Student: Jesse McDavitt (Mech.) Class: ET-493 Semester: Spring 2014 Advisor: Riana Mitra

 Friction Stir Welding (FSW) was invented in 1991 Figure 1

 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

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

Poor quality welds with major defects Figure 2

Figure 3

 Ideas –Tool design Figure 4

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

 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.

 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.

 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.

Figure 5 Figure 6

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 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.