Friction Stir Welding and Processing XII: Derivative Technologies
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Shaping and Forming Committee
Program Organizers: Yuri Hovanski, Brigham Young University; Yutaka Sato, Tohoku University; Piyush Upadhyay, Pacific Northwest National Laboratory; Anton Naumov, Peter The Great St. Petersburg Polytechnic University; Nilesh Kumar, University of Alabama, Tuscaloosa
Thursday 2:00 PM
March 23, 2023
Room: 29A
Location: SDCC
Session Chair: Carter Hamilton, Miami University; Keerti Kappagantula, Pacific Northwest National Laboratory
2:00 PM Invited
Assessing the Performance of Liquid Cooled Plates for Inverter Stacks Produced by CoreFlow: Joao Gandra1; Sam Holdsworth1; Jonathan Peter Martin2; 1TWI Ltd.; 2TWI
TWI Ltd has recently invented a new sub-surface machining technique called CoreFlow™. This new solid-state process is an evolution from friction stir welding and friction stir channeling that allows for sub-surface networks of channels to be machined within monolithic metallic parts in a single manufacturing step. The present investigation addresses the manufacturing of liquid cooled plates for inverter stack assemblies typically used in transport applications and power generation. Channels exhibiting a cross section of 6x2mm were produced in AA6082-T6 plates measuring 300x200mm, with a thickness of 8mm. Serpentine prototypes were produced and benchmarked against traditional manufacturing methods for a number of key performance variables, namely thermal efficiency, pressure loss and pump flow energy consumption. Cold plates manufactured by CoreFlow™ showed improved thermal efficiency with respect to conventional press-lock smooth copper tubing cold plates with comparable volume for a given flow rate. Data on the economic savings are presented.
2:20 PM Invited
Submerged Bobbin Tool (SBT) Tunneling Technology: Dwight Burford1; Maurizio Manzo1; Hector Siller1; Supreeth Gaddam1; Anurag Gumaste1; James Koonce1; Aleandro Saez1; Rajiv Mishra1; 1University of North Texas
Submerged bobbin tool (SBT) tunneling is a new friction stir processing (FSP) technique for making integral channels within malleable materials. Like a conventional bobbin tool (BT) for friction stir welding (FSW), an SBT toolset has two opposing shoulders spaced apart along the bobbin or probe section of the tool. Unlike a conventional BT, an SBT is used to form integral sub-surface channels by passing the shoulder at the distal end of the probe through the workpiece during processing. Example uses of internal pathways are found in heat exchangers, cooling plates, and vacuum tools. Advance uses may include lessening weight and modifying the stiffness of structural components. A preliminary evaluation in AA6061-T6511 plates shows this special form of FSP has low process forces and is therefore capable of being deployed on CNC (computer numerical control) machining centers and friction stir-capable industrial robots as well as purpose-built FSP machines. Consequently, SBT tunneling holds potential use in a wide range of applications requiring curvilinear internal pathways for wiring, gases, and fluids, as well as internal spaces for the placement of powders and solid materials like composites.
2:40 PM
Friction Extrusion of Thermoplastics: Manufacturing and Recycling: Xiao Li1; Tianhao Wang1; Russ Burnett1; Aye Meyer1; Yelin Ni1; Wenbin Kuang1; Kevin Simmons1; 1Pacific Northwest National Laboratory
Plastic waste is an urgent global issue for environmental protection and sustainable energy. The existing methods of recycling end-of-user mixed plastics are energy-inefficient and uneconomic. This work developed friction extrusion as a new technology that manufactures and recycles thermoplastics with high energy efficiency and low cost. Single stream Polypropylene (PP), Polyethylene (PE), and Acrylonitrile butadiene styrene (ABS) filaments were extruded respectively from powder, pellet, or solid billet precursors. Mixed plastics were also recycled into a homogeneous composite filament via single-step friction extrusion. The crystallinity of the filaments was determined by Differential Scanning Calorimetry (DSC) and correlated with process thermal history. Tensile properties were tested and compared to the raw materials. The energy efficiency of friction extrusion plastic recycling was estimated, and the economic impact of the technology is discussed.
3:00 PM
In-Situ Friction Stir Forging: An Innovative and Alternative Approach towards Gear Fabrication: Hrishikesh Das1; Vineet Joshi1; Lei Li1; Nicole Overman1; Jens Darsell1; Piyush Upadhyay1; Ayoub Soulami1; Darrell Herling1; Mark Rhodes1; 1Pacific Northwest National Laboratory
In this work we present first direct experimental evidence of single step manufacturing process to produce gears via an innovative In-situ friction stir forging (I-FSF) process. The I-FSF process is robust and viable for wide range of non-ferrous materials and fabricating complex designed forged product. We successfully demonstrated manufacturing of 8 and 14 teeth spur gears and 6 teeth fin gears in this work. A thermomechanical smoothed particle hydrodynamics (SPH) model was developed to simulate in-situ friction stir forged 14 teeth spur gear to understand material flow pattern radially and through thickness in gear teeth. The plastic strain distribution and temperature profile were also simulated using the SPH model. EBSD analysis exhibits directional material flow pattern due to forging action and formation of dynamically recrystallized grains across radial, through thickness direction. The flow pattern determined using imaging, and temperatures measured were in good agreement with the corresponding SPH simulation results
3:20 PM
Investigation of Shear Deformation Introduction n Friction Extrusion from Al-Cu Alloy: Lars Rath1; Uceu Suhuddin1; Benjamin Klusemann1; 1Helmholtz-Zentrum Hereon
Friction extrusion describes the extrusion of metallic materials via severe plastic deformation induced by frictional heating and shear strain. A relative rotational motion between die and billet characterizes the process that offers the capability of processing a wide range of alloys at a lower energy demand due to locally introduced energy. In order to fully utilize the potential of the process to generate wires and bars with refined and homogenized microstructure, control of the shear deformation in the core area is of importance. In front of the central die bore no shearing can be imposed onto the billet material via friction and the relative velocity towards the die face reaches a minimum. Therefore, this work is investigating the mechanisms controlling the deformation and subsequent grain refinement in the core region. The experimental approach focuses on geometrical modification of billets from Al-Cu alloy to determine material conditions during friction extrusion.
3:40 PM Break
4:00 PM
Robust Temperature Control for Shear Assisted Processing and Extrusion (ShAPE): Woongjo Choi1; Xiao Li1; Kenneth Ross1; 1Pacific Northwest National Laboratory
This work presents robust temperature controlled copper wire extrusion via Shear Assisted Processing and Extrusion (ShAPETM). In the ShAPE process, a rotating tool generates heat at the tool/billet interface. In this demonstrated temperature control algorithm, the amount of heat generated through the spindle axis is controlled by the modulating mechanical input power, which is the product of torque and speed of the spindle motor. The torque modulation of the spindle motor in response to spindle speed feedback is used to control spindle power. Temperature measured at the tool workpiece interface is controlled using a novel proportional–integral–derivative (PID) closed loop structure that sets the spindle power setpoint. Empirical system identification via frequency analysis was conducted to model the system and understand how model parameter varies with various conditions. The results show that the developed algorithm successfully achieve both process stability and disturbance rejection in ShAPE.
4:20 PM
The Effect of Additional Impulses on Microstructure and Mechanical Performance of Impulse Friction Stir Welded AA7075-T6 Joints: Keqi Wang1; Svetlana Shalnova2; Anton Naumov1; Olga Klimova2; Fedor Isupov1; Ahmad Alali Alkhalaf1; 1Peter The Great St. Petersburg Polytechnic University; 2St. Petersburg State Marine Technical University
Electron backscatter diffraction (EBSD) was used to study the microstructure characteristics of different regions in 7075-T6 aluminum alloy (AlZnMgCu1.5) joint by impluse friction stir welding and conventional friction stir welding. According to the EBSD results, combined with the precipitation behavior and mechanical properties of the welded joints the effect of impulses was investigated for AA7075-T6 joints. By means of IFSW a fine-grained equiaxed microstructure in the Stir zone (SZ), the fraction of the low-angle grain boundaries (LAGBs) and high-angle grain boundaries (HAGBs) distribution for the SZ and Heat-Affected zone (HAZ) of the studied joints are obtained, the transformation of the LAGBs into HAGBs occurred more effectively under impulses influence. Higher mechanical performance of the joints produced by IFSW could be related to the grain refinement and the transformation of the grain orientation.