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
Recommended Citation
Henderson, Lewis T..
"Load Characteristics for an Aluminum Alloy Friction Stir Weld"
(2006). Master of Science (MS), Thesis, Mechanical & Aerospace Engineering, Old Dominion University, DOI: 10.25777/p86q-wt29
https://digitalcommons.odu.edu/mae_etds/521