EWI https://ewi.org/ EWI Thu, 16 Jul 2026 15:25:04 +0000 en-US hourly 1 https://wordpress.org/?v=7.0.2 EWI Announces the Promotion of Kelly Roach to General Counsel https://ewi.org/ewi-announces-the-promotion-of-kelly-roach-to-general-counsel/ https://ewi.org/ewi-announces-the-promotion-of-kelly-roach-to-general-counsel/#respond Thu, 16 Jul 2026 15:25:03 +0000 https://ewi.org/?p=141658 Columbus, OH – EWI, headquartered in Columbus, Ohio, announced the promotion of Kelly Roach to General Counsel. Since joining EWI in 2013, Kelly has been a trusted legal advisor, providing strategic counsel across the organization and supporting the successful execution of key business initiatives. Her role has expanded significantly over the years to include corporate […]

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Columbus, OH – EWI, headquartered in Columbus, Ohio, announced the promotion of Kelly Roach to General Counsel.

Since joining EWI in 2013, Kelly has been a trusted legal advisor, providing strategic counsel across the organization and supporting the successful execution of key business initiatives. Her role has expanded significantly over the years to include corporate governance, regulatory compliance, strategic partnerships, intellectual property, and enterprise risk management.

As General Counsel, Kelly will lead EWI’s legal affairs, including corporate governance, regulatory compliance, intellectual property strategy, risk management, and legal support for the organization’s strategic initiatives and new ventures. She will continue to serve as a member of EWI’s executive leadership team.

About EWI

EWI empowers industry leaders to overcome complex manufacturing challenges and integrate new processes to bring products to market more quickly and efficiently. Since 1984, EWI’s comprehensive engineering services have helped companies identify, develop, and implement the best options for their specific applications. Our customers include but are not limited to aerospace and defense, automotive, aviation, energy, consumer electronics, medical devices, industrial products, and heavy equipment. Backed by unmatched professional expertise, state-of-the-art lab facilities, and technology resources, we offer customized solutions that deliver game-changing results. Learn more at ewi.org.

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]]> https://ewi.org/ewi-announces-the-promotion-of-kelly-roach-to-general-counsel/feed/ 0 Acoustic-based Real-time Quality Assurance for Ultrasonic Metal Welding https://ewi.org/acoustic-based-real-time-quality-assurance-for-ultrasonic-metal-welding/ https://ewi.org/acoustic-based-real-time-quality-assurance-for-ultrasonic-metal-welding/#respond Thu, 16 Jul 2026 15:05:42 +0000 https://ewi.org/?p=141625 Ultrasonic metal welding (UMW) is widely used in high-volume manufacturing, particularly lithium-ion battery assembly, due to its fast cycle time and ability to join thin or dissimilar materials. But the process is sensitive to variations in tooling, materials, and process conditions, and conventional quality control relies on destructive testing methods that are costly, time-consuming, and […]

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Ultrasonic metal welding (UMW) is widely used in high-volume manufacturing, particularly lithium-ion battery assembly, due to its fast cycle time and ability to join thin or dissimilar materials. But the process is sensitive to variations in tooling, materials, and process conditions, and conventional quality control relies on destructive testing methods that are costly, time-consuming, and unsuitable for 100% inspection.

In this new paper, EWI Applications Engineer Amin Moghaddas evaluates acoustic emission (AE) sensors and microphones as a real-time, non-destructive alternative for monitoring UMW quality. Using welds produced under underweld, good weld, and overweld conditions representative of lithium-ion battery manufacturing, the study demonstrates strong classification accuracy across multiple acoustic sensing approaches, offering a practical path toward in-process quality monitoring on the factory floor.

Complete this form to download the paper:

Topics explored in this paper include:

  • How AE sensors and microphones can classify weld quality in real time
  • Classification accuracy results across AE sensors of varying frequency ranges and non-contact microphone sensing
  • Advanced methods used to correlate acoustic signals with weld quality

To access the full paper for FREE, complete the form on this page.

To learn more, contact Amin Moghaddas, Applications Engineer, at amoghaddas@ewi.org.

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]]> https://ewi.org/acoustic-based-real-time-quality-assurance-for-ultrasonic-metal-welding/feed/ 0 Solid-state Weld Repair of Structural Castings https://ewi.org/solid-state-weld-repair-of-structural-castings/ Thu, 25 Jun 2026 13:25:45 +0000 https://ewi.org/?p=141359 Casting defect repair is a persistent challenge across many manufacturing industries. Traditional arc welding methods rely on a shrinking pool of skilled welders, have limitations when applied to difficult-to-weld alloys, and become impractical for large or complex repairs, particularly as industries push toward gigacasting. When defects can’t be repaired, parts are scrapped and recast, driving […]

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]]> Paper title: Solid-state Weld Repair of Structural Casings

Casting defect repair is a persistent challenge across many manufacturing industries. Traditional arc welding methods rely on a shrinking pool of skilled welders, have limitations when applied to difficult-to-weld alloys, and become impractical for large or complex repairs, particularly as industries push toward gigacasting. When defects can’t be repaired, parts are scrapped and recast, driving up cost and lead time.

In this new paper, EWI engineers Jerry Kovacich, Rafael Giorjao, and Michael Eff investigate additive friction stir deposition (AFSD) as an automated, solid-state alternative for repairing structural castings across a range of alloys. Drawing on hands-on process development and mechanical testing with two common casting alloys — A380 aluminum and C95500 nickel aluminum bronze (NAB) — the authors demonstrate how AFSD avoids the fundamental limitations of fusion welding while delivering deposit properties that meet or exceed casting material requirements.

Complete this form to download the paper:

Read the full paper to discover:

  • Why traditional arc welding repair is increasingly impractical for structural castings
  • How AFSD eliminates hot cracking and porosity concerns inherent to fusion welding
  • Mechanical property results for AFSD-deposited NAB, including yield and tensile strength exceeding heat-treated cast material requirements
  • How AFSD produces dense, defect-free deposits even in highly porous base material
  • Implications for gigacasting repair and broader structural casting applications

To access the full paper for FREE, complete the form on this page.

To learn more, contact Jerry Kovacich, Applications Engineer, at jkovacich@ewi.org.

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]]> Application of Aluminum Composite Materials Processed Through Resistance-based Sintering for High-voltage Transmission Conductors https://ewi.org/application-of-aluminum-composite-materials-processed-through-resistance-based-sintering-for-high-voltage-transmission-conductors/ Thu, 11 Jun 2026 19:46:39 +0000 https://ewi.org/?p=141217 High-voltage transmission conductors are critical to the electrical grid, but the aluminum alloys used to manufacture them have remained largely unchanged for decades. While these materials provide good conductivity, they can have limited performance in applications requiring higher strength, lower thermal expansion, or improved conductivity at elevated temperatures. Aluminum-based composite materials offer a potential path […]

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High-voltage transmission conductors are critical to the electrical grid, but the aluminum alloys used to manufacture them have remained largely unchanged for decades. While these materials provide good conductivity, they can have limited performance in applications requiring higher strength, lower thermal expansion, or improved conductivity at elevated temperatures.

Aluminum-based composite materials offer a potential path forward, but producing them cost-effectively and at scale has remained a challenge.

In this new paper, EWI researcher Jerry Gould investigates resistance-based sintering (RBS) as a manufacturing method for aluminum (Al) composite materials intended for transmission conductor applications.

Complete this form to download the paper:

It specifically looks at composite systems including Al-graphene, Al-carbon nanotube (CNT), Al-titanium diboride (TiB2), and others, along with the processing advantages RBS offers over conventional approaches.

Read the full paper to discover:

  • Aluminum composite systems being developed for transmission conductor applications and the property improvements they may offer over conventional aluminum alloys
  • How RBS rapidly consolidates composite powders in milliseconds to seconds without shielding atmospheres
  • Demonstrated production of Al-graphene composites at near-full density (~99%) without reactive products at the matrix-graphene interface
  • Extrudability results that point toward a potential manufacturing route for transmission conductor strands

To access the full paper for FREE, complete the form on this page.

To learn more, contact Jerry Gould, Senior Technology Leader, at jgould@ewi.org.

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]]> Recycling of Rare Earth Magnets using Hydrogen Decomposition and Resistance-based Sintering https://ewi.org/recycling-of-rare-earth-magnets-using-hydrogen-decomposition-and-resistance-based-sintering/ Thu, 21 May 2026 16:28:13 +0000 https://ewi.org/?p=141056 Rare earth magnets are a key component of electrical power applications intended to reduce carbon emissions, with wide-ranging uses in electric vehicles, wind power generation, and more. These magnets rely on critical rare earth elements, mainly neodymium, which is predominantly sourced from China, creating significant risks around availability and pricing. As a result, there is […]

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Rare earth magnets are a key component of electrical power applications intended to reduce carbon emissions, with wide-ranging uses in electric vehicles, wind power generation, and more. These magnets rely on critical rare earth elements, mainly neodymium, which is predominantly sourced from China, creating significant risks around availability and pricing. As a result, there is strong interest in recycling available rare earth magnetic material as a way of extending supply and easing supply chain constraints.

In this new paper, EWI engineers Jerry Gould and Olga Eliseeva examine how existing magnetic materials can be recycled through hydrogen decrepitation and resistance-based sintering (RBS) — a cost-effective, high-speed process that reduces scrap magnets to a reusable powder and reconsolidates it into new magnetic product.

Complete this form to download the paper:

The paper also explores compositional blending strategies to address variation across feedstock sources, offering a path to maximum recycling yield.

Other key topics include:

  • How hydrogen decrepitation is used to break down scrap rare earth magnets into a coercive powder suitable for reprocessing
  • How RBS rapidly reconsolidates recovered powders into near-net-shape magnets without shielding atmospheres
  • How compositional differences across feedstock sources can be managed through powder cataloging and targeted blending
  • Implications for supply chain resilience and domestic rare earth availability

To access the full paper for FREE, complete the form on this page.

To learn more, contact Jerry Gould, Senior Technology Leader, at jgould@ewi.org, or Olga Eliseeva, Applications Engineer, at oeliseeva@ewi.org.

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]]> EWI and Powders on Demand Announce Strategic Partnership to Commercialize Breakthrough Resistance-Based Sintering Technology https://ewi.org/ewi-and-powders-on-demand-announce-strategic-partnership-to-commercialize-breakthrough-resistance-based-sintering-technology/ Mon, 30 Mar 2026 16:35:33 +0000 https://ewi.org/?p=140758 EWI and Powders on Demand Announce Strategic Partnership to Commercialize Breakthrough Resistance-Based Sintering Technology Voltic Forms will enable faster, more efficient manufacturing of high-performance components Columbus, OH – EWI, a leading advanced manufacturing and engineering solutions company, and Powders on Demand, a pioneer in advanced powder-based materials, announced the formation of Voltic Forms, a new […]

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]]> EWI and Powders on Demand Announce Strategic Partnership to Commercialize Breakthrough Resistance-Based Sintering Technology

Voltic Forms will enable faster, more efficient manufacturing of high-performance components

Columbus, OH – EWI, a leading advanced manufacturing and engineering solutions company, and Powders on Demand, a pioneer in advanced powder-based materials, announced the formation of Voltic Forms, a new joint venture focused on commercializing resistance-based sintering (RBS).

While the concept of using resistance heating for sintering has been around for decades, recent developments by EWI have advanced RBS into a manufacturing technology capable of consolidating metal and composite powders up to 300 times faster while using up to 97% less energy than conventional processes. Voltic Forms will focus on advancing and deploying this technology to enable manufacturers to produce high-performance metal and composite components with unprecedented speed, efficiency, and material flexibility.

“Resistance-based sintering reflects the kind of innovative manufacturing technologies EWI is committed to advancing,” said Blake McAllister, vice president of strategic technologies at EWI. “Through Voltic Forms, we can help companies produce high-performance components faster and more efficiently, giving them the tools to stay competitive in an increasingly advanced materials-driven market.”

Resistance-based sintering offers a fundamentally new approach to manufacturing that can dramatically improve speed, efficiency, and material performance. Unlike traditional methods that rely on long furnace cycles and bulk heating, RBS can consolidate powders in milliseconds rather than hours, producing components with full density comparable to or exceeding forged structures. The process eliminates the need for vacuum chambers, inert gases, and furnaces, while enabling near-net-shape production of advanced materials such as titanium, superalloys, steels, refractory metals, metal matrix composites, and novel functional composites.

By combining EWI’s expertise in advanced manufacturing process development with Powders on Demand’s leadership in material to process commercialization, Voltic Forms is positioned to industrialize production of high-performance components that were previously unattainable at scale. This new approach opens the door for manufacturers to adopt a faster, more energy-efficient, and more flexible production process, helping them meet growing demand for advanced materials and components.

“A titanium part today can pass through three or four suppliers before it’s finished — melting, forging, machining — each with its own lead time and cost structure. Resistance-based sintering collapses all of that into a single second from powder feedstock. Voltic Forms exists to make that capability accessible at scale.” said Powders on Demand Co-founder and CEO Brad Richards. “Defense and commercial customers require shorter supply chains and faster delivery — that’s exactly what we’re bringing them.”

Media Contact

Alison Landefeld: alandefeld@ewi.org

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About EWI
EWI empowers industry leaders to overcome complex manufacturing challenges and integrate new processes to bring products to market more quickly and efficiently. Since 1984, EWI’s comprehensive engineering services have helped companies identify, develop, and implement the best options for their specific applications. Backed by unmatched professional expertise, state-of-the-art lab facilities, and technology resources, EWI offers customized solutions that deliver game-changing results. Learn more at ewi.org.

About Powders on Demand
Powders on Demand (POD), a spinoff company of Solvus Global, specializes in the R&D to commercialization transition of materials and process development for high-quality and application-specific feedstocks and processes, including advanced aluminum, titanium, superalloy, cermet, and refractory metal systems. The business operates out of three facilities with strong collaboration with end customers and partners in central Massachusetts. Learn more at powdersondemand.com.

About Voltic Forms
Voltic Forms is a joint venture formed by EWI and Powders on Demand to commercialize resistance-based sintering technology and accelerate the adoption of next-generation powder consolidation methods for advanced manufacturing, addressing critical capability and availability gaps in the supply chain.

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]]> Unlocking AM for Oil and Gas Markets – Understanding Corrosion to Enable Qualification https://ewi.org/unlocking-am-for-oil-and-gas-markets-understanding-corrosion-to-enable-qualification/ Thu, 12 Mar 2026 15:26:49 +0000 https://ewi.org/?p=140586 Additive manufacturing (AM) offers powerful advantages for oil and gas operators, including reduced lead times, agile production of complex parts, and improved supply chain resilience. However, widespread adoption remains limited by one persistent challenge: procedure and part qualification, particularly for components operating in corrosive service environments. In this new paper, EWI engineers examine how the […]

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Additive manufacturing (AM) offers powerful advantages for oil and gas operators, including reduced lead times, agile production of complex parts, and improved supply chain resilience. However, widespread adoption remains limited by one persistent challenge: procedure and part qualification, particularly for components operating in corrosive service environments.

In this new paper, EWI engineers examine how the unique microstructures inherent to AM components influence corrosion performance and long-term reliability. Drawing on decades of experience in materials joining, metallurgy, AM, and standards development, the authors explore why conventional qualification frameworks fall short and how qualification requirements must evolve to enable safe, efficient deployment of AM in oil and gas applications.

Complete this form to download the paper:

Key topics explored in this paper include:

  • Why traditional qualification approaches are insufficient for AM components
  • How AM microstructures affect corrosion initiation and damage progression
  • Implications for sour service and other aggressive operating environments
  • Considerations for developing corrosion-informed AM qualification strategies

To access the full paper for FREE, complete the form on this page.

To learn more, contact Jerry Kovacich, Applications Engineer, at jkovacich@ewi.org.

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]]> EWI Announces New Chief Executive Officer https://ewi.org/ewi-announces-new-chief-executive-officer/ Wed, 04 Feb 2026 17:58:00 +0000 https://ewi.org/?p=140392 EWI Announces New Chief Executive Officer Industry leader Stephen Kelly hired to succeed longtime CEO who is retiring Columbus, OH/Buffalo, NY – EWI, headquartered in Columbus, Ohio, announced the appointment of Stephen “Steve” Kelly as its next President and Chief Executive Officer, following a comprehensive national search led by the organization’s Board of Directors. Kelly […]

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EWI Announces New Chief Executive Officer

Industry leader Stephen Kelly hired to succeed longtime CEO who is retiring

Columbus, OH/Buffalo, NY – EWI, headquartered in Columbus, Ohio, announced the appointment of Stephen “Steve” Kelly as its next President and Chief Executive Officer, following a comprehensive national search led by the organization’s Board of Directors. Kelly is an innovative executive with decades of experience leading organizations in highly competitive and rapidly evolving markets. His background spans early-stage ventures, mid-scale growth organizations, and large, complex institutions.

“Steve emerged as a clear choice because of his ability to connect strategy, innovation, and execution in highly complex environments,” said Greg Moore, Chair of EWI’s Board of Directors. “He understands how to help organizations deliver real-world impact, and he brings the federal and industrial experience, particularly within the defense industrial base and nuclear energy infrastructure, that will be critical as EWI continues to grow. The Board is confident he is the right leader for this moment.”

Most recently, Kelly served as CEO of the Indiana Innovation Institute, where he built a start-up applied research organization from the ground up. Under his leadership, the institute established strong partnerships across industry, academia, and government; secured programs with the DoD Joint Artificial Intelligence Center, DARPA, and the U.S. Navy; and grew revenue from zero to more than $20 million in three years. Through his consulting work, Kelly has supported early-stage defense and advanced technology ventures, commercial firms entering federal markets, and national laboratories and federally funded research and development centers on strategy and performance improvement.

Stephen “Steve” Kelly,
EWI’s new President & CEO

“I’m excited to join EWI at a time when its mission is more important than ever,” said Steve Kelly, President and CEO of EWI. “EWI has a unique ability to translate advanced technology into practical solutions that strengthen U.S. industry and national competitiveness. I’m looking forward to working with the talented EWI team, our clients, partners, and the Board to build on that foundation and expand the organization’s impact.”

Longtime EWI President and CEO Henry Cialone announced his retirement in June 2025 and is staying at EWI until the end of February to ensure a smooth leadership transition.

Media Contacts

Heidi Wilson, hwilson@ewi.org, and Carolyn Human, carolyn@carolynhuman.com

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About EWI

EWI empowers industry leaders to overcome complex manufacturing challenges and integrate new processes to bring products to market more quickly and efficiently. Since 1984, EWI’s comprehensive engineering services have helped companies identify, develop, and implement the best options for their specific applications. Our customers include but are not limited to aerospace and defense, automotive, aviation, energy, consumer electronics, medical devices, industrial products, and heavy equipment. Backed by unmatched professional expertise, state-of-the-art lab facilities, and technology resources, we offer customized solutions that deliver game-changing results. Learn more at ewi.org.

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]]> Looking Back on 2025: A Year of Progress, Innovation, and Impact https://ewi.org/looking-back-on-2025-a-year-of-progress-innovation-and-impact/ Wed, 07 Jan 2026 19:29:08 +0000 https://ewi.org/?p=140213 At EWI, our focus has always been on helping manufacturers solve real problems and move advanced technologies from concept to production. In 2025, that mission translated into meaningful progress across research, technology development, and knowledge sharing to support industries navigating increasingly complex technical and economic challenges. Throughout the year, our teams worked closely with partners […]

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]]> At EWI, our focus has always been on helping manufacturers solve real problems and move advanced technologies from concept to production. In 2025, that mission translated into meaningful progress across research, technology development, and knowledge sharing to support industries navigating increasingly complex technical and economic challenges.

Throughout the year, our teams worked closely with partners across energy, aerospace, automotive, and other high-performance sectors to advance manufacturing capabilities, expand technical resources, and deliver practical solutions that make an impact on the shop floor.

Some of the themes that defined 2025 include:

  • Advancing additive manufacturing capabilities to support complex geometries, demanding materials, and faster production environments
  • Expanding expertise in materials, joining, testing, and validation to meet the needs of evolving industrial applications
  • Delivering innovative tools and programs that help manufacturers improve efficiency, reliability, and decision-making
  • Sharing knowledge more broadly than ever, through refereed technical publications, conference presentations, podcasts, webinars, and hands-on training

Together, these efforts reflect a year focused not just on innovation, but on translating that innovation into real-world value for our industry partners.

Click for enlarged view

As we move into 2026, EWI remains committed to helping manufacturers adapt, innovate, and succeed through applied research, technical expertise, and collaborative problem-solving. If you’re exploring a new product, process improvement, or technology challenge, we invite you to connect with our team.

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]]> Tele-manufacturing™: Real-time FANUC CRX Motion Control for Tele-polishing https://ewi.org/tele-manufacturing-real-time-fanuc-crx-motion-control-for-tele-polishing/ Tue, 21 Oct 2025 15:00:05 +0000 https://ewi.org/?p=139499 Tele-manufacturing™ combines advanced robotics, sensing, control systems, and digital communication to enable remote execution of manufacturing tasks. This approach addresses challenges around skilled labor shortages, physically demanding work, and the need for more flexible industrial processes. EWI engineers have demonstrated these principles with a tele-polishing system using a FANUC CRX collaborative robot and a Logitech […]

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Tele-manufacturing™ combines advanced robotics, sensing, control systems, and digital communication to enable remote execution of manufacturing tasks. This approach addresses challenges around skilled labor shortages, physically demanding work, and the need for more flexible industrial processes.

EWI engineers have demonstrated these principles with a tele-polishing system using a FANUC CRX collaborative robot and a Logitech 310 controller. The system allows operators to perform high-precision polishing tasks remotely, maintaining quality and consistency while reducing the need for hands-on engagement with the material.

Key advantages of EWI’s tele-polishing approach include:

  • Real-time remote control for precise and consistent operations
  • Safer and more ergonomic working conditions for operators
  • Accessibility for operators of varied experience levels
  • Collection of operational data for in-process quality assurance
  • Flexible and adaptable setup for multiple applications and environments

To access the full paper for FREE, complete the form on this page.

To learn more, contact Luke Mohr, Data Science Engineering Group Leader, at lmohr@ewi.org.

Complete this form to download the paper:

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