Ultrasonic Processes

The EWI ultrasonics team leads the field in finding new ways to apply high-power ultrasound to manufacturing. Recent innovations in joining, tooling, and additive manufacturing have already contributed to cost savings, time savings, and worker safety throughout the industry.


Ultrasonic Machining

EWI has broad capabilities in high-power ultrasound (HPU), a technology based on the principal of converting electrical energy into mechanical energy for the purpose of changing the physical, chemical, or biological properties of materials or systems. We develop HPU technology in areas such as welding, additive manufacturing, metalworking and machining, friction reduction, forming, de-foaming, wire drawing, soldering/brazing, and cleaning. Our highly skilled technologists use state-of-the-art equipment to expand existing ultrasonics technologies and develop new ones. EWI’s expertise includes the design and fabrication of HPU systems, process development using design-of-experiments approaches, and quality control via in-process monitoring, nondestructive evaluation, and testing.

EWI’s core competency in high-power ultrasound lies in the design, fabrication, and demonstration of novel power ultrasonic systems to suit industry or client-specific needs. Our expertise in HPU systems allows us to innovate in many different technology areas offering value driven solutions once thought impossible.

Technical Expertise

  • Plastics joining
  • Microjoining
  • Metal welding
  • Machining
  • Forming
  • Additive manufacturing
  • Soldering
  • Wire drawing
  • Friction reduction
  • Defoaming
  • Cleaning
  • Food processing
  • HPU system design
  • Test and evaluation of HPU systems
  • Process development
  • Design of experiments
  • In-process monitoring
  • Test and evaluation of HPU processes

Equipment and Lab Resources

  • Metal welding systems
    • Frequencies range from 15- to 60-kHz
    • Power ranges from 500- to 10,000-W
    • Lateral drive
    • Wedge-Reed
    • Torsion
    • Seam welders
  • Plastics welding systems
    • Frequencies range from 15- to 60-kHz
    • Power ranges from 500- to 4.5-kW
    • Pneumatic and servo controlled welders
    • Spin
    • Hot gas
    • Laser
    • Hot plate
  • Ultrasonic assisted machining
    • Drilling, milling, tapping, reaming
  • Ultrasonic Package Sealing
    • Vertical Form Fill Seal Demonstration Unit
    • Benchtop Sealing Equipment for Feasibility
  • Lead free Ultrasonic Solder and Brazing
  • PU system test and evaluation
    • 1 and 2D laser virometer
    • Impedance Analyzer
    • Spectrum Analyzer
    • High power motor-generator transducer test bench
    • Infrared thermography for thermal profiling
  • HPU Design and Modeling capabilities
    • Pro-E
    • SolidWorks
    • Abaqus
    • Ansys
    • Piezotran
  • Developed of a modular ultrasonically assisted machining system that can be fitted to new or existing machine tools while utilizing standard metalworking tooling.
  • Developed thin-film weld tooling addressing legacy issues of multi-layer stack-up and metal-to-metal contact due to over-welding.
  • Developed high-power ultrasound additive manufacturing system using solid state welding to “print” three dimensional objects. While solid-state welding has it benefits with material properties, the low heat nature also facilitates the means to embed materials such as sensor, thermocouples, or even shape memory alloys.

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