CW-EMD
Manufacturing Capabilities

The Division's manufacturing operations are qualified to military standards and are among the most broad-based in the world. CW-EMD's manufacturing operations personnel consist of master and journey level machinists, machine operators, electrical coil winders, welders and brazers, assemblers and maintenance technicians. The Division's manufacturing operations are supported by a full complement of manufacturing engineers, material and process engineers, numerical control programmers, tool designers, quality engineers, inspectors and cognizant design/analytical engineers. CW-EMD currently machines a wide range of components to tolerances as small as .0001 inches. High-speed rotors are regularly precisely machined at CW-EMD. The Division routinely welds materials ranging from 0.018-inch to 8 inches thick and is a world leader in the manufacture, assembly and welding of thin, high-reliability stator and rotor cans, as well as other critical application pressure boundary components.

Welding
CW-EMD employees have welding expertise working with carbon steel, low and high alloy, stainless, nickel and copper base. The Division uses the following welding processes:

Shielded Metal Arc Gas Tungsten Arc (manual, automatic, hot wire) Gas Metal Arc Plasma Arc (manual, automatic) Submerged Arc Can Fabrication Additionally, CW-EMD offers the following special applications: Can Fabrication Dissimilar Metal Welding Narrow Groove Welding Buttering, Cladding

Winding
CW-EMD employees have expertise in the winding of all electrical machines and provide resistance, induction and torch blazing to military standards. Additionally, CW-EMD provides electrical testing, vacuum impregnation and sand potting insulation. Winding involves an operator placing electrical conductors either in the shape of preformed insulated copper strands or soft copper wire into machined or formed slots located circumferentially around the inside diameter of stator cores or the outside diameter of rotors. The copper strands are secured in place by installing micarta and or ceramic wedging material in the top of the slots. Subsequent winding functions include the joining of individual copper strands or wire to create the required electrical configuration using either soldering or brazing metal joining techniques. All electrical connections are ultimately insulated before operation by applying the appropriate insulating resins, putties, binders and tapes.

Machining
CW-EMD has 80 machines and two automated multi-machine manufacturing cells. Additionally, the Division has the capability to superfinish rotor journals and utilize manufacturing/assembly cells for key products. Machining involves forming metal, plastic and composite parts to specified drawing configurations by bringing a cutting tool in contact with the appropriate material and manipulating the cutter using manual and or computer controlled techniques to achieve the desired part configuration and finish. A variety of cutting tools, drilling, milling and turning manual and computer controlled machines and fixtures are used to achieve the desired results.

Assembly
CW-EMD has a clean room assembly facility per military standards and crane capacity up to 70 tons. Assembly involves the application of mechanical manipulation techniques to individual machined and or fabricated components resulting in a desired configuration per engineering drawing that yields subassemblies that are subsequently configured into a final major assembly yielding a finished pump, propulsor, motor or generator product.

Inspection
CW-EMD's inspection capabilities include personnel trained and qualified to stringent Military and ASME Code criteria. Inspection processes include both dimensional and nondestructive testing methodologies. Dimensional inspections are done using a comprehensive inventory of standard inspection equipment, various automated coordinate measuring machines and other equipment that are calibrated and capable of determining dimensional features from 10 ^ -6 inches. The nondestructive inspection processes are visual examination, liquid penetrant, magnetic particle, radiographic and ultrasonic testing.