september 13, 2011 dissimilar materials joining seminar chris conrardy chief technology officer...
TRANSCRIPT
September 13, 2011
Dissimilar Materials Joining Seminar
Chris ConrardyChief Technology [email protected]
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 [email protected]