Team FRW

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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:

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:

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:

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:

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.

Final Prototype:

Ultimately Team FRW met all of its goals. Weld seams came out looking very consistent. Once the tool was optimized the team




The Team: