Student: Jesse McDavitt (Mech.) Class: ET-494 Semester: Fall 2014 Advisor: Rana Mitra.
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Transcript of 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
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
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
??
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.