Projects Gallery
Evaluation of Tungsten Carbide RFSSW Tool Life
Sponsor: Toyota
Project Start Date: 01/01/2025
RFSSW has been found to produce significantly stronger welds than traditional Resistance Spot Welding (RSW), but is more costly per weld. By increasing RFSSW tool life, RFSSW can become a more cost-effective improvement to RSW. This study aims to extend the tool life of Tungsten Carbide (WC) RFSSW tools in automotive production. A recent study indicates that proper cleaning could enable a WC RFSSW tool to endure over 200,000 welds with minimal wear. Using a custom mechanical cleaning solution, we are exploring procedures to achieve and surpass a tool life of 200,000 welds as well as apply this technology to robotic assemblies.
-Jared Jackson
Project Start Date: 01/01/2025
RFSSW has been found to produce significantly stronger welds than traditional Resistance Spot Welding (RSW), but is more costly per weld. By increasing RFSSW tool life, RFSSW can become a more cost-effective improvement to RSW. This study aims to extend the tool life of Tungsten Carbide (WC) RFSSW tools in automotive production. A recent study indicates that proper cleaning could enable a WC RFSSW tool to endure over 200,000 welds with minimal wear. Using a custom mechanical cleaning solution, we are exploring procedures to achieve and surpass a tool life of 200,000 welds as well as apply this technology to robotic assemblies.
-Jared Jackson
Evaluating Dispensables in RFSSW of Aerospace Alloys
Sponsor: Supernal
Project Start Date: June 2025
Dispensables such as sealants, adhesives, primers, and coatings are commonly used on aerospace aluminum sheets, but little is understood about how to create quality refill friction stir spot welds (RFSSW) in the presence of these materials. This project seeks to understand why some dispensables prevent weldability and what can be done to weld through them. We investigate the interactions, methods, and limitations at play, allowing manufacturers to combining these technologies in their assemblies.
-Taylor Smith
Project Start Date: June 2025
Dispensables such as sealants, adhesives, primers, and coatings are commonly used on aerospace aluminum sheets, but little is understood about how to create quality refill friction stir spot welds (RFSSW) in the presence of these materials. This project seeks to understand why some dispensables prevent weldability and what can be done to weld through them. We investigate the interactions, methods, and limitations at play, allowing manufacturers to combining these technologies in their assemblies.
-Taylor Smith
FSW Tool Wear Analysis and Coating Strategies for Extended Tool Life
Sponsor: TWB
Project Start Date: 02/01/2025
Specific wear mechanics resulted in a significant decrease in this FSW tools life. This study seeks to evaluate the wear mechanisms and locations on production tooling in an effort to increase tool life through the use of coatings. Current progress suggests 3x tool life for only 10% increase in tool cost.
Project Start Date: 02/01/2025
Specific wear mechanics resulted in a significant decrease in this FSW tools life. This study seeks to evaluate the wear mechanisms and locations on production tooling in an effort to increase tool life through the use of coatings. Current progress suggests 3x tool life for only 10% increase in tool cost.
Sponsor: Toyota
Refill Friction stir spot welding Uses 40 times less energy, emits fewer emissions, and produces welds that are 10 times stronger Read Full Story
Refill Friction stir spot welding Uses 40 times less energy, emits fewer emissions, and produces welds that are 10 times stronger Read Full Story