1. Shock absorber manufacturing factory in Dayton, Ohio
2. Automotive structural fabrication factory in Portugal
3. Automotive factory in southern Spain
4. Automotive exhaust factory in India
5. Automotive rear-axle factory in Brazil
6. Brake systems manufacturer in Ohio
7. Large stainless steel paper pulp filter manufacturer in China

How do you help capture lessons learned from such efforts?
Lessons learned are only captured if they are used to change a drawing or a specification.  We help the customer accomplish such a change in their design or quality systems practice.  We also organize a training course at the end of the improvement effort to help everyone involved understand the improvements.

Can you help successfully validate difficult welding technologies and equipment for large-volume production?
We have accomplished this in many factories around the world.  Examples are given below.

An automotive strut rod (Chromium plated AISI 1045 steel) resistance welded to a low carbon steel part close to a heat-sensitive Teflon sleeve;  This part had to be water quenched upon welding to facilitate one-piece flow in manufacture;  we successfully quenched and tempered the weld in the weld tooling to facilitate such post-weld water cooling.  The equipment successfully manufactured parts for several years after this

A suspension component for a Range Rover vehicle in UK (AISI 4365 steel) that was resistance welded and had to pass impact tests at -40ºC;  we successfully accomplished this by managing post-weld cooling rates and weld and heat-affected zone microstructures

A large high-speed automated resistance seam-weld machine for a hot water heater manufacturer in the US:  We helped validate this machine by redesigning the weld tooling to nearly equalize heat and current densities on the outer and inner surfaces welded;  We also put in innovative new weld schedules for the weld starts and ends to accomplish tears outside the heat-pattern when tear-tested at the ends

Accomplishing a dissimilar stainless steel –commercially pure titanium tubular weld for a rocket nozzle; we accomplished this dissimilar material tubular weld by using a diffusion-barrier interlayer tube and solid-state interference welding the three tubes together.  The welds successfully passed thermal cycling tests from room temperature to a 1000ºC.

Welding low carbon steel rebound-stop sleeves to chromium plated shock rods (AISI 1045 steel) without making the weld or the heat-affected zone brittle; we again accomplished at many different locations by appropriately managing post-weld cooling rates.  These welds were made in large-volume production for many years.

Which welding processes can you help with?
We have validated large volume and/or high quality manufacturing  welding processes in the nuclear, automotive and other industries during the last three decades.  We have worked with every welding process in the books, such as arc, resistance, laser, electron-beam, friction, ultrasonic welding of a variety of materials.  We have even invented new welding processes when the existing welding processes are found to be inadequate in some way or other, having authored nearly twenty five US Patents on welding.  Some of the uncommon welding efforts lately include Induction Pressure Welding (IPW) of boiler tubes, Magnetically Impelled Arc Butt (MIAB) Welding of automotive axles, Focused Current Resistance Welding (FCRW) of automotive magnesium alloys and others

Can you help put in a company-wide welding quality system?
We were responsible for a global weld quality system in a large automotive manufacturer for nearly two decades and accomplished very high first time quality and customer satisfaction with respect to weld quality and durability.