Team FRW was tasked with creating a friction stir welding process for use in the University of Nevada Manufacturing Lab. This would require adapting the Haas VF-2 CNC machine with a custom tool in order to complete the process. The goal of the team was to weld multiple materials, multiple thicknesses, and make a tool last for 10 feet.
Phase 1 involved research into welding methods and outlining product specifications. Team FRW eliminated all methods other than CNC adaptation at this point.
Phase 2 was dedicated to the design and modeling of the friction stir welding tool. The tool geometry was based on specifications found in the literature study.
Phase 3 began with testing on the new tool design. Initial results were promising; the team was pleased with the deformation that occurred during the tests. Tool design was changed and optimized.
Phase 4 verified and validated the new design. Team FRW was able to weld multiple thicknesses of aluminum, as well as different types of aluminum, for a continuous length of 10 inches. The tool was able to complete 10 feet of total welds.
Ultimately Team FRW met all of its goals. Weld seams came out looking very consistent. Once the tool was optimized the team