EWI, previously known as Edison Welding Institute, is a nonprofit engineering and technology organization dedicated to advanced materials joining and allied technologies, state-chartered in Ohio, USA. EWI staff provide materials joining assistance, contract research, consulting services and training to manufacturing companies in the aerospace, automotive, defense, energy, government, heavy manufacturing, medical and electronics industries. Approximately 150 employees staff the Institute. EWI holds numerous patents for various materials joining and manufacturing technologies.The organization was founded in 1984 in a research park adjacent to Ohio State University, when then Ohio Governor Richard Celeste established the Thomas Edison Program, an initiative to establish the Edison Technology Excellence Centers within the state, including a center for welding research and development. Today EWI operates independently and is considered one of the leading engineering and technology innovator for advanced manufacturing in North America. The EWI has collaborated with the Ohio Supercomputer Center under its "Blue Collar Computing Initiative" to develop supercomputer simulations of welding.EWI has offices and laboratories in Columbus, Ohio, Metro Detroit, Metro DC, and Buffalo, New York.The organization's sales in 2005 were $30 million. The organization receives a substantial part of its support from a governmental unit or the general public. In 1997, EWI spent $8.8 million on research and development. Wikipedia.
Edison Welding Institute | Date: 2016-08-29
A method for creating metallic sandwich structures that includes providing at least two face sheets; providing at least two core sheets; orienting the core sheets relative to one another in a predetermined manner; and using indirect resistance roll brazing to join the core sheets to the face sheets to create a sandwich structure.
Edison Welding Institute | Date: 2016-09-26
A process for welding metallic sections that includes providing first and second metallic sections to be welded together, and wherein the welded rail sections will include a weld fusion zone that further includes a weld terminus at each rail section; providing thermite welding dies for use in welding the metallic sections together; covering the thermite welding dies with an oxide displacing or oxide dissolving flux added locally to the edges of the thermite welding dies that are immediately adjacent to the weld fusion zone and the metallic sections; positioning the thermite welding dies on the metallic sections in the region where the metallic sections are to be joined together; and initiating an exothermic reaction between the thermite welding dies and the metallic sections by introducing molten metal into the region where the metallic sections are to be joined together, wherein the exothermic reaction creates a weld between the metallic sections.
Edison Welding Institute | Date: 2016-12-28
A portable system for non-destructively characterizing spot welds that includes at least one matrix phased array probe and a body, wherein the body is designed to be hand-held and further includes an economically designed outer casing; at least one input for connecting to the at least one matrix phased array probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer that further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds; and at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time.
Edison Welding Institute | Date: 2015-09-03
An ultrasonic machining module that includes an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a machining tool and a vibration-isolating housing adapted to be both compatible with a machining system and to receive the ultrasonic transducer therein, wherein the housing further includes at least one modification for isolating all vibrations generated by the ultrasonic transducer when the device is in operation except axial vibrations transmitted to the machining tool, thereby preventing unwanted vibrations from traveling backward or upward into the machining system.
Edison Welding Institute | Date: 2016-04-06
A system for non-destructively characterizing laser welds that includes at least one phased array probe that includes a plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof, wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; a combination of materials for allowing the probe to conform to a contoured surface of a laser weld while enabling sound energy to be transferred directly into a laser weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber material disposed between the membrane and the array of ultrasonic transducer elements; and a data processor in communication with the at least one phased array probe that includes software having at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of a characterized laser weld.
Edison Welding Institute | Date: 2015-12-16
A system for non-destructively evaluating components fabricated by additive manufacturing, comprising a sensor array that includes a plurality of individual elements arranged in a predetermined pattern for allowing uniform coverage of an area of an electrically conductive component to be evaluated, wherein each element in the plurality of elements further includes at least one coil that acts as an exciter coil for generating an alternating electromagnetic field when activated or a receiver coil for measuring a change in impedance of the at least one coil or both an exciter coil and receiver coil, wherein the alternating electromagnetic field generates eddy currents in the component to be evaluated, and wherein the individual elements in the sensor array are excited in a predetermined sequence during a single pass of the array over the area to be evaluated; and an XY-scanner arm adapted to receive the sensor array, wherein the XY-scanner arm is operative to generate a C-scan of the area being evaluated during the single pass.
Edison Welding Institute | Date: 2015-12-22
Electromagnetic and eddy current techniques for fast automated real-time and near real-time inspection and monitoring systems for high production rate joining processes. An eddy current system, array and method for the fast examination of welds to detect anomalies such as missed seam (MS) and lack of penetration (LOP) the system, array and methods capable of detecting and sizing surface and slightly subsurface flaws at various orientations in connection with at least the first and second weld pass.
Edison Welding Institute | Date: 2016-04-20
A method for characterizing a spot weld, including acquiring a sequence of A-scans from an ultrasonic phased array, wherein the A-scans describe individual portions of a field of view of the phased array; manually applying an interface gate and a flaw gate to each individual A-scan within the sequence of A-scans; calculating a gate ratio between a maximum amplitude under the interface gate and a maximum amplitude under the flaw gate for each individual A-scan; plotting the gate ratio for each individual A-scan as a function of location within the phased array field of view to generate a weld fusion map; using a predetermined threshold to differentiate fused locations from unfused locations on the weld fusion map; and calculating predetermined weld metrics, wherein the predetermined weld metrics include area, diameter, width, length, percent fused, or combinations thereof.
Edison Welding Institute | Date: 2016-08-19
A non-destructive system for characterizing welds that includes at least one weldment that further includes at least two components joined together a weld; at least one source of heat energy directed toward one side of the weldment, wherein the source of heat energy is operative to direct a predetermined amount of heat energy through the first component toward one side of the weld, through the weld and the area surrounding the weld, and through the second component to the opposite side of the weldment, and wherein the heat energy is sufficient to induce a temperature change in the weld and the area surrounding the weld; and a temperature measuring device directed toward the opposite side of the weldment for gathering temperature data from heat passing through the second component away from the weld and the area surrounding the weld, wherein the gathered temperature data is indicative of weld quality.
Edison Welding Institute | Date: 2016-06-08
A method for fabricating assemblies includes providing first and second components that include ceramic, metal, or composite; positioning a multiphase joining interlayer between the first and second components, wherein the joining interlayer includes a first phase that melts at a first temperature and a second phase interspersed throughout the first phase, and wherein the second phase melts at a second temperature that is lower than the melting temperature of the first phase; and heating the joining interlayer to a temperature in the range of 725 C. to 1450 C. for a predetermined period of time to soften the first phase and melt the second phase, wherein the first phase remains in a solid or a semi-solid state, and wherein the second phase segregates to the boundaries of the first phase and transforms the joining interlayer into a substantially porosity-free adherent material that joins the first component to the second component.