Archives For Arc Welding

Last week EWI had the first EWI ShipIt! Days. Employees were given 24-hours to do anything they wanted that wasn’t related to their regular job. The catch? You have to deliver something at the end of the 24-hours. This commercial about EWI is what my team delivered. Enjoy!!



If you are not familiar with the original Dollar Shave Club video, check it out.

Buffalo BuildingNew York State has confirmed its investment plans for the new advanced manufacturing institute to be operated by EWI in Buffalo. The announcement to dedicate  $45 million for the new center was made last week. This allocation will fund facilities, equipment, and start-up operations for the first five years, after which the institute will be self-sustaining.

Activities will focus on four areas of manufacturing innovation: flexible automation and controls, advanced materials and testing, additive manufacturing, and advanced fabrication.

The facility, located downtown Buffalo, NY, is set to open in stages with some operations starting up this summer. About half of the space will function as laboraties, with meeting rooms and offices in the other half.

For more details about EWI and the launch of the advanced manufacturing institute in Western New York, click here.

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Excitement is building in Western New York as state and local officials, businesses, and community leaders get ready to welcome EWI to downtown Buffalo. EWI will launch the new advanced manufacturing institute at the end of February as part of the Buffalo Billion Investment Development Plan.

Here’s what we’re hearing from New York…

Governor Andrew Cuomo:
“As operator of the Institute, EWI will bring a proven record of helping the industry tackle and solve manufacturing and production issues. Under this partnership, EWI will make Western New York more competitive and position the region as a leader in manufacturing technology and innovation, which will help spur new economic opportunities for years to come.”

Chris Sansone, President of Buffalo Niagara Manufacturing Alliance:
“I’m excited about [EWI] opening up shop. Their forte is bridging the gap between government-funded research and the commercialization of those technologies.”

Buffalo Mayor Byron Brown:
“EWI’s selection to provide Buffalo’s advanced manufacturing sector with the tools needed to be highly competitive continues the great momentum that’s underway in Buffalo.”

Erie Community College President Jack Quinn on the relationship between ECC and EWI:
“We’ll be working together, and they’re a world-class operation.”

To read the latest from Buffalo Business First, click here.

Components made from titanium are candidates for additive manufacturing due to both the high material cost and the long lead times on material purchases.  Electron Beam Freeform Fabrication (EBFFF) is the most widely used method for additive manufacturing of large scale titanium parts.  This process is well established but is expensive and requires the parts to be made in a vacuum chamber.  EWI is investigating gas tungsten arc welding with resistively heated wire (GTAW-HW) as an alternative to EBFFF for Ti 6-4 components.  The work discussed here has been done to obtain baseline property data for a Ti 6-4 weld deposit made with the GTAW-HW process.  A blog was previously posted about some of this work.  In this post additional data is presented including the tensile test results of specimens subjected to different post-weld heat treatments.

A 7-in long x 1 1/4-in wide x 2 1/2-in tall weld deposit was produced on Ti 6-4 ELI plate using the GTAW-HW process and Ti 6-4 ELI wire.  The weld deposit was made out-of-chamber using argon for both the torch gas and the trail shield gas.  A heat input 20-KJ/in was used for the GTAW torch and the deposition rate was around 4-lbs/hr.


After the weld deposit was produced the base plate was removed.  A small section was removed and tested to determine the interstitial contents of hydrogen, nitrogen, and oxygen using the Leco Furnace Method.  The results were compared to the maximum permissible compositions for Ti 6-4 ELI forgings because there is no ASTM specification for Ti 6-4 ELI castings.  The maximum permissible levels for Ti 6-4 ELI forgings are:

  • Hydrogen – less than 0.0125 wt%,
  • Nitrogen – less than 0.03 wt%,
  • Oxygen – less than 0.13 wt%.

The composition of these detrimental interstitial elements in the weld deposit was much less than the requirements for forgings.  The weld deposit contained 0.0013 wt% hydrogen, 0.0078 wt% nitrogen, and 0.077 wt% oxygen.  These results indicate that other reactive metal alloys could also be additively manufactured out-of-chamber with acceptable impurity levels, provided suitable shielding methods are used.

A transverse section was subjected to metallographic evaluation.  This section contained no discontinuities such as incomplete fusion or porosity.

HW - TIG - Macro

Six sub-sized tensile specimens were taken from both the direction of travel and in the build direction (a total of 12 specimens were prepared and tested).  For each orientation, 2 specimens were tested in the as-welded condition, 2 specimens were tested after a solution heat treatment followed by an anneal heat treatment, and 2 specimens were tested after a anneal heat treatment only.  The solution heat treatment was done above the beta transus temperature, while the anneal heat treatment was performed between 700°C and 785°C.  Typical tensile test values for Ti 6-4 ELI castings are listed below along with the tensile test results.

Tensile Test Results

The tensile tests results were not affected by specimen orientation but were affected by the specimen heat treatment condition.  The tensile specimens tested in the as-welded condition as well as those tested in the annealed condition had strength that surpassed the typical values for Ti 6-4 ELI castings, but either elongation or reduction in area were less than the typical values for castings.  The specimens subjected to the solution heat treatment plus anneal had strength that was less than the typical values for Ti 6-4 ELI castings, but most elongation and reduction in area values were greater than the typical values for castings.

The ASTM F-42 Committee defines additive manufacturing as follows:  ”Process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing technologies”.  The next step in developing a CAD-to-part additive manufacturing technology is to combine the GTAW-HW process with available path programming software and a suitable positioning system (such as a 6-axis robot).

If you are interested in learning more about additive manufacturing or the properties of materials being used in additive manufactured parts, please contact me at 614-688-5175, or










EWI welcomes Engineered Wire Products to membership.



Engineered Wire Products is a leading manufacturer of welded wire reinforcement (WWR) for the concrete industry. 




Welcome to EWI!

EWI is pleased to welcome Vulcan Global Manufacturing Solutions to EWI Membership.

Vulcan GMS is the leading radiation shielding manufacturer in the world.  They design and manufacture lead, tungsten, lead-alternative and high-density plastic components and assemblies.

Welcome to EWI!




Perfect 10!

Mark Schimming —  December 17, 2013 — Leave a comment

Ultrasonic Additive Mfg

Like all businesses, EWI tracks quite a few metrics. Since 2012 we have been tracking our Net Promoter Score (NPS). This score is derived from the one survey question we ask after every customer interaction – “Would you recommend EWI to a friend or colleague?”

A score of 9 or 10 is considered a “promoter score” versus lower number detractor scores. Promoters are those loyal enthusiasts who keep buying from a company and urge others to do the same. Our NPS score has typically averaged around 9.1; however, this fall for the first time we averaged a perfect 10!

EWI Associates work very hard to satisfy our customers, and we are honored to receive this top rating from a client. More importantly, we appreciate the comments that come along with that score such as:

EWI continues to be an extremely valuable technical resource, not only with respect to joining technologies, but in related fields as well.

Excellent and very reliable engineering support.

Very responsive and smooth communication.

Continuing to improve our business to better meet the needs of our customers is our number one priority. Give us a call at 614-688-5000 or learn more about us on from website. We would love to deliver a perfect score for you.

EWI is excited to welcome Welspun Tubular into EWI Membership.








Welspun Tubular LLC sits on a 740-acre site adjacent to the Little Rock Port in Arkansas.  The state of the art $150 million API-certified facility is capable of producing 350,000 net tons of HSAW (spiral welded) pipes annually. With diversified sizes ranging from 24 to 60 inches as outer diameter (OD) and 0.23 to 0.98 inches as wall thickness (WT), as well as coating and double jointing capabilities, the Arkansas facility provides a one-stop solution to valued Oil and Gas customers in and around the United States.


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EWI is hitting the road again! This time we’re off to DMC 2013 in Orlando from December 2 through December 6 at the Gaylord Palms Resort & Convention Center. Come hear technical presentations from EWI Associates Nancy Porter and Larry Brown, or stop by Exhibit Booth #922 to view demonstrations and samples of our new technologies and capabilities. If you would like to schedule a meeting with us in advance, please contact Jesse Bonfeld, VP of Federal Business Development (, or Larry Brown, Director of Government Technology Programs ( Hope to see you in Florida!

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EWI has enhanced drawn arc stud welding with funding provided by the Center for Naval Shipbuilding Technology, a Navy ManTech Center of Excellence.

The secret to this revolutionary patent-pending process enhancement is a fluxed ferrule that produces a drawn arc stud weld that is aesthetically pleasing.  When’s the last time you heard someone say that about a stud weld?  On top of that, the resultant stud weld has improved fatigue performance and needs significantly less welding current to produce.

FabtechWant the scoop on how this works?  If you’re going to FABTECH, you have two options.  On November 19th, Dave Workman will be in EWI’s booth (#N2192) located in the North Hall Annex of McCormick Place in Chicago.  On November 20th, Dave is presenting “Improved Stud Improvement to Drawn Arc Stud Welding Process” at 10:30 a.m. in AWS Professional Program Session 10 – Applied Technologies II. If you’re not going to FABTECH, give Dave a call at 614-688-5244 or drop him an Email at

Want to try a fluxed ferrule?  The exclusive U.S. provider of the super ferrule is Image Industries.  Give Blake Hobson a call at 847-659-0100, ext-33 or send him an email at

We don’t make the studs, we just make them better.

Reference:  U.S. Pat. App. No. 61/814,500