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Tooled Welding
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I can say with absolute certainty that many of you reading this are now exploring the possibilities of transitioning your company from historically-dependent automotive markets, to newer, diversified markets such as alternative energy. But since this "green" movement is fledgling in its presence in North America there aren't many tool, die and mold shops that have gone before us and set a true precedent. A tried and true blueprint of "best practices". No specific steps, methods or guiding regulations clearly define the best point of entry for auto suppliers to manufacture wind, solar, hydropower and geothermal systems components.
The loss of domestic manufacturing jobs have been well-documented and perhaps some companies that were 100% reliant on the carmakers could be accused of myopic management. However, I feel very strongly that not only will the North American manufacturing sector bounce back but the Detroit Three will as well. However, as with any other strategy dealing with supply, demand, profits, losses and most important of all-risk-the number one rule will always be diversification.
Those companies who stay close with automotive and diversify into new markets like energy, medical, aerospace or military will be the strongest. And within energy circles, no other type of renewable power stands to grow as much as wind. Despite the lack of a map to follow, what does the TD&A recommend to a company trying to enter new markets such as supplying to wind energy manufacturers?
Whether a company builds or offers large transfer or smaller progressive stamping dies, injection mold machines, 5-axis machining or advanced welding operations-it's about knowing the current energy components being made and matching their manufacturing processes to their own capabilities.
Similarities & Differences of Manufacturing Philosophies
Although volumes are increasing, some notable differences between automotive and energy manufacturing philosophies are:
o Green components tend to be rather complex and in smaller volumes while auto parts are high volume and mass produced.
o Suppliers to car OEMs are familiar with fabricating many types of metals such as steel, HSS, or aluminum. Wind turbine manufacturers currently machine a couple steels too, such as aluminum but they focus more on composites such as fiberglass.
o Tier 2 and Tier 3 suppliers currently look for any excess that can be cut while energy suppliers are faced with the most efficient steps to expand.
o Geographic locations rather than union presence will play more of a factor of large wind and solar OEMs decision to relocate.
Geographic Location-not lack of union presence-provides Regional Advantages
General Electric recently stated that Michigan, Ohio, California and Texas are likely to be the largest "growth" states for wind turbine farms and production. It should be noted that it's not as easy to retool a stamping press that normally cycles out car hoods into one that is able to produce turbine blades. One thing auto suppliers do have going for them is the experience of adhering to demanding tolerances from auto OEMs.
With more efficient technologies in place, constant pressure for innovations and better technology the automotive industry is primed to make the leap into other markets after learning the requirements. Since most of you have been tooled up for high volume, for instance the large batch sizes car programs require for parts has made it logical to use metal stampings for cost efficiencies sake.
It will take different business process, operation and financial models. As mentioned above, perhaps dies were built for production life cycles of 4 million hits and now you only need tools for 40,000 parts. Perhaps there's some cost savings and efficiencies in scale by building tooling that doesn't necessarily need to withstand the heavy rigors of continuous pounding millions of cycles.
Geographic locations can provide competitive advantages for certain parts of the country where wind speeds are fast and consistent enough. Fortunately, some of the aforementioned states such as coastal states as California, the windy plains of Texas and especially the struggling economies of the rustbelt states around the Great Lakes.
Joe J. Brown
Uses for Ultra Sonic Welding
Ultra sonic welding is a technique that has been used for many decades and is being applied more and more as our technology and access to materials advances in the information age. In this article we will take a look at some areas wherein the use of ultra sonic welding may be quite useful to an endeavour.
First of all, consider price
While not as expensive as laser welding, using ultra sonic welding technology carries a significantly higher price tag than traditional heat and pressure welding or a soldering process. It is therefore best used when the end result of production is a piece of equipment or good that can be sold at a high value of return, or repaired for such.
Size of the materials
One of the most significant areas in which ultra sonic welding can be the best option is when bonding together materials that are too small to accommodate the normal welding process. The use of sonic waves to create a bonding frequency can be greatly focused and pinpointed, making it possible to work on surface areas that are only centimetres in square size. In addition, sonic welding can take place within a much smaller area as well.
The use of different materials
Sonic welding is also highly touted as a very effective way of bonding two dissimilar materials to each other in a much stronger way than can be achieved by any other welding process. In particular, various forms of plastics will achieve a lasting and hard to detect bond guaranteed to act more effectively than the use of glue or other adhesive materials.
Products created through ultra sonic welding
As you may have guessed from the above criteria, many of the devices and instruments in your home have likely been put together using ultra sonic welding techniques. Here are some of the items which rely on the process not only for creation, but often for repair as well:
Household: Cell phone parts, computer parts, DVD players, and even the inner workings of some automobile engines are bonded together through the use of ultra sonic welding.
In Medicine: Small and intricate medical instruments using several different types of materials are also dependent on ultra sonic welding technology. These tools use durable and non-contaminating plastics created on a small scale, and without the technology used in ultra sonic welding they would not function properly.
Ultra sonic welding may not be a process known to exist in every household, but it is central to many of the aspects of our daily lives.
About the Author
Wire harnesses and electrical cable assemblies are produced on electronic boards and checked with cable scanners for 100% continuity and point-to-point.
What's the name of (&where can I buy) a tool used in fabrication that sets a gap between two pipes (welding)?
Your talking about the root opening.
Remembering Rutherford: Ledgers were business necessities
Binded documents functional, artistic
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