Use of Design of Experiments (DOE) Methods in Materials Joining Research

By Jerry Gould on Tuesday, August 15th, 2017 in Advanced Manufacturing, Manufacturing Competitiveness, Manufacturing Innovation, Manufacturing Technology, Technology Innovation. No Comments

Design of Experiments (DOE) methods have been used as a tool for industrial research for many decades. These methods allow empirical correlation between defined input data factors and any number of responses from the process of interest.  For example, in resistance spot welding input parameters might be current, weld time, and force. Responses would thenRead more


Paper: Joining of Steel to Titanium with Interlayers

By Jerry Gould on Tuesday, January 31st, 2017 in Papers. No Comments

EWI has been engaged in a new class of technologies for joining titanium alloys to steels. Implicit in applying thermal joining processes to this material combination is the formation of low-melting eutectics as well as a range of intermetallic compounds. The technologies described here combine the use of refractory metal interlayers with established forge welding processes.


Detroit Sheet Metal Welding Conference is a Wrap!

By Jerry Gould on Tuesday, November 1st, 2016 in Advanced Manufacturing, Arc Welding, Automotive, Dissimilar Materials, Dissimilar Metals Joining, Events, EWI Network, Friction Processes, Heavy Industry, Lightweighting, Manufacturing Competitiveness, Manufacturing Innovation, Materials Engineering, Metal Composites, Resistance Processes/Solid-State Processes. No Comments

The AWS Detroit Sheet Metal Welding Conference (SMWC) is a bi-annual event focused on new research in the areas of automotive joining and assembly.  EWI has long been a event sponsor, and serves on the technical leadership team.  The 17th conference (32rd year!) took place October 19-20. SWMC XVII featured three keynote presentations.  The first, by Dr. FelixRead more


Paper: Candidate Friction Welding Methods for Joining Aluminum to Steel

By Jerry Gould on Monday, June 13th, 2016 in Papers. No Comments

The joining of aluminum to steel is of broad interest to manufacturers, but is plagued by a host of metallurgical problems. Friction welding offers unique potential for overcoming many of these concerns. This article provides examples of three friction welding variants and discusses how they can be used to join aluminum to steel.


Preliminary Evaluations in the Welding of Bulk Metallic Glasses (Part 1)

By Jerry Gould on Monday, April 30th, 2012 in Advanced Energy, Aerospace, Automotive, Consumer Electronics, Defense, Laser Processing, Resistance Processes/Solid-State Processes. No Comments

Metallic glasses offer a unique combination of properties, including high tensile strengths (2000 – 4000 MPa) and elongations to yield (~2%).  Bulk metallic glasses are those that can be cast into section thicknesses of up to several millimeters.  These products have only been experimentally demonstrated over the last 15 years or so.  Such bulk metallicRead more


Supercapacitors as a Power Supply for Resistance Welding?

By Jerry Gould on Friday, April 6th, 2012 in Advanced Energy, Aerospace, Automotive, Consumer Electronics, Government, Modeling & Simulation, Resistance Processes/Solid-State Processes. 3 Comments

Modern resistance spot welding guns typically incorporate either pneumatic or electro-mechanical force activated forcing systems and medium-frequency power for operation.  The mechanical systems are used to apply force to the electrodes and workpieces, and the power supply provides the necessary electrical energy for resistance heating and subsequent joining.  Servo-guns are designed to provide the maximumRead more


EWI to Host a Technical Seminar on Surface Engineering, March 28, 2012

By Jerry Gould on Friday, March 16th, 2012 in Advanced Energy, Aerospace, Arc Welding, Automotive, Consumer Electronics, EWI – Company, Government, Heavy Industry, Laser Processing, Materials Engineering, Membership, NDE and Inspection, Oil & Gas, Rail, Resistance Processes/Solid-State Processes. No Comments

EWI has been hosting a series of technical seminars on a range of critical manufacturing topics.  The next in this series is a technical seminar on surface engineering.  Surface engineering is seen as a key enabling technology for the optimization of multi-materials systems.  Surface engineering can facilitate best application specific materials attributes in achieving solutionsRead more


Intermetallic Formation in Aluminum to Steel Welds

By Jerry Gould on Sunday, March 4th, 2012 in Automotive, Consumer Electronics, Friction Processes, Heavy Industry, Oil & Gas, Resistance Processes/Solid-State Processes. 1 Comment

A review of the literature on welding aluminum alloys to steels suggests that resultant performance is heavily influenced by the formation of intermetallic phases.  Joining of aluminum to steel can result in a number of these intermetallic phases, including FeAl, Fe3Al, and Fe2Al5.   Previous observations have suggested that these phases form along the bond lineRead more


Physics Based Modeling for Economic Assessments

By Jerry Gould on Friday, February 17th, 2012 in Advanced Energy, Aerospace, Automotive, Consumer Electronics, Oil & Gas, Resistance Processes/Solid-State Processes. No Comments

Welding exists in the world of manufacturing as a cost effective vehicle for the production of increasing complexity components.  If welding was not the cost effective solution, than some other technology or technologies would be dominant where joining is predominant today.  Of course, variants of welding and joining continue to proliferate as the science ofRead more


Friction and Heat Generation during Inertia Welding of Aluminum to Steel

By Jerry Gould on Monday, April 4th, 2011 in Automotive, Friction Processes, Government, Oil & Gas, Resistance Processes/Solid-State Processes. 1 Comment

EWI has spent considerable time over the last decade investigating the potential for friction welding aluminum to steel.  That work has encompassed both direct drive friction welding, as well as inertia welding.  One key element that has been demonstrated in these studies is the need to minimize actual times at temperature during processing.  Short thermalRead more