SBIR-STTR Award

This program is designed to development and implement portable friction stir welding for both repair and subassembly of Navy Al structures. This dual use requirement necessitates two different approaches. For example, subassembly implies relatively small structures and a moderate number of components. Further, subassemblies can be welded remote from their final assembly location and moved to, and final assembled, into the ship. A simple low-cost approach will be considered. Conversely, repair, by its nature implies at times one-offs, a multitude of geometries, and welding at a variety of locations. Access to the repair site and the ability to track a variety of paths requires a more versatile design. Components of the two systems can be the same and indeed interchangeable. However, the cost for a dedicated subassembly FSW system would be much less than that for a versatile repair system. Therefore, for eventual acquisition cost considerations, we are proposing to provide conceptual designs for both approaches. Further, studies will be completed to establish tool designs and weld parameters to minimize loads on the system. Program goals will be to make these systems robust, but lightweight and portable, and in the case of the repair FSW system, as versatile as possible.

Keywords:
Friction Stir Welding, Portable, Welding, Aluminum Alloys, Low Cost, Versatile

During Phase I, goals of initial design and demonstration of system concepts for a portable friction stir welding (FSW) system were successfully completed. During Phase II, the objective is to design, fabricate, and demonstrate a portable and versatile FSW system. To support AMP’s design, BYU will continue engineering and application studies in parallel with the design effort. BYU will optimize FSW tool designs for minimum system loads and optimize the attachment approach. The final product of the BYU studies will be an “Attachment Application Process Specification” that will achieve both maximum strength and consistency in application. The BYU results will be integrated into the AMP design resulting in the most efficient and light weight portable FSW system design. Following completion of the Phase II Base and Option programs we expect to attain a TRL of 6+. The above addresses the Phase II technical design, optimization, fabrication, and demonstration tasks. However, application to specific structures and commercialization are also important and will be addressed early during the Phase II Base program and more so during the Phase II Options. Initially, our emphasis will be Navy structures and as such we will identify pertinent Navy facilities and personnel for early discussions.

Keywords:
Friction Stir Welding, Repair, Versatility, Aluminum Alloys, Portability,