STIR FRICTION WELDING

SENIOR DESIGNStudent: Jesse McDavitt (Mech.)

Class: ET-493Semester: Spring 2014

Advisor: Riana 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.

Time Line: Spring 2014 January 27th - February 14th- Meet and discuss project with Advisers. February 17th - February 21th- Work on Proposal February 24th - February 25th- Finish Proposal February 26th - February 28th Research COMSOL and how to use a moving mesh. March 3rd - March 28th - Work with COMSOL and making the simulation work. March 31th - April 11th - Input Dr. Mitra’s original design and test the simulation. April14th - May 2nd - Prepare for final presentation. Fall 2014 August20th - August22th - Meet with advisor and discuss last semester’s work. August25th - August29th - Begin working on design ideas and inputting into

simulation. September1st - October 3rd - Try different designs in simulations and find best. October6th - October17th - Have tool design sent off for fabrication. October20th - October24th - Begin defining parameters for welding procedure. October27th- October31st - Run and test procedure November3rd - November14th - Send test specimen off to be inspected and tested

for quality. November17th - November28th - Prepare for finale report and presentation.

Road Map

Currently working on inputting Dr. Mitra’s data into COMSOL

Road Blocks Do not have some of the Parameters Need to correlate Dr. Mitra’s experimental

results with COMSOL simulation.

Comparing Results

Figure 5

Figure 6

Questions

??

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 and 6 – How the simulation will

correlate with Original results.