When it comes to joining dissimilar materials in lithium-ion batteries, ultrasonic metal welding is fast and efficient. However, due to tool wear, the sonotrodes used in battery joining have to be completely replaced frequently.
EWI has developed a new design approach that uses finite element analysis (FEA) to evaluate ultrasonic welding tools with replaceable knurl pads. As a result, new sonotrodes can be custom-designed for specific applications, quickly validated, and deployed.
You are invited to learn more about this approach in Sonotrode Design for Ultrasonic Metal Welding of Lithium-ion Batteries using Finite Element Analysis, written by EWI Project Engineer Amin Moghaddas. To view this paper, at no charge, simply complete the form on this page.
If you have questions about this process, you can reach the author 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.
As interest in transitioning to hydrogen as a replacement for fossil fuels increases, there is a need to evaluate existing natural gas pipelines to see if they can be effectively retrofitted for safe, reliable hydrogen transport.
EWI has established a joint industry program to conduct rigorous testing, close the knowledge gaps, and develop operator guidance for transitioning legacy pipeline for hydrogen service.
For a prospectus about this critical program and how your organization can participate, simply complete the form below:
Questions? Contact us directly for more information:
The re-emergence of hydrogen as a viable energy source for future use is driving research to develop a safe and durable interstate fuel delivery system. Converting sections of the existing natural gas network may offer part of the solution, but new lines designed specifically for hydrogen will be a necessary requirement.
EWI has established a joint industry program to develop guidance and recommendations for qualifying new pipe steels and their welds for use in high-pressure hydrogen service.
For a prospectus of this important program and how your organization can participate, simply complete the form below:
Questions? Contact us directly for more information:
Over the past several years, there has been great interest in developing ways to remotely execute critical manufacturing processes like welding, machining, and inspecting across long distances.
In 2018, a joint research team led by EWI identified the challenge of creating a “tele-manufacturing” system that could do exactly that – enable workers to operate functional equipment from a distant console to complete production-related tasks in another location.
What followed was a three-year process to develop the technology and hardware to achieve this goal.
With the successful implementation of the system in two naval shipbuilding sites this spring, tele-manufacturing — and specifically tele-welding — has become a reality. Other uses for the system are now being actively investigated and tested.
How did this state-of-the-art system get developed and implemented so quickly? What does it mean for manufacturing operations in the future? How can you explore potential applications of tele-manufacturing for your operation?
To learn more about the EWI tele-manufacturing system, EWI invites you to download Tele-Manufacturing: Applying Advanced Automation Solutions for Enhanced Productivity.
You can view this presentation – for free – by completing the form below:
Identify. Develop. Implement.
WE MANUFACTURE INNOVATION.
For additional details about this groundbreaking project and EWI’s plans to advance tele-manufacturing technology, contact Connie Reichert LaMorte at [email protected].
We are pleased to welcome TURBOCAM, Inc., to EWI membership this month. The company, headquartered in Barrington, NH, specializes in manufacturing core turbomachinery flow path components for aviation, rocketry, automotive turbocharger, and power generation.
At EWI, we’ve noticed that the global mindset toward inserting automation into the production line has shifted in a positive direction. Companies have realized that people really are the most important resource, and simply replacing them with robots is not the best approach. The greatest opportunities lie in the right mix of people and machines. Today, there is an increased interest in using automation to augment the current workforce, especially to relieve them of tedious, repetitive, or potentially dangerous tasks.
One such example is CNC machine tending, a task that requires little need for experience or on-the-job decisions but has traditionally been performed by highly skilled CNC machinists. Adding a robot to automatically load and unload parts can free up the machinist for more critical (and interesting) tasks like writing programs, performing changeovers, and training junior staff members.
At the other end of the spectrum, there is an increasing need for advanced automation systems to handle novel processes and new types of inspection, such as welding in a hazardous environment or in-processes monitoring of an additive manufacturing build.
EWI has a long history of automation work, particularly related to welding processes. In the past, however, the technology was simply viewed as a tool that could be applied to enhance a project. The growing demand for automated solutions, combined with the rapid evolution in robot, sensor, and process technologies has given EWI the opportunity to re-evaluate this approach. As a result, we are rolling out a dedicated R&D program aimed towards custom automation solutions that solve difficult high-mix production and fabrication challenges.
EWI’s automation development lab in Buffalo, NY
EWI’s automation initiative revolves around four key technology pillars – 1) automated quality control and sensor technologies, 2) tele-manufacturing, 3) collaborative automation (cobot) platforms, and 4) automated path planning. Industrial training is a common thread throughout. The automation staff and labs at both EWI’s NY and OH facilities are being expanded, and new development projects are already underway with clients throughout the country.
EWI’s automation team is fully activated and ready to help your organization harness the power of advanced automation. From identifying the right automation opportunities, to developing and proving out applications, to mapping out a path to implementation on the factory floor, our team members can help at any point along your automation journey.
To find out how you can benefit from our automation services, contact Matt Malloy at [email protected].
While spot weld performance has become easy to simulate in recent years, failure models for arc-welded sheet steel have never proved very reliable.
Recently, EWI developed and tested a new approach to modeling failure of arc welds used in sheet-steel construction. The work is described in a paper by EWI associates Bill Mohr and Amin Moghaddas, Testing to Determine Failure Criteria for Arc-welded Sheet Steel.You are invited to download the paper – for free – by completing the form on this page.
Would you like learn more about this model and its applications? Contact Bill Mohr, Principal Engineer for Structural Integrity, 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.
