University of Kentucky
Studies in Engineering and Physics: Study 2: Friction Stir Welding: Green Manufacturing Technology
Institution
University of Kentucky
Faculty Advisor/ Mentor
Philip Metzger; Alan Male
Abstract
Friction stir welding is an approximately ten-year old technology initially developed by The Welding Institute of Cambridge, England. Unlike conventional welding, it does not involve melting of the component materials, thus requiring lower temperatures with no noxious fumes emitted. It has been demonstrated to require less total energy and be a more inexpensive process than fusion welding; the resulting welds have generally superior properties. In Friction Stir Welding, a rotating tool with either a slightly angled shoulder and pin or a self-reacting pin (developed by NASA) is pushed along the joint between two adjacent metals. The friction between the shoulder and the material heats the material sufficiently to allow the tool to mix the materials together, thus creating a weld. The process is energy efficient and doesn’t require a skilled welder for operation, thus reducing cost to industry while providing the possibility for more jobs. Until recently, the process has been developed primarily for high performance and aerospace applications. However, the potential benefits make it advantageous to search for wider applications in manufacturing operations. This study was conducted in collaboration with a Kentucky company to apply the process to join thin lead sheets in a near perfect manner so that the seam of the weld is smooth enough to be used in the making of x-ray machine shields. Ultimately, it is anticipated that a portable, hand-held device will be developed to allow roofers to use it to join lead or copper sheets together safely without the potential of fire.
Studies in Engineering and Physics: Study 2: Friction Stir Welding: Green Manufacturing Technology
Friction stir welding is an approximately ten-year old technology initially developed by The Welding Institute of Cambridge, England. Unlike conventional welding, it does not involve melting of the component materials, thus requiring lower temperatures with no noxious fumes emitted. It has been demonstrated to require less total energy and be a more inexpensive process than fusion welding; the resulting welds have generally superior properties. In Friction Stir Welding, a rotating tool with either a slightly angled shoulder and pin or a self-reacting pin (developed by NASA) is pushed along the joint between two adjacent metals. The friction between the shoulder and the material heats the material sufficiently to allow the tool to mix the materials together, thus creating a weld. The process is energy efficient and doesn’t require a skilled welder for operation, thus reducing cost to industry while providing the possibility for more jobs. Until recently, the process has been developed primarily for high performance and aerospace applications. However, the potential benefits make it advantageous to search for wider applications in manufacturing operations. This study was conducted in collaboration with a Kentucky company to apply the process to join thin lead sheets in a near perfect manner so that the seam of the weld is smooth enough to be used in the making of x-ray machine shields. Ultimately, it is anticipated that a portable, hand-held device will be developed to allow roofers to use it to join lead or copper sheets together safely without the potential of fire.