1. Stir Friction Welding Senior Design
Student: Jesse McDavitt (Mech.)
Class: ET-493
Semester: Spring 2014
Advisor: Riana Mitra

2. BackGround
Friction Stir Welding (FSW) was invented in 1991
Figure 1

3. 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

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

5. Original Design
Figure 2
Poor quality welds with major defects

6. Defects
Figure 3

7. Improving Experiment
Ideas –Tool design
Figure 4

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

9. 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.

10. 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.

11. Comparing Results
Figure 5
Figure 6

12. 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

13. Questions ?

14. 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.