineered properties. Often, a more costly material needs to be joined to a less expensive material in an area of the assembly which does not require the same specialized properties.
A third factor – as more products are miniaturized across industrial sectors – is the need to save space in very small or compact assemblies. Even a thin layer of adhesive can be a significant barrier to performance for some products, such as small electronics. Lastly, an assembly may require the joining of components that must be manufactured via different processes, such as joining an injection molded frame to an extruded bag. Due to the different plastics production processes used, the two parts can have very different thermal properties, even if they are the same type of polymer.
System concept to allow IR and hot plate welding of two dissimilar plastic materials.
At EWI, we’ve seen an influx of the above types of applications. To provide better service to our customers, EWI is building a system which will allow heating of two parts to different temperatures using either infrared (IR) or hot plate heating to attempt to match viscosity during welding. We expect this equipment to be ready to support new research and development work in the late summer.
To learn more about this project, contact Miranda Marcus at [email protected].
Miranda Marcus will present this system at EWI’s upcoming Member Day on May 11, 2021. Click here for details.
While conventional flash thermography is ideal for polymer materials, it can be challenging when used with metals due to reflectivity of the component. With pulsed eddy-current-assisted thermography (PECT), ferrous and non-ferrous steels, as well as titanium, can be inspected without surface reflection interference. Internal research on flattened, painted, and steel pipe is ongoing at EWI using various NDE methods to identify stress corrosion cracking. PECT has enabled the identification of such cracks in just a few seconds. Depth of crack can also be resolved with the thickness of the specimen known.
EWI now has in-house capability to use PECT to inspect surface breaking cracks due to weld defects and stress corrosion cracking. The PECT technique is enabled by using equivalent wave field transformation (EWFT) from diffusive propagation (in this case, thermal) for a 3D image of a component and its defects. Eddy currents introduced into the material by an induction coil interact with defects. In the case of a crack, eddy currents flow around the crack which can be observed by monitoring the effects of minimal heating diffusing through the thickness of the sample. Using the EWFT allows sizing of flaws including crack depth.
If you are interested in learning more about EWI’s work in non-contact thermography inspection, contact Lindsey Lindamood, Applications Engineer, at [email protected]ewi.org.
We are excited to welcome JBT Foodtech to membership. JBT Foodtech provides solutions for the food processing industry with focus on proteins, liquid foods, and automated systems, and is a global leader in poultry and meat processing; blended value-added vegetable, fruit juices, and dairy products; and food and beverage preservation. JBT Foodtech has offices in the Americas, Europe, Asia, and Africa.
You may be ready to adopt additive manufacturing technology for production — but you still have questions about how to get the most out of additive technology. What key factors do you need to examine before adopting AM for your applications?
To address your questions, EWI presents the Guide to Metal Additive Manufacturing, Part II: AM Application Development Considerations. This e-book provides a framework for determining the best part candidates for AM and helps you get the full benefits of today’s additive technology.
You are invited to view this guide for free by completing this form:
To learn about EWI’s comprehensive services to help clients identify, develop, and implement the best AM technology for their requirements, contact Ajay Krishnan at [email protected] or Aaron Wertz at [email protected].
To speak to an EWI expert about a project, call 614.688.5152 or click here.
If you missed our Guide to Metal Additive Manufacturing, Part I: An Introduction to Metal AM Processes, you can access now it by clicking here.
Vehicle electrification systems are comprised of batteries, cables, inverters, motors, and other high-power electrical devices. Electric systems depend on the reliable interconnection of these components. Requirements go beyond joint strength; joints must be vibration resistant and have low electrical resistance, high current carrying capacity, and high thermal conductivity.
EWI has worked on interconnects for different levels of vehicle electrification – from hybrid electric to fully electric, stop/start – and has even worked with lead and other types of starter batteries. What many of these applications have in common is the need to join highly electrically-conductive metals, such as copper and aluminum.
Some applications, like copper-to-copper, have several options for joining processes. While the joining method is often selected after the assembly is designed, designing- for weldability is important. This can help reduce process development costs later in the design verification cycle. In addition to ultrasonic metal welding and laser welding, other processes such as resistance brazing or resistance projection welding can be used effectively.
Recently, EWI developed a resistance brazing process to meet the high-current interconnection requirement. Resistance brazing was chosen as the assembly design was already frozen, so making design changes to enable other joining processes was not possible. Having a large-area joint to conduct very high currents (>600 amps) without raising the temperature within the assembly was also considered critical. A self-fluxing brazing alloy, a simple, reliable filler metal for resistance brazing in many applications, was selected. In this process, tens of thousands of amps are imposed on each joint for a few hundred milliseconds, but the overall heating of the assembly is minimal. Additionally, the process is ESD (electrostatic discharge) safe, provided the resistance welder used for brazing is properly earth grounded.
For another application, a copper busbar had to be joined to a laminated aluminum “strap” with built-in flexures. These aluminum straps, manufactured either by diffusion welding or ultrasonic additive manufacturing, were comprised of many layers of aluminum foil that were consolidated into a solid bar at selected locations for rigidity while retaining flexibility in other areas. Neither brazing nor laser welding were options for this material combination, so EWI developed an ultrasonic metal welding process with custom tooling to ensure proper ultrasonic energy transfer to both materials. Just as that solution was developed, that application was re-designed as a three-layer stack, which only required minimal modification for ultrasonic metal welding.
Development of interconnection methods for electric vehicle applications requires an understanding of the materials involved, metal platings, joint design considerations, and joint performance requirements. EWI’s experience with these issues and expertise in all joining processes for these applications can be a valuable resource as you design your product and develop you joining processes.
For more information on joining of cells, tabs, and busbars, please contact Tim Frech, Senior Engineer, at [email protected] or 614.688.5113.
We are pleased to introduce Dover Corporation as a new EWI member. Dover is a global manufacturer that delivers innovative equipment and components, consumable supplies, aftermarket parts, software and digital solutions, and support services through five operating segments: engineered products, fueling solutions, imaging & identification, pumps & process solutions and refrigeration & food equipment. The company is headquartered in Illinois.
As a technology innovation organization dedicated to advancing the state of manufacturing, EWI frequently develops new diagnostic tools to improve production processes and efficiencies. Companies can work with EWI to take advantage of these cutting-edge applications for testing, inspection, and increased productivity.
Over the last few months, EWI has released three diagnostic tool sheets to help customers explore the various ways EWI can help identify tough manufacturing challenges. In the coming months we will continue to add to this knowledge base:
Are you looking for better ways to evaluate your materials, inspect your finished components, or trouble shoot a production issue? EWI can help. For more information about our tools and services, contact [email protected] or 614.688.5152.
