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We would like to welcome Energy Power Systems as a new EWI member

Founded in 2011 by leaders in the energy and business industries, Energy Power Systems is headquartered in Metro Detroit and brings together a team of dedicated and talented scientists, engineers and manufacturing experts.


Energy Power Systems 2

We would like to welcome TE Connectivity as a new EWI Member

TE is the world’s largest provider of connectivity solutions.

TE Connectivity

DSC_0366On October 3rd, EWI hosted its second annual Open House. More than sixty curious guests from Columbus and central Ohio visited our labs to learn about the applied research and development we do to bring cutting-edge technologies to manufacturers worldwide.

The Open House was held on Manufacturing Day, a national day designated by the manufacturing industry to educate the public about US manufacturing and its vital role in today’s economy. Throughout the country, events were held simultaneously to highlight the importance of manufacturing, the innovations being introduced into the industry, and the career possibilities in the field today.

To see photos of EWI’s Open House event, click here.Take a tour of EWI on National Manufacturing Day

To learn more about EWI, visit

We would like to welcome Keystone Engineering as a new EWI Member

Keystone Engineering is a multi-disciplined engineering consulting firm which offers civil/structural, mechanical, process, electrical, instrumentation and controls programming/integration engineering services to a largely industrial clientele.Keystone

WELDEREWI will again host its five-day Fundamentals of Welding Engineering course at its Columbus, OH, headquarters, November 10-14, 2014.

Taught by top-notch EWI engineers, this class provides engineers and technicians with an overview of the various aspects of welding technology including welding processes, welding metallurgy and weldability, welding design and testing (including mechanical testing and NDT), and qualifications and procedure review.

“This course provides an excellent mix of classroom and laboratory training with the lab portion enhanced by EWI’s world-class welding facility,” says Dr. Doug Fairchild, Sr. Metallurgical and Welding Consultant with ExxonMobil Upstream Research Company. “We have found it particularly useful for engineers who were not originally educated as welding engineers.”

Registration is limited to ensure all attendees will have the opportunity to interact directly with instructors. For more details or to register, please click here.

Fabtech focus groups 2014EWI will be chairing two special focus groups at FABTECH 2014 in Atlanta, GA, November 10-13. The sessions, geared toward manufacturing industry leaders and stakeholders, will be conducted as part of the NIST AMTech initiative to develop the first comprehensive national technology roadmaps for materials joining and forming technology.

Admission to the focus group meetings is by invitation only. If you are interested in participating in either group, please contact the session leader directly:

Materials Joining Focus Group, Monday 11/10 (pre-show)
Group Leader: Tom McGaughy, Director of Technology (

Forming Center Technology Focus Group, Thursday 11/13
Group Leader: Hyunok Kim, EWI Forming Center Technical Director (

Have you wondered how Buffalo Manufacturing Works can help small companies gain a competitive advantage? Check out the Buffalo News to learn about Eastman Manufacturing’s involvement with the new advanced manufacturing center, operated by EWI.

BMW logo

Who Let the Frogs Out?

Marc Purslow —  October 13, 2014 — 1 Comment
Suhas Frogman

AMS Frog installed in TTCI’s test track

I recently rode my bicycle across America and saw a whole bunch of craziness: A hurricane in Maine, hail storms in the Arizona desert, a haboob in the California sand dunes, and hundreds of giant frogs…giant steel frogs…more specifically, giant battered austenitic manganese-steel frogs!

No, I didn’t lose my mind cycling for 43 days alone. I’m talking about a type of special trackwork used by railroads which allows track to converge, diverge, or cross. These components take a serious beating on a daily basis, and must be repaired due to wear, fatigue cracks, or when the train’s wheels simply rip a chunk of damaged material out as they make a transition (a.k.a. a “breakout”). It turns out that these battered frogs require the most maintenance of any track component and are unsurprisingly the most expensive to keep in good working order.


Typical AMS “breakout” defect in need of repair

Here’s the kicker – While austenitic manganese steel (AMS) has some great qualities (high toughness and great work-hardenability), it’s a bit tricky to weld. Unlike typical rail steels,  AMS does not respond well to high preheat and interpass temperatures. When this material gets too hot carbide precipitation occurs and it loses much of the toughness that makes it so attractive for this application. As such, the temperature of the base material must be kept unusually low. This impacts productivity negatively, making it difficult for repairs to be completed properly within the time allotted. In addition, since repairs are currently made with manually applied shielded metal arc welding (SMAW) and flux cored arc welding (FCAW), adherence to strict interpass temperature limitations is up to the individual welder and can’t be easily controlled.

EWI has conducted a project sponsored by the Federal Railroad Administration to develop a better method of repairing these components. Through a partnership with the Transportation Technology Center, Inc., and with guidance from the CSX corporation, EWI successfully used automated FCAW to achieve impressive results. Laboratory testing has revealed that EWI’s automated FCAW frog repair process results in a significant improvement in weld quality, reduced interpass temperatures, and increased productivity. The real proof is in the performance of these welds during in-track testing at Transportation Technology, Inc. (TTCI).

Repaired and Cropped

AMS frog repaired using EWI’s automated FCAW process

The life of rail components is measured in million gross tons, or MGTs. When an AMS frog is new, it will typically last between 55 and 60 MGTs before repair is required. Once a repair is performed this number drops to between 30 and 35 MGTs, provided that proper repair procedures are followed. A frog repaired with EWI’s automated FCAW process is currently being tested by TTCI and has accumulated over 90 MGTs to date. This is nearly triple the typical life of a repaired AMS frog and 50% more MGTs than a new frog, and testing hasn’t ended yet.

If you’re stomach turns at the thought of a battered frog, give Marc Purslow a call at 614.688.5150 or email him at



I had the opportunity to attend the 2014 IMTS (International Manufacturing Technology Show) in Chicago thanks to EWI’s involvement in the new venture Acoustech Systems. IMTS is a major trade show for any company that manufactures machine tools, CNC machines, production robotics, and more. From the tiniest drill bits to CNC machines the size of some apartments, one could see them all at IMTS. Attendees come from all over to find the latest and greatest tools and machines for their production facility. I attended to see the results of our hard work on the Acoustech Machining system, on display for industry leaders to marvel over. While not at the Acoustech exhibit, I walked the show floor checking out the cutting edge technology on display. The following is a sample of my favorite tech demos from IMTS .

The 3D printed car

3DcarArizona car manufacturer Local Motors was able to 3D print and assemble an entire working car live, start to finish, in front of attendees during the six days of IMTS. The last car to be 3D printed took a couple months. Unfortunately, I only attended IMTS the first day when the car consisted only of a few hunks of plastic. To read more and see it drive check out:


The Robot programed by motion

Baxter_Robot_from_RethinkRobotics_8Created by Rethink Robotics, Baxter is a person sized, two armed, production robot. While most robotics requires complex programming and hours of planning to encode a series of motions, Baxter is programmed by hand through direct manipulation of its appendages. It learns tasks by movement instead of code! If you find this interesting, check out:





Additive and subtractive manufacturing in one machine

LasertecThe Lasertec 65 3D is an integrated machine, able to create complex parts that are impossible to machine from a single block of material without interference. It is a hybrid of a five-axis CNC milling machine and additive manufacturing via metal powder deposition. It can exchange its mill head with a laser array tool head attached to a nozzle. As the nozzle shoots metal powder through the laser array, it fuses onto the work along the path of the CNC controlled head. It can build up a surface, finish it, drill holes, and then build up new surfaces. Take a look at:

Acoustech Systems

Drill moduleBe sure to check out the amazing Acoustech Machining technology, designed to vastly enhance metalworking capabilities of machining systems through the application of high power ultrasonics. All of us at EWI involved in the Acoustech project had our noses to the grindstone, making sure our latest and greatest was ready for demonstration at IMTS. It was rewarding to see that hard work come to fruition as my fellow employees showcased for the first time the ultrasonic drilling system EWI developed for Acoustech. To learn more about Acoustech Systems, visit or contact Matt Short ( or 614.688.5266).


EWI Forming Center LogoBe sure to sign up now for the upcoming workshop on Advanced Sheet Metal Forming Technology hosted by the EWI Forming Center and The Ohio State University’s Center for Precision Forming (OSU/CPF). The workshop is being held at EWI in Columbus on October 15-16, 2014.

To register for the workshop, please click here. To view the workshop agenda, click here. We look forward to seeing you!

Please do not hesitate to contact Hyunok Kim (, phone: 614.688.5239) or Taylan Altan (, phone: 614.292.5063) with any questions.