Success Stories

Implementation of Friction Stir Welding in Car Bumper Assemblies (December 6, 2012)
CFSP - Wichita State University - Advancements in weld tool designs for friction stir welding (FSW) have enabled the development of a prototype lightweight automotive bumper / crash box assembly. Assemblies fabricated with FSW and Gas Metal Arc Welding (GMAW) were subjected to crash sled and drop tower testing to provide a comparison in performance under dynamic loading conditions. The FSW development work included micro-structural examination and static mechanical testing.
Returning Parts to Service (December 6, 2012)
CFSP - South Dakota School of Mines & Technology - Friction stir welding has shown the potential to repair defective or damaged areas in metals, and to reduce scrap rates in welded parts by reworking select areas.  Parts repaired this way showed an enhancement in fatigue performance returning it to a level comparable to the unaffected base material.
Robust Temperature Control (December 6, 2012)
CFSP - Brigham Young University - Figure 1 shows a weld that started in RPM control mode then given a temperature command 51°C lower than the current temperature.   The overshoot was 29%, rise time 3.325 seconds, 10% settling time of 17.3 seconds and 1°C settling time of 29.5 seconds.
e-NDE Algorithims for Friction Stir Welding (December 4, 2012)
CFSP - Wichita State University - Two electronic Non-Destructive Evaluation (e-NDE) algorithms for Friction Stir Welding (FSW) have been successfully developed in collaboration with Wichita State University (WSU) and South Dakota School of Mines and Technology (SDSM&T). According to the Probability of Detection (POD) analysis based on the maximum-likelihood method, the e-NDE method gave significantly better detection performances compared to the conventional ultrasonic-phased-array and the X-ray techniques.