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

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

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

5. Poor quality welds with major defects Figure 2

6. Figure 3

7.  Ideas –Tool design Figure 4

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

9.  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.  Currently on designing the WPS Figure 5

11. Figure 6

12. Figure 7

13. Figure 8

14. Figure 9

15. Figure 10

16. Figure 11

17. Figure 12

18. Figure 13

19. Figure 14

20. Figure 15

21.  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

22.  Write WPS  Pick tool design  Have tool Milled  Qualify WPS with PQR  Have specimen tested.

23. ?? ??

24.  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.