Additively Manufactured High Temperature Friction Stir Tooling through Thermal Spray Techniques

NCMS Project #: 142043

Problem: To permit the general public/end users in seeing the benefits to vehicle light weighting, manufacturing strategies that enable these multi- material solutions are needed.  Friction stir welding (FSW) has been shown as one of the most promising solutions.  An alternate manufacturing process for developing FSW tools is required to reduce cost associated with joining of advanced multi-material systems.

Benefit: The completion of these tasks will also serve as an example to the commercial industry in how to develop an affordable technology that will improve the performance, reduce the cost and increase the life of FSW tools.  These studies will form the basis of design of a novel FSW tool component for the specific high temperature applications.

Solution/Approach: The overall objective of this initiative is to advance the solid state joining technique of FSW for the U.S. commercial industry by providing a streamlined process and common approach to develop new tools to advance FSW material joining processes that are more resistant to heat and will decrease associated maintenance tooling costs.  This will be accomplished by assessing the capability of a thermal spray solution for depositing refractory materials onto an FSW tool to lower tool costs and increase tool life.

Impact on Warfighter:

  • Improve performance and lifespan of FSW tools 
  • Reduce overall tooling costs 
  • Expand efficiencies in current manufacturing processes 
  • Enhance warfighter mission readiness 

DOD Participation:

  • U.S. Army
  • U.S. Navy (observer)

Industry Participation:

  • North Dakota State University
  • NCMS

Benefit Area(s):

  • Cost savings
  • Durability
  • Lightweighting

Focus Area:

  • Additive manufacturing