CFSP NSF Annual Report Format and Example

From Center for Friction Stir Processing Guide

APPENDIX O – CFSP NSF Annual Report Format and Example

Major Accomplishments SDSMT: “Built-Up” Aluminum FSW and FSSW Structures

• Completion of fabrication of Type 1 and Type 2 beams, mechanical, metallurgical and static structural tests, data analysis, theoretical work, and documentation
• Static structural test of a built-up beam configuration with two sheets welded to square tubes to form box beams (Type 4)
• Process development of Type 3 beam FSW configurations
• Fabrication of several stiffened panels with angle stiffeners or T-stiffeners, related mechanical, metallurgical and static structural tests, data analysis, theoretical work and documentation
• FSSW trials
• Preliminary work for FSW residual stresses –procured residual stress measurement system
• Fabrication of panels for fatigue studies and coupon tests (in progress)

SDSMT: Intelligent Process Control System Algorithms for Aluminum and Steel FSW

• Performed four experiments (FSW05088, FSW05128, FSW06008 and FSW06010) and got weld data for various parameter settings
• Fourier analysis of data from welds of the experiments has verified the hypothesis which is stated in Toshio Morihara’s master’s work. The hypothesis is FFT’s of y force appear to give information that can be used to classify the volumetric quality of a weld
• In order to classify FFT’s, we trained a neural network and got approximately 97% accuracy on the weld quality classification. Thus, we concluded that a neural network and FFT based algorithm can be used to classify quality of weld
• We are attempting to remove machine dependent noise from the distorted feedback signals (FSW06010-Noise Detection Experiment)
• Shape of the trajectories of feedback signals in phase space can be correlated to quality of weld. We are continuing to investigate this processing parameters and weld evaluation for training the control system that is being developed

SDSMT/CNDE TIE: Effects of Defects in Friction Stir Welds

• An existing pin tool (#-250-750) was used with a large shoulder, small and fine threads, and a shortened pin length of 0.246”.
• Trial welds were made (work order number FSW05185) for 0.25” thick panels, metallography was completed, area of the defect was measured, and diameter of the defect was calculated assuming the wormhole to be spherical. A process map was also created.
• Trial welds (work order number FSW05185) were sent to CNDE at Iowa State University.
• A Boeing pin tool (#04003) was used with a pin length of 0.121” for making trial welds on 0.125” thick panels.
• Trial welds were made (work order number FSW06008) for 0.125” thick panels, metallography was completed, area of the defect was measured, and diameter of the defect was calculated assuming the wormhole to be spherical. The development of a process map is in progress.

UMR: Microstructural Modification through Friction Stir Processing

• Training of the graduate students to program and run the robotic and two-axis FSW machines, and to conduct metallurgical and mechanical tests
• Obtained F357 investment cast boxes
• FSP trials on investment cast 357 specimens, and related metallurgical and mechanical tests, data analysis and theoretical work
• Design of pin tools for FSP of cast boxes

UMR: Robotic Friction Stir Welding of Thin Sheets

• Training of the graduate students to program and run the robotic and two-axis FSW machines, and to conduct metallurgical and mechanical tests
• Obtained 6111 and 5083 alloy sheets from General Motors
• Obtained sheet welding fixtures and tools from Friction Stir Link
• FSW trials on thin sheet welding of coupons, and related metallurgical and mechanical tests, data analysis and theoretical work

USC: Thermal Management for Improved Properties and Weldability in Aluminum and Titanium

• Completed 12 of 32 DOE welds for the Thick Plate Transient studies.
  • Hardness profiled for all welds.
  • Temperature data obtained.
• Completed fatigue testing of 7050 thin plate fast and slow welds with as welded geometry.
• Begun fatigue testing of 7050 thin plate fast and slow welds with surface modified geometry (flash removed, edges polished).
• Residual stress measurement in thick and thin plate 7050 welds has been completed.
• Torque/x-force/y-force vs. rpm have been mapped for 6019 and 6056 at one welding speed.
• Thermal simulation now includes modeling of heat flow into the tool.
• Thermal simulations with varying heat generation volumes have been tested.
• Effect of hardness minimum depth on crack path has been simulated using critical COD criterion.
• Submerged (underwater) welding apparatus complete.

BYU: Friction Stir Welding of X-65 Steel

• Process windows developed for smooth truncated cone pin, step spiral pin, and convex shoulder, step spiral pin tools.
• Full consolidation achieved from 2-7 inches/minute and 350-750 rpm
• Grains sizes between 0.5 and 10 m achieved
• Upper bainite observed in stir zone
• Weld metal and HAZ have higher strength than base metal
• Weld parameters observed to affect locations of maximum deformation
• Weld and HAZ material exceeds base metal minimum specified properties.

BYU: Friction Stir Welding of Alloy 718

• Process parameters explored with truncated cone pin and step spiral pin tools
• Significant grain size reduction observed in weld zone
• Weld properties intermediate between annealed and precipitation hardened base metal
• Convex scrolled shoulder, step spiral pin tools tested in 304L stainless
• Reduced tendency for sigma formation in 304L

RESEARCH GOALS SDSMT: “Built-Up” Aluminum FSW and FSSW Structures

• Develop design and analysis methodologies for built-up aluminum FSW beams, skin stiffened panels, and friction stir spot welded structures
• Design, fabricate, and test response of aluminum built-up beams, skin stiffened panels and friction stir spot welded panel
• Compare test results with the behavior predicted by the models developed
• Provide design and analysis guidelines

SDSMT: Intelligent Process Control System Algorithms for Aluminum and Steel FSW

• Expand the understanding and knowledge of the requirements for performing FSW on large “Built-up” aluminum structures and to develop process control system algorithms that ensure highest quality welds.
• Systematic removal of the assumptions on the types of materials involved.
• Use of other forces for control algorithms.

SDSMT/CNDE TIE: Effects of Defects in Friction Stir Welds

• Find the effects of defects on the strength and reliability of friction stir welded joints in aluminum 7075 T73 alloy.
• Develop a data relating the defect size to fatigue and tensile properties, as well as non-destructive evaluation data.

BYU: Friction Stir Welding of X-65 Steel

• Process Develop weld schedules for FSW of X-65 in thicknesses up to 13 mm
• Develop relationships between process parameters and resultant properties in this alloy
• Extend tool life in FSW of X-65

BYU: Friction Stir Welding of Alloy 718

• Develop parameters for FSW of Alloy 718
• Determine mechanical properties achievable in 718
• Increase process speed for FSW of 718
• Explore effects of tool geometry on sigma phase formation

UMR: Microstructural Modification through Friction Stir Processing

• Process-microstructure correlations
• Microstructure-strength-fatigue correlations
• Establish the method for best incorporation of particles
• Basic property data for surface modified material

UMR: Robotic Friction Stir Welding of Thin Sheets

• Welding parameters-microstructure-strength correlations
• Microstructure-formability correlations

USC: Thermal Management for improved properties and weld ability in Aluminum and Titanium

• Perform DOE for determination of critical parameters during start up of thick plate welds.
• Use simulations to assess the efficacy of extrinsic cooling/heating for management of process temperatures.
• Complete fatigue and fracture characterization of the 7050 thin plate welds.
• Begin weld process development and characterization of the 6019 plate.

SHORT DESCRIPTION OF COMMUNICATION WITH CENTER MEMBERS

Communication has been maintained throughout the first year via the Center website, email and mail. A secure website has been established by UMR. The website outlines the Centers objectives, participants, and focus of the Center for the general public. A secure Section of this website has been set up for the centers university sites and industrial sponsors to access proprietary reports and communication. Quarterly reports have been prepared and sent to all industrial sponsors via mail and website distribution. Likewise, the semiannual meeting notes and presentations were provided to the sponsors in CD format as well as on the CFSP website. Progress reports for the current projects are posted on the CFSP website. All other reports that are currently being produced will be placed in a secure portion of the CFSP website from where the members can download the reports. The IAB Chair communicates with the Center members and the University researchers.

PROJECT SELECTION PROCESS USED BY THE CENTER

Project proposals for year 2004-2005 were presented by the PI’s of the project to the Center members at the fall 2004 kick-off meeting, and the members approved the projects by voice vote. At the spring 2005 IAB meeting the industrial members agreed to develop a selection process and present it at the fall 2005 meeting for approval.

QUANTITATIVE INFORMATION

Number and Diversity of Students

• SDSMT:
  • Male: 9
  • Female: 2
• BYU:
  • Male: 5
  • Female: 1
• USC:
  • Male: 5
  • Female: 1
• UMR:
  • Male: 4
  • Female: 0

Number and Diversity of Faculty and Senior Personnel

• SDSMT:
  • Male: 5
  • Female: 0
• BYU:
  • Male: 3
  • Female: 0
• USC:
  • Male: 4
  • Female: 0
• UMR:
  • Male: 2
  • Female: 0

Industrial Members

• SDSMT: 6
• BYU: 5
• USC: 5
• UMR: 4

Degrees Granted to Students Involved in Center activities

• SDSMT: 0
• BYU: 1
• USC: 0
• UMR: 0

Amounts and sources of income to the center, patents, licenses and publications created

• SDSMT: None
• BYU: None
• USC: None
• UMR: None

GENERAL CENTER IDENTIFICATION NUMBER

Year of Initial Funding: 2004

Center Director and Contact Information

Mr. William J. Arbegast

Center Director, NSF Center for Friction Stir Processing (CFSP)

Director, Advanced Materials Processing and Joining Laboratory (AMP)

South Dakota School of Mines and Technology

501 East Saint Joseph Street

Rapid City, South Dakota 57701, USA

(605)-394-6924

william.arbegast@sdsmt.edu

Partner University Site Directors and Contact Information

Dr. Anil Patnaik

Assistant Professor

Department of Civil and Environmental Engineering

South Dakota School of Mines and Technology

501 East Saint Joseph Street

Rapid City, South Dakota 57701, USA

Phone: (605)-394-2442

Dr. Tracy W. Nelson

Associate Professor

Mechanical Engineering Department

Brigham Young University

435 CTB

Provo, UT 84602

801-422-6233

nelsontw@byu.edu

Dr. Anthony P. Reynolds

Associate Professor

Department of Mechanical Engineering

University of South Carolina

300 Main Street

Columbia, SC 29208

Phone: (803) 777-9548

Fax: (803) 777-0106

Email: apr@sc.edu

Dr. Rajiv S. Mishra

Associate Professor, Metallurgical Engineering

University of Missouri

B37 McNutt Hall

Rolla, MO 65409-0340

Phone: (573) 341 6361

Fax: (573) 341 6934

rsmishra@umr.edu

OPERATING BUDGET AND TOTAL FUNDING

Total Center Funding

• SDSMT: $375,000
• BYU: $190,000
• USC: $235,500
• UMR: $186,000
• Total: $986,500

NSF/IUCRC funding received

• SDSMT: $80,000
• BYU: $50,000
• USC: $50,000
• UMR: $50,000

Other NSF Funding Received

• SDSMT:
  • $70,000 (two year MIPR for ARL Membership Fee)
  • $50,000 (Two Year CFSP/CNDE TIE Supplemental)
• BYU: None
• USC: $33,530 (MIPR for NASA Membership Fee)
• UMR: $6,000 (REU supplemental)

Industry Membership Fees (non-MIPR)

• SDSMT: $175,000
• BYU: $140,000
• USC: $139,970
• UMR: $130,000 (includes $35K in-kind)

Additional Support

• SDSMT Cost Share:
  • $31,475 Student Salary Support (includes fringe and OH)
• BYU Cost Share:
  • $40,000 in waived indirect costs
• USC Cost Share
  • $62,700 waiver of indirect cost on membership fees
• UMR Cost Share:
  • $60,500 (waiver of indirect cost on membership fees and NSF grant + $12,800 from UMR Intelligent Systems Center)

CAPITAL AND IN-KIND SUPPORT

Equipment

• SDSMT: $2,275 –Waive Equipment User Fees
• BYU: $75,000 for new water-jet cutting equipment
• USC: 6019 Aluminum Plate from Kaiser.
• UMR: $5,000 (from Intelligent Systems Center)

Facilities

• SDSMT: None
• BYU: 800 square foot laboratory for new FSW equipment
• USC: None
• UMR: None

Personnel

• SDSMT: None
• BYU: None
• USC: None
• UMR: None

Software

• SDSMT: Access to numerical modeling software
• BYU: Access to numerical modeling software
• USC: None
• UMR: None

Other Support

• SDSMT: None
• BYU: Advanced Metal Products provided PCBN tooling as an in-kind membership fee
• USC: Kaiser Aluminum provided aluminum plates as in kind for partial membership fee
• UMR: Friction Stir Link’s $35K fee as fixtures, tooling and other support for the robotic FSW machine

INDUSTRY MEMBERSHIP DESCRIPTORS FOR THE CURRENT AWARD

Membership identification

• Current Members:
  • SDSMT: Boeing Phantom Works, Army Research Laboratory, Pacific Northwest National Laboratory, MTS Systems, BAE Systems (United Defense), Sikorsky Aircraft
  • BYU: Advanced Metal Products, Hitachi Ltd, JFE Steel Corp, Mitsubishi, Toshiba Corp.
  • USC: Spirit Aerosystems (formerly Boeing-Wichita), NASA Langley Research Center, EADS Airbus, Lockheed-Martin, Kaiser Aluminum
  • UMR: Boeing Phantom Works, Pacific Northwest National Laboratory, General Motors, Friction Stir Link

• Members At Start of Center Award:
  • SDSMT: Boeing Phantom Works, Army Research Laboratory, Pacific Northwest National Laboratory, MTS Systems, BAE Systems (United Defense)
  • BYU: Advanced Metal Products, Hitachi Ltd, JFE Steel Corp, Mitsubishi, Oak Ridge National Lab, Toshiba Corp
  • USC: Spirit Aerosystems (formerly Boeing-Wichita), NASA Langley Research Center, EADS Airbus, Lockheed-Martin, Kaiser Aluminum
  • UMR: Boeing Phantom Works, Pacific Northwest National Laboratory, General Motors, Friction Stir Link
• New Members Added:
  • SDSMT: Sikorsky Aircraft Systems
  • BYU: None
  • USC: None
  • UMR: None

• Identify Members Who Left The Center:
  • SDSMT: None
  • BYU: Oak Ridge National Lab (They have indicated they will join again next year)
  • USC: None
  • UMR: None

Annual Membership Fees

• $35,000 Primary
• $30,000 Secondary
• $30,000 Tertiary

Human Resources

• Researchers
  • SDSMT: faculty scientists/engineers = 5
  • BYU: faculty scientists/engineers = 3
  • USC: faculty scientists/engineers = 3
  • UMR: faculty scientists/engineers = 2
• Students
  • SDSMT: graduate students = 4, undergraduate students = 6
  • BYU: graduate students = 1, undergraduate students = 4
  • USC: graduate students = 2, undergraduate students =2
  • UMR: graduate students = 4, undergraduate students = 1

• Administration, number of full and part time professional and clerical staff
  • SDSMT: student administrators = 1 graduate student
  • BYU: Clerical and Professional Staff = 1
  • USC: Laboratory engineer= 1 , Administrative assistant= 1
  • UMR: Clerical and Professional Staff = 1

• Diversity information on the above with plans to increase diversity, if necessary –
  • SDSMT: 2 female students
  • BYU: 1 female student, 1 female staff member. Currently recruiting another female undergraduate student and a female graduate student.
  • USC: 8 Male; 1 Female (recruited for a Spring 06 start.)
  • UMR: see above

CENTER DIRECTOR DESCRIPTORS

Center Director (South Dakota School of Mines and Technology)

• Position/Rank of the Center Director
  • Mr. William J. Arbegast
  • Director, Advanced Materials Processing and Joining Laboratory (AMP)
• Status of tenure –
  • N/A
• Identify the name and position of the person to whom the Center Director reports to
  • Gautam Pillay, Ph.D., Vice President for Research
• Director Assignment of Duties
  • Center Administration: 15%
  • Other Administration: 30%
  • Research: 45%
  • Teaching: 5%
  • Other: 5%

Site Director (South Dakota School of Mines and Technology)

• Position/Rank of the Site Director
  • Dr. Anil Patnaik
  • Assistant Professor, Department of Civil and Environmental Engineering
• Status of tenure –
  • Not Tenured
• Identify the name and position of the person to whom the Center Director reports to
  • Dr. Scott Kenner, Chair, Department of Civil and Environmental Engineering
• Director Assignment of Duties
  • Center Administration: 5%
  • Other Administration: 0%
  • Research: 25%
  • Teaching: 60%
  • Other: 10%

Site Director (Brigham Young University)

• Position/Rank of the Site Director
  • Dr. Tracy Nelson
  • Associate Professor
  • Department of Mechanical Engineering
• Status of tenure –
  • Tenured
• Identify the name and position of the person to whom the Center Director reports to
  • Dr. Larry Howell, Department Chair, Department of Mechanical Engineering
• Director Assignment of Duties
  • Center Administration: 20%
  • Other Administration: 30%
  • Research: 25%
  • Teaching: 20%
  • Other: 5%

Site Director (University of South Carolina)

• Position/Rank of the Director
  • Dr. Tony Reynolds
  • Associate Professor
  • Department of Mechanical Engineering
• Status of tenure –
  • Tenured
• Identify the name and position of the person to whom the Center Director reports to
  • Jamil Khan, Ph.D., Department Chair, Department of Mechanical Engineering
• Director Assignment of Duties
  • Center Administration: 10%
  • Other Administration: 10%
  • Research: 45%
  • Teaching: 30%
  • Other: 5%

Site Director (University of Missouri-Rolla)

• Position/Rank of the Site Director
  • Dr. Rajiv S. Mishra
  • Associate Professor, Department of Materials Science and Engineering
• Status of tenure –
  • Tenured
• Identify the name and position of the person to whom the Center Director reports to
  • Dr. Richard Brow, Chair, Department of Materials Science and Engineering
• Director Assignment of Duties
  • Center Administration: 5%
  • Other Administration: 0%
  • Research: 60%
  • Teaching: 25%
  • Other: 10%

CENTER OUTCOMES

Students Receiving Degrees and Type of Degree Earned

• • SDSMT: 1 MS in Materials Engineering and Science
  • BYU: 1 BS in Mechanical Engineering; 1 MS in Mechanical Engineering
  • USC: 1 MS in Mechanical Engineering; 1 PhD in Mechanical Engineering
  • UMR: None

Students Hired by Industry by Type of Degree

• • SDSMT: 1 MS in Materials Engineering and Science
  • BYU: 1 MS in Mechanical Engineering
  • USC: 1 MS in Mechanical Engineering; 1 PhD in Mechanical Engineering.
  • UMR: None

Publications with Center Research

• • SDSMT: 5 publications in area FSW but not supported by Center funds
  • BYU: None
  • USC: 7 publications in the area of FSW but not supported by Center funds
  • UMR: None

Publications with IAB Members

• • SDSMT: 2 publications in area FSW but not supported by Center funds
  • BYU: None
  • USC: None
  • UMR: None

Number of Presentations

• • SDSMT: 4 presentations in the area of FSW but not supported by

Center funds

• • BYU: None
  • USC: 3 presentations in the area of FSW but not supported by

Center funds

• • UMR: None

INTELLECTUAL PROPERTY EVENTS

Invention Disclosures

• • SDSMT: None
  • BYU: None
  • USC: None
  • UMR: None

Patent Applications

• • SDSMT: None
  • BYU: None
  • USC: None
  • UMR: None

Software copyrights

• • SDSMT: None
  • BYU: None
  • USC: None
  • UMR: None

Patents Granted/Derived

• • SDSMT: None
  • BYU: None
  • USC: None
  • UMR: None

Licensing Agreements

• • SDSMT: None
  • BYU: None
  • USC: None
  • UMR: None

Royalties Realized

• • SDSMT: None
  • BYU: None
  • USC: None
  • UMR: None