GOALI: Friction Stir Alloying and Additive Processes

该奖项的目的是开发“智能”搅拌摩擦工艺（FSP），并推进对FSP中材料变形和合金化的基本理解。 与GOALI的合作者福特汽车公司合作，本研究可改善轻量化铝车身结构的点摩擦焊（SFW）接头的形状、质量和强度。 一个新的想法，应用FSP添加或建筑材料也将被调查。 实验分析将使更好地了解块体和合金材料的混合和流动的摩擦搅拌区。 本研究将采用具有温度及力感测功能之智慧型主轴。 使用先进的过程中监测和温度和力的控制可以优化SFW过程。如果成功，这项研究可以导致FSP的三个额外的广泛影响。 首先是裂纹的搅拌摩擦修复。 目前的摩擦搅拌焊接在从表面缩回之后留下工具尖端形状的孔。 使用材料添加剂工艺，可以填充孔，并可能在现场修复有裂缝的部件。 其次，这个过程可能会导致基于FSP的快速原型，从简单的几何形状建立功能部件。 第三，在搅拌摩擦区的大变形和高温下，可以生成小批量的新合金材料。 这项研究将与南非纳尔逊曼德拉都市大学密切合作。

The objective of this GOALI award is to develop the "intelligent" friction stir processes (FSP) and advance the fundamental understanding of the material deformation and alloying in FSP. Working together with Ford Motor Company, the GOALI collaborator, this research can improve the shape, quality, and strength of the spot friction welding (SFW) joint for light-weight aluminum automotive body structure. A novel idea to apply the FSP for addition or building of material will also be investigated. Experimental analysis will enable better understanding of the bulk- and alloy material mixing and flow in the friction stir zone. The intelligent spindle with temperature and force sensing capability will be adopted in this research. Using advanced in-process monitoring and control of temperature and force can optimize the SFW process.If successful, this research can lead to three additional broad impacts of FSP. First is the friction stir repair of cracks. Current friction stir welding leaves a hole of the tool tip shape after retracting from the surface. Using the material additive process, the hole can be filled and components with cracks can be repaired, possibly on-site. Second, this process can potentially lead to FSP-based rapid prototyping to build functional part from simple geometry. Third, small batch of new alloy materials can be generated under the large deformation and high temperature in the friction stir zone. This research will have close collaboration with the Nelson Mandela Metropolitan University of South Africa.