material types
Ferrous
Ferrous alloys are extensively used in wide range of industries due to its flexibility to meet wide range of strength, toughness, impact and high-temperature strength. This flexibility is achieved through careful selection of heat treatment procedures which modifies the final microstructure. However, the welding often modifies this microstructure and ensuing properties. Therefore, we need fundamental understanding of the microstructure evolution in these alloys to arrive at optimum combination of process and material combinations. To meet these needs, EWI has developed strong expertise in the metallurgy, corrosion resistance and property optimization of ferrous alloys including carbon steels, low-alloy steels, advanced high-strength steels, stainless steels and high-Cr steels. This expertise includes the weldability, weld microstructure evolution, consumable development, measurements of phase transformations and microstructure characterization.
Ferrous Materials Capabilities:
- C-Mn Steels
- High-strength Low-Alloy Steels
- Advanced High-Strength Low Alloy Steels (DP600, DP980, TRIP 980, etc)
- Stainless Steels
- Austenitic
- Ferritic
- Duplex Stainless Steel Welds
- Martensitic
- Welding Consumable Design & Evaluation
- High-Temperature Steels (2 ¼ Cr – 1Mo; 9 Cr, 11Cr, etc)
- High-Performance Steels (Super-bainitic steels, 17-4 PH, 17-7 Ph)
- Phase Transformation Investigations
- Continuous Cooling and Heating Transformations
- Microstructural Characterizations
- Metallography and Scanning Electron Microscopy
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Non-Ferrous
Nonferrous alloys are extensively complex since each alloy system uses different mechanism to arrive at the required mechanical properties. For example, in heat-treatable Al-Cu aluminum alloys, the strength is achieved by the precipitation of nanoscale precipitates including GP zones and q’ precipitates. In non-heat treatable alloys, the strength is achieved by grain size control. During welding of both of these alloys, the thermal cycles modify these microstructures and often lead to softening and some times cracking. In addition, the weld microstructure exhibits different corrosion resistance than that of the base metal microstructure.EWI is uniquely positioned to address these changes and its effect on the final properties of weldment through well-developed knowledge base from the years of internal research and also staff expertise. Many of the associates are world leaders in the industrial sectors that extensively use nonferrous alloys. The nonferrous expertise spans from aluminum alloys (heat-treatable & non-heat-treatable), nickel base superalloys (polycrystalline, directionally solidified and single crystals), titanium alloys (a and ß alloys), refractory alloys, and magnesium.
Non-Ferrous Materials Capabilities:
- Nickel Base Superalloys
- Polycrystalline Alloys (e.g. Alloy 800, 600, 939 etc)
- Directionally Solidified Alloys (e.g CM247 etc)
- Single-crystal Alloys (e.g. CMSX4, Rene-N5 etc)
- Welding Metallurgy
- Ductility dip cracking
- Liquation Cracking
- Solidification Cracking
- Repair Welding
- Aluminum Alloys
- Heat treatable (e.g. 6000 & 7000 series)
- Non-heat treatable (e.g. 5000 series)
- Titanium Alloys
- Commercially Pure Titanium
- a-ß alloys (Ti-6Al-4V etc)
- Development of Brazing Filler Wires
- Nickel base and other alloys
- Phase Transformation Investigations of Non-Ferrous Alloys
- Electron microscopy characterizations
- Development of Brazing Filler Wires
- Microstructural Characterizations
- Metallography and Scanning Electron Microscopy
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Metal Matrix Composites
Metal matrix composites often produced by special processes to distribute hard fiber (e.g. SiC) or particles (e.g. Al2O3) within a matrix of metal to improve its properties. However, the joining of these materials requires a detailed understanding how these strengthening second phases react with matrix during thermomechanical conditions of welding. EWI has extensive knowledge on the effects of welding on the stability and properties of these metal matrix composites. Often this knowledge is used to develop alternate joining processes. The expertise includes aluminum metal matrix composites and oxide dispersion strengthened alloys.
Ceramics & Glass
Joining methods for ceramics and glass can include adhesive bonding, ultraonisc soldering, and brazing.
Plastics & Adhesives
Adhesives are necessary for bonding many thin materials, small components, materials that can not be welded, dissimilar materials, and many plastics. Modern techniques allow most combinations of materials to be joined, especially combinations of different plastics, elastomers and rigid plastics, plastics and metals, and ceramics with plastics and ceramics or metals. Often, adhesive bonding issues revolve around application and curing processes. A major strength of EWI service is the wide variety and combination of processing options available in one location. EWI has experience with many metals, plastics, and ceramics which leads to more efficient use of time and resources.
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