Date of Award

Fall 2006

Document Type

Thesis

Degree Name

Master of Science (MS)

Department

Mechanical & Aerospace Engineering

Program/Concentration

Mechanical Engineering

Committee Director

Ayodeji Demuren

Committee Member

Gene J. W. Hou

Committee Member

Sebastian Bawab

Call Number for Print

Special Collections; LD4331.E56 H42 2006

Abstract

A process was developed to modify a vintage 1960's milling machine to allow axial load measurements to be taken and to allow automated control of the plunging stage during the friction stir welding process. The installation of a load cell in the housing of the mill machine was accomplished by way of modifying internal machine parts and introducing new external hardware. Successful post removal inspections and operational checks show that the conversion of a vintage 1960's milling machine to allow axial load measurements is feasible. The automation of the plunge process during friction stir welding was proven feasible by the installation of a stepper motor and motion control software. Testing indicated a step motor with a rating of greater than 1100oz-in of torque and a motor driver that outputs greater than 7 amps per phase is required to produce the high output torque.

With the ability to measure load, several tests were performed to characterize the relationship between the plunge rate and material flow conditions. The research showed that axial load varies with the plunging rate and characterizes the flow condition under the friction stir welding tool. The faster the plunge rate, the less time for heat to develop, and the more the flow condition becomes unstable.

Rights

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DOI

10.25777/p86q-wt29

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