Consumable inserts are critical to weld quality and consistency in many industries, including the aerospace, oil & gas, and hydrogen sectors. Conventional manufacturing methods — rolling, machining, or laser-based processes — often fall short due to high material waste, long lead times, design restrictions, and elevated costs.
EWI engineers Michael Carney and Travis Peterson have pioneered a new fabrication method that overcomes these limitations. By using directed energy deposition (DED) with gas metal arc welding (GMAW), shaped consumable inserts can be built layer-by-layer directly from standard filler wires. A final machining step ensures precise dimensions and surface finish quality.
This approach:
- Supports the ability to produce superior welded connections for high-quality assemblies
- Minimizes material waste and reduces costs
- Produces complex geometries not possible with rolling or machining
- Delivers high-quality parts that meet AWS filler material requirements
- Is adaptable to multiple filler metals and scalable for industrial use
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This technology is patent pending. For opportunities to leverage this technology or for more information, contact Michael Carney at [email protected].