EWI Published Papers

Ultrasonic metal welding (UMW) is widely used in high-volume manufacturing, particularly lithium-ion battery assembly, due to its fast cycle time and ability to join thin or dissimilar materials. But the process is sensitive to variations in tooling, materials, and process conditions, and conventional quality control relies on destructive testing methods that are costly, time-consuming, and...

Additive manufacturing (AM) offers powerful advantages for oil and gas operators, including reduced lead times, agile production of complex parts, and improved supply chain resilience. However, widespread adoption remains limited by one persistent challenge: procedure and part qualification, particularly for components operating in corrosive service environments. In this new paper, EWI engineers examine how the...

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...