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Undergraduate Design: Design of a Reusable Stir Friction Welding Tool

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2011 ASEE Annual Conference & Exposition


Vancouver, BC

Publication Date

June 26, 2011

Start Date

June 26, 2011

End Date

June 29, 2011



Conference Session

Design Education I

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Page Count


Page Numbers

22.1564.1 - 22.1564.6



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Paper Authors


Fredrick A. Nitterright Pennsylvania State Erie, The Behrend College

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Mr. Fred Nitterright is a lecturer in engineering at Penn State Erie, The Behrend College. He received the A. A. S. in Mechanical Drafting and Design in 1989 from Westmoreland County Community College, the B. S. in Mechanical Engineering Technology in 1991 from Penn State Erie, The Behrend College, and the M. S. in Manufacturing Systems Engineering from the University of Pittsburgh in 1998. Mr. Nitterright is a member of the American Society for Engineering Education (ASEE).

Fred Nitterright began his career as a machinist at Elliott Support Services in Donora, Pennsylvania in 1986. He was employed as a computer-aided draftsman at Powerex, Inc, a project engineering at Stanko Products, a process engineer at Ami-Doduco, Inc., and a project engineer and team leader at Classic Industries, Inc., in Latrobe, Pennsylvania. Mr. Nitterright’s employment at Behrend commenced in 1999.

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Robert Michael P.E. Penn State Erie, The Behrend College

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Robert J. Michael, P.E. and Lecturer for the School of Engineering at Penn State Behrend obtained his B.S. degree from Akron University where he graduated summa cum laude and his M.S. degree from Case Western University. Bob is currently working towards his doctorate in mechanical and aerospace engineering at Case Western Reserve and expects to graduate in May 2008.
He joined the faculty at Penn State Behrend in the fall of 1999 as a lecturer in Mechanical Engineering Technology. Prior to Penn State Behrend, Bob spent several years in industry where he worked as an industrial product designer and aerospace product designer for Lord Corporation and general manager for National Tool and Equipment.

Courses taught include finite element analysis, material science, statics, strength of materials, materials lab, machine design, product design, production design, plastic design and FE analysis, and engineering graphics.
Research interests include design and optimization of elastomer components, elastomeric fatigue properties, hyperelastic modeling of elastomers, failure analysis of elastomeric components, seismic analysis of storage racks, experimental testing and characterization of materials and general machine design.
Engineering Consultant – provide consulting services to local industry. Services include: elastomeric product design and analysis, machine design, finite element analysis, solid modeling, vibration analysis and diagnostic testing.
Bob holds several patents and has several patents pending primarily in the area of noise and vibration isolation products. Bob is a licensed professional engineer in the state of Pennsylvania.

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Christopher Murosky

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Michael A. Ragen

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Undergraduate Design: Design of a Prototype Reusable Stir Friction Welding ToolAt XXX________, undergraduate research is encouraged. The college has worked diligently atdeveloping funding and recognition programs that enhance research opportunities at theundergraduate level. The benefits of undergraduate research are many. This paper will discussthe design of a reusable Stir Friction Welding (SFW) tool performed by two undergraduateMechanical Engineering Technology students (sophomores)SFW uses a solid-state joining process, which heats the material by using friction under pressureto heat the material just under its melting point. This heat is used to form the weld along thejoint of the two butted substances. This process allows for many advantages over traditional arcwelding with electricity.The design group consisted of two students that were part of a larger group of studentsconducting research in the area of SFW. SFW tools are not standardized. They cannot bepurchased off-the-shelf from an industrial supplier. SFW tools are quite often damaged orfractured during their use, especially during research. Common SFW tools that are generallymanufactured are tools that include the probe and shoulder as one solid piece. This is a majordisadvantage when the welding tip breaks. It may take days if not weeks to have another SFWtool made or repaired. This research project will involve researching and designing a prototypeSFW tool that will allow the user to quickly change the welding tip so that it may take minutesinstead of days to continue welding. The outcome of this project is to design a Stir FrictionWelding tool that can be reusable with minimal down-time.

Nitterright, F. A., & Michael, R., & Murosky, C., & Ragen, M. A. (2011, June), Undergraduate Design: Design of a Reusable Stir Friction Welding Tool Paper presented at 2011 ASEE Annual Conference & Exposition, Vancouver, BC. 10.18260/1-2--18822

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