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Columbus, OH, United States

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.

Gould J.E.,Edison Welding Institute
Welding Journal | Year: 2012

Aluminum has been used in the automotive industry for more than half a century. During the last 30 years, however, interest in the use of aluminum has been coupled with needs for improved vehicle performance. This has largely focused on improved fuel economy, and by extension, weight reduction. Aluminum generally cannot be implemented in vehicle construction without an associated manufacturing infrastructure. A key element of that infrastructure is welding. Conventionally, resistance spot welding is the dominant joining technology for unitized vehicle construction. This paper reviews the impact of aluminum implementation on the joining technologies used in body-in-white construction. This review includes a discussion of the specific aluminum alloys used (nominally 5XXX and 6XXX sheet products, and 3XX cast products) as well as a discussion of candidate joining technologies. It is noted that assembly of aluminum sheet products is still dominated by resistance spot welding. Basic requirements for aluminum spot welding are discussed, as well as key manufacturing challenges. The state-of-the-art technology is described, including the impacts of new generation approaches that are entering the industry. A description is also provided of alternative resistance welding approaches that are applicable to aluminum automotive fabrication. The use of mechanical fasteners for aluminum construction is discussed. On emerging technologies, this paper also provides an overview of ultrasonic spot welding. This method is being investigated as a candidate replacement technology for resistance spot welding.

Edison Welding Institute | Date: 2015-08-11

A friction stir welding tool includes that a body and a pin formed integrally with the body at one end thereof. The body and pin further include a first material and a second material; wherein the first material further includes a molybdenum-based refractory alloy; and wherein the second material further includes hafnium, lanthanum, carbon, titanium, zirconium, or combinations thereof.

Edison Welding Institute | Date: 2015-04-17

A gas metal arc welding system that includes leading and trailing welding torch assemblies arranged to operate in tandem. The leading welding torch assembly further includes a torch body; a contact tip connected to one end of the rotatable torch body, wherein the contact tip further includes a passage formed therethrough; a consumable wire electrode passing through the body and exiting the contact tip through an exit hole; and a source of shielding gas. The trailing welding torch assembly further includes a non-rotatable torch body; a contact tip connected to one end of the non-rotatable torch body; a consumable wire electrode passing through the non-rotatable torch body and exiting through the contact tip; and a source of shielding gas.

A method for joining materials such as metal alloys that includes a first component, wherein the first component includes a first alloy having a known austenization temperature below which martensite forms when the component is heated and then cooled at a predetermined rate of cooling; a second component, wherein the second component includes a second alloy; and a welding apparatus operative to create a weld between the first and second components without crossing the austenization temperature of the first alloy.

Edison Welding Institute | Date: 2015-07-17

A method for reducing areas of friction within a forming die that includes identifying at least one region of interest in the forming die, wherein the at least one region of interest further includes a problematic aspect of a predetermined nature; designing a die segment corresponding to the at least one region of interest, wherein the die segment further includes at least one ultrasonic transducer embedded therein; modifying the forming die to receive the die segment; installing the die segment in the forming die and acoustically isolating the die segment from the remainder of the forming die; and energizing the ultrasonic transducer to provide ultrasonic energy to the die segment, wherein providing ultrasonic energy to the die segment addresses the problematic aspect of the at least one region of interest in the forming die.

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