New Capability Added to EWI Laser Processing Lab

Laser welding has traditionally been limited to mechanized welding systems requiring a motion system with the ability to accommodate all required joint locations and orientations. Recently, EWI acquired an IPG LightWELD handheld laser welding system, which combines the flexibility of a handheld process like GMAW welding with the low-heat input, high travel speeds of the laser welding process. 

This new capability opens possibilities of applying laser welding to applications with continually changing part geometries and/or replace some current manual arc welding applications.  The low-heat input laser process offers significant advantages for welding sheet metal and other applications where distortion is critical.  With guided (“in-contact”) welding (for laser safety considerations) and the addition of a wire feeder to provide more consistent travel speed, the system requires less operator skill than typical, manual arc welding. 

Initial welding results

The LightWELD system also has laser cleaning capabilities that allow for material weld joint preparation using the same system and can provide a pristine surface suitable for welding. With all these capabilities combined into this small form factor end effector, EWI has plans to employ the LightWELD system to many manual and automated laser processing application in the coming months.

EWI continues to invest in the latest joining technologies including laser welding technologies that continue to advance, evolve, and grow.  To learn more about EWI’s Laser Processing capabilities, contact  [email protected] or click here.

For help with an immediate project, contact EWI by clicking the button below:

This post is for informational purposes only and is not intended as an endorsement of the IPG Lightweld.

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New R&D from EWI to Be Presented in May and June

EWI is pleased to present its latest applied R&D work at the following professional events and shows this spring:

AWS Shipbuilding and Aluminum Conference, May 3-5, 2022
  • Deep Penetrating Buried Arc — Nick Kapustka, EWI Engineering Manager
  • In-situ Process Monitoring to Support the NDE of AM Components — Ron Aman, Senior Technology Leader for Additive Manufacturing
  • High Quality, Reduced Cost Aluminum Welding — Nick Kapustka, Engineering Manager, and Paul Blomquist, Business Development Director of Maritime Technology
  • Rotating Electrode GMAW for Improved Horizontal Erection Joints — Jim Hansen, Project Engineer for Arc Welding
RAPID+TCT, May 17-19, 2022
  • Procedure Qualification Scheme Portfolio for Metal Directed Energy Deposition Additive Manufacturing — Dennis Harwig, Senior Technology Leader

EWI will also host an exhibit at RAPID+TCT. Please visit Booth #2935.

Great Designs in Steel, May 18 , 2022
  • Unique Formability Characteristics of the Laser Welded Blank of 3rd GEN AHSS — Hyunok Kim, EWI Forming Center Director

EWI will also host an exhibit at Great Designs in Steel. Please visit Booth #10.

Interphex, May 22-24, 2022
  • Innovations in Metal and Plastic Micro Welding for Medical Products — Jeff Ellis, Senior Technology Leader
  • Weld Quality Evaluation: Heating After Cross-section (HACS) — Miranda Marcus, Senior Engineer

EWI will also host an exhibit at Interphex. Please visit Booth #3745 in the Innophex Pavilion.

OMAE, June 6-9, 2022
  • Transitions in Charpy Energy and Splitting for X80 Pipe Steel — Bill Mohr, Principal Engineer
3D Metal Printing Experience and Tech Tour, June 7-8, 2022
  • Qualification of Metal AM Processes — Ron Aman, Senior Technology Leader
Advanced Laser Application Workshop (ALAW), June 7-9, 2022
  • The Role of Thermal History in In-situ Process Monitoring for Powder Bed — Ajay Krishnan, AM Research Leader 
  • Procedure Qualification and Quality Evaluation for Laser Metal Directed Energy Deposition AM — Jacob Hay, Senior Engineer

EWI will also host an exhibit at ALAW. Please visit our booth at the show.

Battery Show and Electric Vehicle Conference, June 8-9, 2022
  • Pulsed-arc Welding of Battery Tabs — Tim Frech, Senior Engineer
ANTEC, June 14-16, 2022
  • Welding of Dissimilar Polymers — Miranda Marcus, Senior Engineer
AM Industry Summit, June 20-22, 2022
  • Surface Engineering Approaches — Arushi Dhakad, EWI Project Engineer
Oil & Gas Polymer Engineering, June 21-22, 2022
  • Assessing Polymer Integrity for High Pressure CO2 and H2 Service — Jeff Ellis, Senior Technology Leader
North American Manufacturing Research Conference 50, June 27 – July 1, 2022
  • Tele-Welding: Developing Tools for a Tele-Manufacturing Workforce — Connie Reicher LaMorte, Principal Engineer
Adhesives & Bonding Expo, June 28-30
  • Demystifying Adhesive Selection, Dispensing Equipment, and Surface Preparation for Optimal Results — Jeff Ellis, Senior Technology Leader

Want to find out where EWI associates are presenting next? Click below:

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Choosing the Right Test for Qualifying AM Processes

With so many new materials available today for additive manufacturing (AM) production, how do you determine the best way to qualify your new feedstock? And is the AM method you want to use going to make a difference?

These questions are discussed in Choices for Mechanical Testing for Qualification of Additive Manufacturing Processes, written by EWI Principal Engineer Bill Mohr. You are invited to download this paper for FREE by submitting the form on this page.

If you would like to discuss this work with the author, please 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.

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Applying Low Force Friction Welding to Titanium

Low force friction welding, the robust joining process that combines friction welding and an external heat source, has been validated for metals including steels, aluminum alloys, copper, and more. Recent studies have demonstrated its great potential for titanium alloys as well.

Application of Low Force Friction Welding to a Ti-6AL-4V Alloy, written by EWI Senior Technology Leader Jerry Gould, describes this research. You are invited to download this paper – for free – by competing the form on this page.

If you would like to learn more about EWI’s investigations into applying low force friction welding to different materials, click here. You may also contact the author directly at [email protected].

Complete the form to download the paper:

To view the paper, please submit the form above.


To speak to an EWI expert about a project, call 614.688.5152 or click here.

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EWI’s New Joint Industry Program to Advance the Hydrogen Economy

By Henry Cialone
President & CEO, EWI

I got pretty excited a year or so ago talking about the “new” hydrogen economy, but noted at that time that delivery likely would be the primary challenge to such an economy taking hold.

Since then, it has become clear that part of the response to addressing this challenge will be to retrofit sections of the existing natural gas pipeline network for hydrogen service, which potentially could include inspection, repair, characterization of the pipe material’s hydrogen compatibility, and/or modifications of operating parameters. That’s something EWI and others are beginning to explore.

Retrofitting legacy pipelines, however, won’t work in all instances given hydrogen’s particular properties — properties that simply weren’t taken into consideration when these older pipelines were qualified for natural gas.

So, the other part of the response to the delivery challenge will be to replace certain pipelines (or pipeline sections) with new infrastructure . Additionally, there will be a need to build new transport and distribution lines to accommodate both production sites and large-scale industrial clients making the change from natural gas to hydrogen.

What’s EWI’s role on the “new pipe” front? Let me tell you a little bit about what we’re doing, why we’re doing it, and what we ultimately hope to accomplish….

To read the full article, click here.

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