September 13, 2011

Dissimilar Materials Joining Seminar

Chris ConrardyChief Technology Officercconrardy@ewi.org

Welcome

EWI Mission

Advance Our Customers’ Manufacturing Competitiveness through Innovation in Joining

and Allied Technologies

Innovation is Our Product

Needs Assessment

Expert focus groups─ 25 member Industry Advisory Board

Broad surveys─ Electronic EWI Member surveys

Targeted surveys─ Automotive industry needs

Client interviews─ Hundreds of confidential conversations Top Needs and

Challenges

Expert Focus Group Exercises

Broad Industry Surveys

Targeted Surveys

Interviews

2008 Expert Focus Group Example

Question: “What advancements in joining and allied technologies will have the greatest impact on your business in the next 3-5 years?”

70 responses distilled into major “themes”

1. Improved welding processes

2. Dissimilar material joining

3. Real-time process monitoring

4. Flexible automation

5. Additive manufacturing and repair

6. Improved NDE

7. Performance improvement technologies

8. Welder training / workforce development

9. Numerical Modeling

2008 Member Survey Example~800 responses

% of respondents selecting option

“What technical advancements would have the greatest impact on your business?”

2008 Survey Industry Breakdown

(not all sectors or responses shown)

“What technical advancements would have the greatest impact on your business?”

2010 Expert focus group Top 10 Challenges

Rank Description

1 Reducing Cost of Inspection

2 Shortage of Skilled Workers

3 Affordable and Flexible Mechanization

4 Dissimilar Joining

5 Virtual Tools

6 Proliferation of Materials and Processes

7 Standards Use and Revisions

8 Health & Safety

9 Mainstream Leading Edge Technologies

9 Laser Welding Quality and Reliability

10 3D Modeling of Welded Structures

“What will be the most important challenges in materials joining and allied technologies worldwide by the year 2016?”

2010 Member Survey Advancements Question

Question: What manufacturing technical advancements would have the greatest impact on your business in the next 5 years?

Rank Need Auto

Oil &ga

s

Defen

se

Aero

Heavy

Man

Adv E

nergy

1 J oining of high-performance materials 1 3 1 1 3 2

2Educating designers and engineers on joining alternatives 2 2 4 1

3Arc welding advancements (higher productivity, quality) 1 3 1

4 Dissimilar materials joining methods 2 2 25 On-line access to materials joining expertise and data 4

6“Smart” welding automation that can adapt to changing conditions 4 4

7More sensitive, accurate, and reliable non-destructive evaluation (NDE) 3 4 4

8Real-time monitoring of welding processes for quality assurance

9 Fatigue performance improvement methods 410 High-productivity thick section welding processes 2

2010 Member Survey ~550 responses

Rank Auto

Oil &ga

s

Defen

se

Aero

Heavy

Man

Adv E

nergy

1 Increased use of new materials or material combinations 1 4 3 4 4 12 Qualifying new processes and procedures 5 7 2 1 9 103 Maturing and successfully transitioning technologies from R&D to production 6 6 1 3 10 44 Keeping staff current on the latest materials joining processes and methods 2 6 7 6 35 Shortage of engineers and designers with materials joining expertise 1 4 6 76 Increased joint performance requirements 4 2 10 8 2 87 Competition from low labor-cost countries 3 68 Cost to introduce new processes, procedures, or product designs 10 8 2 29 First-time quality expectations are increasing 9 5 5 3 910 Shortage of skilled welders and other skilled trades 3 7 111 Lack of resources to invest in product and process development 9 512 Reducing the cost of joining operations 9 9 513 NDE methods not sufficiently sensitive or accurate 7 1014 Attracting young people to manufacturing disciplines 815 Shortened product development/launch cycles 1016 Difficulty keeping up with the proliferation of new materials and processes 817 Codes and standards are not keeping pace with technology 518 Increasing use of automation 720 Upgraded or replacing of aging infrastructure 1030 Shortage of quality welding and joining suppliers in emerging countries 8

What will be your most important materials-joining related business challenges in the next five years?

EWI 2010 Materials Joining Leadership Conference

Goal: explore collaborations to advance North America’s competitive position

70 invitees from industry, government, national labs, universities, non-profits

Identified “grand challenges”

Discussed potential solutions

Conference Report Available

High Priority “Themes”

Rank Topic # Votes # Points1 Workforce Training, Education 50 1542 Funding & Policy 34 1153 Quality 30 864 Collaborate to advance competitiveness 29 865 Advanced Materials 26 816 Process / automation 26 787 Modeling 19 498 Standards 18 569 R&D Effectiveness 14 40

10 Management 6 17

0

20

40

60

Workf

orce Tr

aining,

E...

Funding &

Policy

Quality

Collaborat

e to ad

vanc..

.

Advance

d Mate

rials

Process

/ automati

on

Modeling

Standard

s

R&D Effective

ness

Manag

ement

Advanced Materials

# Votes # Points Description26 818 26 Dissimilar metal joining solutions 3 11 Joining dissimilar materials0 0 Weld Bonding

10 34 Advanced Materials & Technology Introduction3 8 Advanced materials2 2 lower quality substrate with some desired bonding agent

Dissimilar materials joining, including adhesives, reapir of advanced materials, validated property data for advanced materials/processes, filler metal substitutions, understand material-process-property interactions

Agenda

Tips to Get the Most Out of the Seminar Ask questions in Q&A Feel free to interact with our presenters Feel free to follow-up with questions after the event Network with other attendees EWI membership review and tour

Questions?

Chris ConrardyChief Technology Officercconrardy@ewi.org