TitleFundamentals of Friction Stir Welding and Processing
WhenSunday, February 16, 8:30 a.m. to 4:30 p.m.
LocationMarriott Marquis and Marina - Palomar
Sponsored ByTMS Structural Materials Division
InstructorAnthony Reynolds, University of South Carolina; Yuri Hovanski, Pacific Northwest National Laboratory
Advance Member: $525.00
Advance Nonmember: $575.00
Advance Student: $300.00
Late/onsite Member: $600.00
Late/onsite Nonmember: $650.00
Late-/onsite Student: $350.00
Fundamentals of Friction Stir Welding and Processing

Friction stir welding (FSW) was invented by TWI, Cambridge, UK and patented in 1991. In the last twenty years, the research community has made significant advances in understanding of the process, and numerous industrial applications have been taken to full implementation. During the same period friction stir processing (FSP) has been developed in parallel with FSW, and essentially employs FSW tooling to perform local thermomechanical treatments rather than to make joints.

The scientific and technical literature is rich with information on joining of aluminum, steel, titanium, magnesium, metal matrix composites, and even superalloys as well as generic information on process fundamentals. The goal of this course is to provide participants with the essence of the accumulated FSW/FSP knowledge: both fundamental and practical. This course is designed to provide a basic understanding of the process and the linkage to performance by introducing aspects from basic process design, controls, tools, and metallurgical aspects. The course will culminate with a demonstration and discussion of how various elements of the course link together.

Fundamentals of Friction Stir Welding and Processing

Tony Reynolds is a chaired, full professor in the Department of Mechanical Engineering at the University of South Carolina. Reynolds obtained his PhD in Materials Science from the University of Virginia in 1990. Since 1998 his research group has been working in the areas of friction stir welding and processing (FSW/P). Since 2004, Reynolds has been the site director at USC for a multi-University NSF I/UCRC, The Center for Friction Stir Processing. Reynolds’ group has published more than 70 ISI articles on FSW/P which articles have garnered over 2000 citations.

Emphases of the group's research include FSW process development for aluminum alloys, steels, and titanium as well as characterization of weld performance and process simulation. The group is also currently investigating other friction-based, solid-state, materials processing techniques. In addition to his academic research, Reynolds has also served as a consultant to SKB (The Swedish Nuclear Fuel and Waste Management Company) for their FSW process development for sealing of copper nuclear waste containers.

Yuri Hovanski is currently a Research Engineer at Pacific Northwest National Laboratory. He earned a B.S. Degree in Mechanical Engineering at Brigham Young University, and then completed his M.S. degree in Mechanical Engineering at Washington State University. He is a member of Tau Beta Pi Engineering Honors Society, and actively participates in AWS and TMS serving on the forming and shaping, as well as joining committees. He has participated in friction stir related research for more than a decade investigating weld formability, abnormal grain growth, and the influence of post-weld microstructure and texture on mechanical properties.

More recently, he has focused on the development of low-cost solutions for friction stir welding, introducing cost efficient solutions for thermal telemetry, new tool materials and production techniques for friction stir spot welding tooling, and utilizing thermo-hydrogen processing to aid friction stir welding of titanium alloys. He continues this effort today furthering the capability of friction stir spot welding in a variety of advanced high strength steel alloys, and recently introducing scribed tooling that enables lap welding of highly dissimilar materials. He actively reviews friction stir related literature for several publications and has documented his work in more than 25 publications.

Fundamentals of Friction Stir Welding and Processing

Session 1 (9:00 a.m.-Noon)
* Overview of friction stir welding and examples of adoptions; highlights and issues - 20 minutes
* Fundamentals of the friction stir process- part I; process parameters - 45 minutes
* Break- 15 minutes
* Fundamental of friction stir process- part II; material flow and microstructural evolution - 45 minutes
* Break- 15 minutes
* Fundamental of friction stir process- part III; history of tool development - 40 minutes
Lunch Break (Noon-1:00 p.m.)

Session 2 (1:00 p.m.-5:00 p.m.)
* Weld configurations and tool selection; gaps and mismatches - 40 minutes
* Low Temperature Metals - 55 minutes
* Break- 15 minutes
* High Temperature materials - 55 minutes
* Break -15 minutes
* Derivative Technologies - 30 minutes
* Discussion- 30 minutes