Student: Jesse McDavitt (Mech.) Class: ET-494 Semester: Fall 2014 Advisor: Rana Mitra

STIR FRICTION WELDING

SENIOR DESIGNStudent: Jesse McDavitt (Mech.)

Class: ET-494Semester: Fall 2014 Advisor: Rana Mitra

BackGround

Friction Stir Welding (FSW) was invented in 1991

Figure 1

Objective

Overall-To perform an experiment with Friction stir welding continuing Dr. Mitra’s pervious work.

Simulate FSW in COMSOL Improve tool design Fabricate tool Write a procedure for FSW govern by

ASME (BPVC )Section IX

Challenges

Heat Generation at tool pin and shoulder Tool Design Speed of rotation Normal Force Large Material Deformation Extrusion Forging

Original Design

Poor quality welds with major defects

Figure 2

Defects

Figure 3

Improving Experiment

Ideas –Tool design

Figure 4

Improving Experiment

COMSOL simulation Simulate different designs Different Forces and Angular velocity Different Radius on shoulder and pin Written procedure Standards to govern (guidelines)

Deliverables:

A simulation using finite element analysis (COMSOL) that will determine the best options for designing a suitable tool geometry (or geometries) for specific heat transfer and deformation conditions.

Tool-Design 3-D Construct of Tool The Tool Geometry (Curved Shoulder/Grooved

tip/Cylindrical Shape, etc.) A procedure for friction stir welding that will be

governed by Welding Standard ASME Section IX 2013 ed.

Test specimens showing the experimental results.

Road Map

Currently on designing the WPS

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TASKS COMPLETED

Knowledge of Heat Transfer Found a Simulation in COMSOL Researched the essential welding

variables out of section IX of ASME Boiler & Piping Code

Define the parameters for the COMSOL

TASK TO BE COMPLETED

Write WPS Pick tool design Have tool Milled Qualify WPS with PQR

Have specimen tested.

Questions

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Figures

Figure 1 - Demo of FSW with Forces Figure 2 - Dr. Mitra’s Original Design

Material MP159 Alloy Figure 3 – Defects found in test specimen Figure 4 – Tool Geometry Examples From

ASME Figure 5-15 – Excerpts from ASME Section

IX BVPC.