When it comes to joining dissimilar materials in lithium-ion batteries, ultrasonic metal welding is fast and efficient. However, due to tool wear, the sonotrodes used in battery joining have to be completely replaced frequently. EWI has developed a new design approach that uses finite element analysis (FEA) to evaluate ultrasonic welding tools with replaceable knurl […]
Read More
Materials science is at the heart of every manufacturing challenge – from solving complex joining problems to turning great ideas into bold new products. The EWI materials engineering group is at the center of every service we offer, impacting every industrial sector we support. The performance of materials is the basis of virtually all engineered […]
Read MoreA standard electric vehicle (EV) automotive battery can be decomposed into cell level, module level, and pack level. A cell mainly includes the anodes and cathodes, a module includes multiple cells, and a pack includes multiple modules. The three most common metal-to-metal joints in a lithium-ion battery pack are foil-to-tab, tab-to-tab, and tab-to-bus. All three […]
Read MoreWelding of dissimilar polymers is becoming more commonplace in manufacturing. There are several key reasons for this trend. First, many new plastics are being used in environments where adhesives cannot be easily applied. Typical examples include medical products for which finding adhesives that pass FDA regulations and join materials with low surface energy (like polyolefins) […]
Read MoreInertia welding is a well-established, friction-based, solid-state joining process. Many different applications use this welding process, ranging from aircraft engine parts to air bag inflators to hand tools. Process parameters associated with inertia welding (spindle speed, welding force, inertia, and displacement) have been widely studied since the process gained traction in the late 1960s. One […]
Read MoreResistance and ultrasonic processes can be superior to soldering when it comes to joining dissimilar materials in micro-components. Technology innovator EWI has the capabilities to do both. In this video, Senior Engineer Tim Frech takes you inside EWI’s fully equipped microjoining lab for a demonstration of parallel gap resistance welding of copper foil to a […]
Read MoreThe AWS Detroit Section has issued a call for papers for its upcoming Sheet Metal Welding Conference XIX. The conference will emphasize recent developments in welding and joining solutions that enable new generations’ vehicle design and construction. You are invited to submit technical papers for presentation at this conference. Abstracts are due by March 28. […]
Read MoreFriction welding, a solid-state process that uses high-speed spindles to weld materials, is notably effective for joining dissimilar materials. EWI has recently developed a new micro-friction welder for small-scale, dissimilar metals joining. The system has been demonstrated on both aluminum-to-titanium and aluminum-to-stainless joints. Application of Micro-friction Welding for Dissimilar Metals, a paper by EWI’s Jerry […]
Read More
Plastics joining is inherently complex. Ensuring strong, well-sealed joints without compromising component design is a constant challenge with new and evolving materials. EWI develops customized solutions for plastic and composite welding applications, including joining dissimilar materials. From plastic welding consulting to evaluation, we do more than just show you how to join your parts. We […]
Read More
Dissimilar metals joining is at best difficult and often impossible to achieve with traditional fusion methods. Resistance welding and solid-state processes have proven to be the most successful in joining dissimilar materials. EWI specializes in all types of resistance and solid-state welding. With broad expertise in materials science and controls engineering, we are able to […]
Read More