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


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


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


On Heating Mechanisms for Solid State Welding Processes

By Jerry Gould on Wednesday, January 5th, 2011 in Advanced Energy, Aerospace, Automotive, Friction Processes, Oil & Gas, Rail, Resistance Processes/Solid-State Processes. No Comments

The majority of solid state welding processes use a combination of heat and deformation to accomplish an effective joint.  Heating is seen as both enabling to the necessary forging for joining, and in addition offers a diffusional component which enhances joint quality and reliability.  Solid state welding processes take advantage of a number of heatRead more


Time and Space in Resistance Welding

By Jerry Gould on Friday, November 12th, 2010 in Advanced Energy, Aerospace, Automotive, Rail, Resistance Processes/Solid-State Processes. No Comments

Reliable processing schedules for resistance spot welding have been readily available since at least the 1930’s.  These welding schedules have been reproduced from handbook to handbook, and are currently available in the  latest versions of the AWS recommended resistance welding practices (AWS C1.1M/C1.1:2000(R2006)).  These practices are typically provided as a function of workpiece thickness.   Generally,Read more