Innovative Thinking Sparks Superior Success

A thorough knowledge of process and materials is extremely valuable in manufacturing when a problem presents itself and no clear solution seems viable. Superior Joining Technologies, a precision welding lab in Machesney Park, IL, demonstrated their knowledge of both when Hamilton Sundstrand came to them with a unique challenge involving a weld of dissimilar aluminum alloys for a new generator rotor assembly. By taking a different approach to a problem that had baffled others before them, Thom Shelow, owner of Superior Joining, was able to deliver a viable solution that met all of Sundstrand's requirements and even exceeded expectations.

Building Trust on a Quick Turnaround

When Hamilton Sundstrand contacted Shelow, the need for a quick solution was rapidly gaining momentum. Having never worked with this group before, Shelow knew he had to produce something of merit, very quickly, to gain Sundstrand's trust. The same day we met, I did a sample of the joint for [Hamilton Sundstrand] to consider. They took it back, cut it up and analyzed a cross-section of it and determined that it had potential. From there, we were onboard to take the process to the next step said Shelow. Michael OToole, Senior Research Engineer for Hamilton Sundstrand saw Superior Joining's response as a telling sign. I was really pleased with Thom's quick turnaround to our challenge. He really gave us the piece of mind we were looking for, he said.

A Different Approach to the Problem

The major challenge with the project was joining dissimilar aluminum parts so they would conduct electricity and form a magnetic field. It had to be a thorough fusion of the parts. They could not be connected in specks, we had to figure out how to make the two pieces into one, Shelow added. In contrast to previous approaches to the problem, Superior Joining recommended a more conventional process with a slight reconfiguration of the joint. Using a Gas Tungsten Arc Weld (GTAW) Shelow was able attain the bond needed without exposing the material to unnecessary stress. Another concern was the heat used during the welding process and its effect on the material. To avoid overheating and distortion of the material, Shelow devised a series of devices, fixtures and Heat Sinks that chilled the critical components during the welding process. We took measurements of each component during the welding process and found each part stayed well within the temperature limits throughout the process, said Michael OToole, Senior Research Engineer for Hamilton Sundstrand. He added, Thanks to Superior Joining, our resulting assemblies met all inspection criteria and exceeded our strength requirements.

Coming Through in the Clutch

Leveraging a keen knowledge of their process and an out-of-the-box approach, Superior Joining Technologies was able to gain the trust of a major manufacturer and deliver a solution that either met, or exceeded expectations. Michael OToole praised Shelow and his team for their dedication to the success of the project and added, Superior's responsiveness and support enabled us to meet the on-time, quality performance that our customers expect of Hamilton Sundstrand.