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Cold spray is one of the fastest metal additive manufacturing (AM) production techniques in the world. It offers an effective method for applying unique coatings and making repairs with similar or dissimilar metals. It eliminates heat affected zones and can be used on heat sensitive materials. It is an environmentally friendly process, particularly when compared to electroplating. 

In early 2022, EWI will establish a center of excellence in our Buffalo facility to unlock the potential of cold spray and mature it into a more reliable, repeatable, and reasonable capability from a cost perspective.

Cold spray is a solid-state, supersonic particle deposition process. The technology uses a heated carrier gas such as (but not limited to) air, nitrogen, or helium ( to accelerate powders above a critical velocity through a nozzle for adhesion to a receiving surface. There is no melting of the sprayed material or receiving surface. Cold spray can be applied to metals, ceramics, and even some composites and plastics. 

The goal of EWI’s cold spray initiative is to advance the knowledge and capability within the field to facilitate and accelerate the successful application of cold spray technology across manufacturing industries.  Our new center will feature state-of-the-art cold spray equipment produced by recognized OEMs in the cold spray ecosystem, including SPEE3D, VRC, and Centerline SST.* By leveraging EWI’s engineering expertise, cutting-edge resources, and technologies, as well as our partner network, the cold spray center will serve as an unbiased hub of innovation that is unmatched in the commercial world, driving and supporting adoption of this promising technology.

To learn more about EWI’s cold spray initiative and how we might help you use cold spray to overcome manufacturing and/or supply chain challenges, please contact EWI’s AM Business Director Howie Marotto at [email protected] .

*References to specific products do not constitute or imply an
endorsement by EWI of the product, its producer, or its provider.

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EWI has a long-established internship program for graduate and undergraduate engineering students. Over the past 35 years, more than 150 interns have gained hands-on experience working with EWI subject matter experts in our labs and learning what applied R&D for manufacturing involves.

Every spring, EWI’s senior technical team selects a core of highly qualified students from U.S. engineering schools to fill spots across our technology specialties in both Columbus, OH, and Buffalo, NY. The focus areas change slightly from year to year, but generally include arc welding and DED processes, resistance and solid-state welding, polymer processing, laser processing, additive manufacturing, nondestructive evaluation, corrosion, and materials engineering. The Intern “class” generally starts working by late May, continuing through the summer. It not uncommon at the end of the season for several interns to stay on through the school year, working their EWI hours around their class schedules.

Do you know promising engineering students who are seeking practical experience in advanced technology application for manufacturing? Applications for the EWI intern class of 2022 can be submitted by visiting the Engineering Internship page on our website. If you have questions about the program, contact Nick Montgomery, Vice President of Human Resources, at [email protected].

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EWI’s Fundamentals of Welding Engineering course is back by popular demand!

This long-running introductory class for engineers and technicians — taught twice annually by EWI’s welding specialists — was curtailed during the coronavirus pandemic. With high demand for the course’s return, the 5-day, comprehensive program will be offered twice in 2022: March 14-18 and October 17-21. Class sessions will take place at EWI headquarters in Columbus, Ohio.

For professionals who prefer a shorter course, EWI also offers a 3-day, condensed version, which will be held at EWI’s Buffalo Manufacturing Works facility in Western New York. Two sessions are scheduled for June 21-23 and August 16-18.

Both versions of the course combine hands-on labs and in-person lectures. Participants are introduced to a range of topics including welding processes, welding metallurgy and weldability, welding design and testing including NDE, and welding codes and qualifications. Participants will be awarded professional development hours and a certificate upon completion.

To view detailed descriptions and agendas for the two course formats, click here.

All four 2022 Fundamentals of Welding Engineering sessions are now open for registration. To reserve your spot for the session of your choice now, click here.

Questions? Contact Susan Witt, Industrial Training Manager, at [email protected].

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EWI is pleased to welcome Gulfstream Aerospace Corporation to EWI membership. The company designs, develops, manufactures, markets, services, and supports advanced business-jet aircraft. Headquartered in Savannah, GA, Gulfstream is a subsidiary of General Dynamics.

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