frictionstirprocessing (1)
TRANSCRIPT
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 131
Friction Stir
R S Mishra K Krishnamur
D Van AkenMissouri University of S
Processing
hy R Landers V Richards
J Newkirk cience and Technology
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 231
bull Intelligent Control and NDE for def PIs K Krishnamurthy R Landers
Talwar R Lederich J Baumann
ndash FSW runs with mismatches and g
ndash Process control algorithms ndash K Kri
ndash NDE techniques ndash V Richardsbull Corrosion Prevention of FSW joint
Boeing John Baumann
ndash Metallic and Polymeric sealants ndash
ndash Surface modification ndash J Newkirk
ndash Static and Fatigue of T joints expo
bull Friction Stir Lap Weld Joint Proper
Mishra S Madria and J Baumann
CAMT FSW Projects O
ct free complex FSW joints (MSampTV Richards R Mishra Boeing R
ps ndash R Mishra R Landers
shnamurthy R Landers
(MSampT PIs D Van Aken J Newkirk
Van Aken
ed to salt fog ndash D Van Aken
y Characterization of Al Li alloys ndash R
erview
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 331
bull Friction Stir Welding and Pro ndash NSF IUCRC (Boeing GM PNNL
bull Microstructural Modification
bull Robotic thin sheet welding
bull Friction stir spot weldingbull E design tools for FSWP (with
ndash NSF project on FS Channeling
ndash ONR STTR on FSP for Superplast
ndash AFOSR STTR on Ultrafine Graine
ndash PampW FSW project on advanced al
Current Additional Rese
essing ResearchSL)
Virginia Tech)
ic Forming with Friction Stir Link
7XXX with Friction Stir Link
minum
rch Projects Overview
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 431
FSP Machine ndash 3 axisFunded by NSF 2000
FSP Infrastructure at M ampTRobotic FSP Machine ndash 6 axis
Funded by ONR 2004
Friction Stir Spot Welding MachineFunded by AFRL 2004
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 531
Mini Tensile and Mini Fat gue Testing Mini fatigue of 7075 T6
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 631
Friction Stir Welding Basic Process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 731
Friction Stir Attributes
bull Large plastic strainbull High strain rate
bull Elevated temperatures
bull Mechanical mixing
bull Material flow
Microstructural Features
bull Fine grain size
bull Homogenization
bull Primary particle breakd
Friction Stir Proces
Potential flaws
bull Wormholes
wn
es
Channeling
Surface composite
Powder processing
Superplasticity
Casting modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 231
bull Intelligent Control and NDE for def PIs K Krishnamurthy R Landers
Talwar R Lederich J Baumann
ndash FSW runs with mismatches and g
ndash Process control algorithms ndash K Kri
ndash NDE techniques ndash V Richardsbull Corrosion Prevention of FSW joint
Boeing John Baumann
ndash Metallic and Polymeric sealants ndash
ndash Surface modification ndash J Newkirk
ndash Static and Fatigue of T joints expo
bull Friction Stir Lap Weld Joint Proper
Mishra S Madria and J Baumann
CAMT FSW Projects O
ct free complex FSW joints (MSampTV Richards R Mishra Boeing R
ps ndash R Mishra R Landers
shnamurthy R Landers
(MSampT PIs D Van Aken J Newkirk
Van Aken
ed to salt fog ndash D Van Aken
y Characterization of Al Li alloys ndash R
erview
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 331
bull Friction Stir Welding and Pro ndash NSF IUCRC (Boeing GM PNNL
bull Microstructural Modification
bull Robotic thin sheet welding
bull Friction stir spot weldingbull E design tools for FSWP (with
ndash NSF project on FS Channeling
ndash ONR STTR on FSP for Superplast
ndash AFOSR STTR on Ultrafine Graine
ndash PampW FSW project on advanced al
Current Additional Rese
essing ResearchSL)
Virginia Tech)
ic Forming with Friction Stir Link
7XXX with Friction Stir Link
minum
rch Projects Overview
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 431
FSP Machine ndash 3 axisFunded by NSF 2000
FSP Infrastructure at M ampTRobotic FSP Machine ndash 6 axis
Funded by ONR 2004
Friction Stir Spot Welding MachineFunded by AFRL 2004
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 531
Mini Tensile and Mini Fat gue Testing Mini fatigue of 7075 T6
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 631
Friction Stir Welding Basic Process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 731
Friction Stir Attributes
bull Large plastic strainbull High strain rate
bull Elevated temperatures
bull Mechanical mixing
bull Material flow
Microstructural Features
bull Fine grain size
bull Homogenization
bull Primary particle breakd
Friction Stir Proces
Potential flaws
bull Wormholes
wn
es
Channeling
Surface composite
Powder processing
Superplasticity
Casting modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 331
bull Friction Stir Welding and Pro ndash NSF IUCRC (Boeing GM PNNL
bull Microstructural Modification
bull Robotic thin sheet welding
bull Friction stir spot weldingbull E design tools for FSWP (with
ndash NSF project on FS Channeling
ndash ONR STTR on FSP for Superplast
ndash AFOSR STTR on Ultrafine Graine
ndash PampW FSW project on advanced al
Current Additional Rese
essing ResearchSL)
Virginia Tech)
ic Forming with Friction Stir Link
7XXX with Friction Stir Link
minum
rch Projects Overview
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 431
FSP Machine ndash 3 axisFunded by NSF 2000
FSP Infrastructure at M ampTRobotic FSP Machine ndash 6 axis
Funded by ONR 2004
Friction Stir Spot Welding MachineFunded by AFRL 2004
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 531
Mini Tensile and Mini Fat gue Testing Mini fatigue of 7075 T6
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 631
Friction Stir Welding Basic Process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 731
Friction Stir Attributes
bull Large plastic strainbull High strain rate
bull Elevated temperatures
bull Mechanical mixing
bull Material flow
Microstructural Features
bull Fine grain size
bull Homogenization
bull Primary particle breakd
Friction Stir Proces
Potential flaws
bull Wormholes
wn
es
Channeling
Surface composite
Powder processing
Superplasticity
Casting modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 431
FSP Machine ndash 3 axisFunded by NSF 2000
FSP Infrastructure at M ampTRobotic FSP Machine ndash 6 axis
Funded by ONR 2004
Friction Stir Spot Welding MachineFunded by AFRL 2004
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 531
Mini Tensile and Mini Fat gue Testing Mini fatigue of 7075 T6
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 631
Friction Stir Welding Basic Process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 731
Friction Stir Attributes
bull Large plastic strainbull High strain rate
bull Elevated temperatures
bull Mechanical mixing
bull Material flow
Microstructural Features
bull Fine grain size
bull Homogenization
bull Primary particle breakd
Friction Stir Proces
Potential flaws
bull Wormholes
wn
es
Channeling
Surface composite
Powder processing
Superplasticity
Casting modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 531
Mini Tensile and Mini Fat gue Testing Mini fatigue of 7075 T6
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 631
Friction Stir Welding Basic Process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 731
Friction Stir Attributes
bull Large plastic strainbull High strain rate
bull Elevated temperatures
bull Mechanical mixing
bull Material flow
Microstructural Features
bull Fine grain size
bull Homogenization
bull Primary particle breakd
Friction Stir Proces
Potential flaws
bull Wormholes
wn
es
Channeling
Surface composite
Powder processing
Superplasticity
Casting modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 631
Friction Stir Welding Basic Process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 731
Friction Stir Attributes
bull Large plastic strainbull High strain rate
bull Elevated temperatures
bull Mechanical mixing
bull Material flow
Microstructural Features
bull Fine grain size
bull Homogenization
bull Primary particle breakd
Friction Stir Proces
Potential flaws
bull Wormholes
wn
es
Channeling
Surface composite
Powder processing
Superplasticity
Casting modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 731
Friction Stir Attributes
bull Large plastic strainbull High strain rate
bull Elevated temperatures
bull Mechanical mixing
bull Material flow
Microstructural Features
bull Fine grain size
bull Homogenization
bull Primary particle breakd
Friction Stir Proces
Potential flaws
bull Wormholes
wn
es
Channeling
Surface composite
Powder processing
Superplasticity
Casting modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 831
Center for Friction Stir Pro KEY Technological Areas
50 mm
Before After
50 mm
Friction Stir Powder Processing
Before After
Friction Stir CastingModification
Friction Stir Welding
FrictionSurfaci
Parent Technology and TWI Patent
CFS
essing ndash Overview
US Patent 6655575
US Patent 6923362
Friction Stir Superplasticity
Friction Stir
Channeling
Friction Stir
Microformingtir g
US Patent 6712916
US Patent
filed
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 931
0 5 10 15 200
200
400
600
800
1000
1200
1400
1600
H e a t
i n
Coarsened grains
and particles
Worm ho
HOT
R P M
IPM
Process map for butt jo
Process map for the friction
bullMaximum tensile properties at n
values between 65 and 10
25 30 35 40
H e a t i n d
e x = 6
4 e x = 1
0
le defect
COLD
nts
stir welding of Al 2024 (T8)
gget are achieved at heat index
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1031
Problem Description
bull Improper fixturing can cause ga
poor welds
bull Analysis tools are needed when
Project Objectives
bull Create and validate force contr
bull Develop analysis tools for FSW
Implementation of Intellig
s and mismatches which lead to
designing new FSW processes
l strategies
processes
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1131
Boeing Brotje FSW
bullSpecific solutions for produ
Implementation of Intel
Production Machine
ction machines
ligent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1231
Force Modeling (
The static and dynamic force proce
Axial Force Results
0 20 40 60 802
3
4
5
F
z ( k N ) Measured Modeled
0 20 40 60 804
45
5
Time (s)
d(mm)
2002
04
F x
S c e n a r i o 1 ( k N )
M
20
2
3
4
v ( m m s )
Scen
6061 Aluminum)
s characteristics were modeled
40 60
asured Modeled
20 40 6002
04
F x
S c e n a r i o 2 ( k N )
Measured Modeled
40 60Time (s)
rio 1 Scenario 2
20 40 6012
14
16
18
2
22
w ( k
r p m )
Time (s)
Scenario 1 Scenario 2
Path Force Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1331
Axial Force Controlle
m
Top axial force with force control (
Bottom axial force without force c
Results (gap = 0381
)
variation ~ 01 kN)
ontrol (variation ~ 04 kN)
20 40 6029
3
F a
( k N )
20 40 60421
433
d c
( m m
)
Time (s)
20 40291
329
Time (s)
F a
( k N )
Measured
Reference
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1431
Axial Force Controller
0762
Axial force and commanded depth wit
1
Travel Direction
Shim Side View
Top View
End Location Start Location
Shim
esults (gap = 0381 rarr
mm)
h force control (variation ~ 01 kN)
20 40 60
295
3
305
F a
( k N )
Measured Reference
20 40 60
4
405
41
d c
( m m )
Time (s)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1531
Path Force Co
10 20 30 40
05
1
15
F p
( k N ) Measured
Reference
10 20 30 40
1
2
w c
( k r p m )
Cont Onreg
Time (s)
(a) nugget with force control
(b) nugget without force control
troller Results
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1631
Analysis of 2024 Alumi
To
Frequency analysis process
effects dominate structural effects
100 120 140 160 180 200 2200
200
400
600
F o r c e ( l b
s )
Time (sec)
Run 1
0 500
100
200
300
M a g ( l b 2 )
F1
0 500
100
200
300FMAX
0 500
100
200F2
0 500
100
200FMIN
0 500
1
2
3
M a g ( l b 2 )
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
0 500
1
2
3
Frequency (Hz)
um with Fixed and RP
ls
Cross section analysis
most runs had no defects
Force analysis path force
mainly affected by travel speed
and pin force is not highly
correlated with process
parameters
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1731
Conclusions
bull FSW processes for 6061 Al hav
bull Control of both axial and path fo
the presence of gaps and mism
bull Analysis tools have been devel
investigate forces in both frequebull Atlas of discontinuities complet
Capabilities
bull Missouri SampT has expertise in a
including dynamic modeling
bull Missouri SampT has expertise in c
when gap and mismatches are
Implementation of Intellig
been successfully modeled
rces have been achieved even in
tches
ped for FSW processes to
ncy and time domainsd
nalyzing FSW processes
ontrolling FSW processes even
present
ent Process Control
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1831
Corrosion Prevention o
Example shows corrosion in FSW 7075 of 500h exposure in neutral sa
The current manufacturing
joints to contain a faying
An additional complication is that thsensitivity
FSW Lap Joints result in cre
FSW Joints
73 Al as a result lt fog
approach requires riveted
urface protective sealant
thermal exposure of FSW increaseso corrosion
ices on both sides of the weld
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 1931
MSampTrsquos Nylon 11 Approac
The FSW operation melts the nylon which
forms a protective fillet upon solidifying
MSampTrsquos Appro bull Apply a thin (0003rdquo) layer of
thermoplastic sealant) to th
bull Weld through this sealant
This sealant is available from MortonCompany as Corvelreg white 78 1001Melts at 185ordmC salt spray resistant
Costs about $10lb
h to Corrosion Protection
chnylon 11 (polyamide
flange of a lsquoTrsquo prior to welding
Polished cross section of the FSW joint
shows that sealant fills crevices between
faying surfaces but has been expelled
from immediate region of the joint
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2031
Joint Strengths are Deter
lsquoTrsquo Pull off testing causes the skins to ustiffer indicating that this sealant carrie
load Sudden drops correspond to fail
ined by T Pull off Tests
plift The joints sealed with nylon 11 arean appreciable portion of the applied
re in the seals on each side of the T
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2131
Adhesive failure of ano
Sealant
0
500
1000
1500
2000
0 002 004 006 008 0
Anodized
1263 28 sealant1266 28
P o u n d s f o r
c e p e r i n c h o f w e l d
Displacement in inches
Sealant adheres to anodi
aluminum interface with
ized layer
Cast A357
Anodized Layers
1
ed layer and failure initiates at
nodized layer
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2231
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2331
Thermoplastic sealants
bull Significant advantage joints
bull thermoplastic bondingduring fatigue loading
bull thermoplastics are eff bull thermoplastics are ea
bull Disadvantages of the
bull FSW is much more of bull initial lift off of top skin
for FSW summar
s of ldquobondedrdquo amp welded lap
shields nugget root weld defects
ctive corrosion sealantsily repairable by reheating
moplastic sealants
a thermal management problemis serious draw back
Metal superplasticity enhan
ement and forming process
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2431
US Patent 6712916 Mishra
FSP will enable new technologibull Selective superplasticity
bull Superplasticity in thick sheetsbull Superplastic forging
bull High strain rate superplasticity fr
bull Superplasticity in contoured she
FSP
nd Mahoney March 30 2004
s and concepts such as
om cast or hot pressed sheet and
ts
omponent courtesy the Boeing Phantom Works
Large Scale Feasibility Demonstration
Rockwell Scientific and Superform
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2531
Superplastic ductility i
bull High strain rate superplastiin three commercial alloys
104
103
102
101
100
0
200
400
600
800
1000
1200
1400
16001800
Superplastic Ductility
480oC
430oC
530oC
480oC
FSP 7075 Al
As rolled 7075 Al
FSP 2024 Al
FSP 5083 Al
E l o n g
a t i o n ( )
Strain Rate (s1
)
n FSP Al alloys
ity has been demonstrated7075 2024 and 5083 Al
400 420 440 460 480 500 520 540 5600
200
400
600
800
1000
1200
1400
16001800
Abnormal Grain Growth
Strain Rate 10x102
s1
Temperature (oC)
FSP 7075 Al (38 mm)
FSP 2024 Al (39 mm)
FSP 5083 Al (6 mm)
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2631
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2731
OslashSi Particle refinement by
OslashStrength improvement by
OslashDuctility improvement by
OslashThe Quality Index improvplates to gt500 after FSP a
Friction Stir Processin
900 rpm8 ipm
factor of 3
more than 5010X
s from ~200 for as castn increase of more than 2X
Casting Modification
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2831
Friction Stir Casting
Oslash 80 improvement in
103
104
1
0
50
100
150
200
250
300
runout
As cast
FSP
Cast + T6
FSP + T6
M a x i m u m S
t r e s s
M P a
Num
odification
atigue strength
5
106
107
108
R = 01
er of Cycles
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 2931
Friction Stir Casting
Oslash Toughness impr
1106
105
104
103
102
Cast A356Cast + T6
FSP A356
FSP + T6
R = 01
d a d N
( m m
c y c l e )
D
odification
vement by 50
10 100
MPa m12
Integral channels in metal components
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3031
US Patent 6923362
Friction stir channeling will enabull Production of integral channels i
bull Incorporation of cooling or heati
a solid component and
bull Design of single piece heat exch
ishra August 2 2005
le concepts such asplates dies and permanent molds
g channels on a curved surfaces of
angers
Internal
Friction
Stirred
Channel
InletOutlet
Connectors
Monolithic
Plate
Integral
channels
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts
862019 FrictionStirProcessing (1)
httpslidepdfcomreaderfullfrictionstirprocessing-1 3131
FSP is a versatile soli
manufact
Our work includes solutions to
bullFundamental understanding
bullProcess parameter developmbullDevelopment of microstructur
bullProcess control development
bullMetallurgical characterization
state processing and
ring tool
applications
f the friction stir process
ent for industrial implementational modification concepts