national science foundation industry / university ...08/billarbegast.pdf · processing technologies...

National Science FoundationNational Science FoundationIndustry / University Cooperative Research Center Industry / University Cooperative Research Center

““The Win The Win –– Win SolutionWin Solutionto FSP Technology Developmentto FSP Technology Development””

Multi-University I/UCRC Management Tools

- A Case Study -Mr. William Arbegast (AMP)Dr. Antonette Logar (MCS)Dr. Edward Corwin (MCS)

Center for Friction Stir ProcessingSouth Dakota School of Mines and

Technology

January 11, 2008

IUCRC Annual Directors MeetingWashington, DC

Draft of the “Book” can be found at http://ampcenter.sdsmt.edu

http://ampcenter.sdsmt.eduCFSP IUCRC

IUCRC Management Tools

http://ampcenter.sdsmt.edu/

Who is the South Dakota School of Mines?

SDSMT is a Small Engineering University Teamed with Larger Academic Institutions under the IUCRC Environment

WSU

• The South Dakota School of Mines and Technology

– Founded 1885– 2,500 students from approximately

30 states and 20 countries. – Four interdisciplinary colleges and

13 departments– 30 degree programs in engineering and

science at the baccalaureate, masters, and doctoral levels

• Location – Rapid City, South Dakota– Population – 60,000– Near the Black Hills, Mount Rushmore

and Crazy Horse

• Our Friction Stir Welding and Processing programs are coordinated within the Advanced Materials Processing and Joining Laboratory (AMP)

SDSMT

USC

UMR

BYU

SDSMT

USC

UMR

BYU

Where Are the University Sites of the NSF Center for Friction Stir Processing?

Original Award 2004

South Dakota School of Mines (2004)Mr. William Arbegast –Center DirectorDr. Mike West – Site Director/PI

University of South Carolina (2004)Dr. Anthony Reynolds – Site Director/PI

Brigham Young University (2004)Dr. Tracy Nelson – Site Director/PIDr. Carl Sorensen – PI

Missouri University of Science and Tech (2005)Dr. Rajiv Mishra – Site Director/PI

Wichita State University (2007)Dr. Dwight Burford – Site Director/PI

6 Directors14 Faculty

3 Professional Admin8 Research Staff

1 Post Doc7 Doctorial Students20 Masters Students

23 Undergraduate Students5 REU Students

2 RET Supplemental

2007

Setting the CFSP Vision and Mission---

1.1 CFSP Vision Statement• The Center for Friction Stir Processing (CFSP) vision is to provide the forum for

industry/university cooperative research on the further development, validation, and industrial implementation of the emerging solid-state materials joining and processing technologies known as Friction Stir Welding (FSW) and Friction Stir Processing (FSP).

1.2 CFSP Mission StatementThe Mission of the NSF Center for Friction Stir Processing is:

• To advance, develop and promote research into the principles and technology of Friction Stir Processing science and engineering through research, development, education, and technology exchange among academic, industry, and governmententities;

• To increase the quantity and quality of the professionals prepared to work in the area;

• To involve the faculty of the University(s) in research in areas of common interestto Sponsors and the University(s);

• To perform research that will allow industrial Friction Stir Processing facilities to be competitive in the world economy

Setting the CFSP Research Objectives---

1.3 CFSP Research ObjectivesThe overall objective of the Center is to develop and deliver relevant scientific

knowledge that will help its industrial members with future challenges. Center programs are designed to complement the members’ in-house research and development in the area of friction stir processing by bringing together theoretical, experimental and application experts from industry and academia. The specific objectives are focused on the following:

• Friction Stir Joining: Process optimization (parameters, pin tool materials, pin tool designs); process modeling (thermal, forces, metal flow, residual stress, distortion, microstructure evolution); microstructural characterizations; property characterizations (tensile, fatigue, fracture, creep, corrosion); nondestructive evaluations; new alloy development.

• Friction Stir Microstructural Modification: Induced superplasticity; grain refinement; sub-micron and nano particle injection; defect removal.

• Friction Stir Post –Processing: Heat treatment; forming (stretch, spin, age, and creep); machining; finishing.

• Friction Stir Structural Designs and Applications: replacement of fusion welds and rivets; static and dynamic response of structures; efficient design and analysis methodologies.

• Friction Stir Intelligent Controllers and Efficient Tooling: Process sensors; logic-based controllers; reconfigurable tooling.

• Friction Stir Cost Benefits Analysis: Business case development and environmental impact assessments.

Setting the CFSP Policies, Procedures and Practices (P3)--

1.4 CFSP Policies Procedures and Practices (P3)• Membership Policy

• IAB Roles and Responsibilities

• Selection of Research Projects

• Selection of Project Investigators

• Regular Reports Policy

• Publications Policy

• Patents Policy

• Termination of Research Policy

The Formal CSFP Policies, Procedures and

Practices (P3)are set forth in the Center

Membership Agreement and Center Bylaws

http://ampcenter.sdsmt.eduCFSP IUCRC

Members Agreement Bylaws

http://ampcenter.sdsmt.edu/

Center Sponsors Are From a Wide Segment of the Industry- “Globality”

How do you structure the research programs to meet All the Sponsors Needs?

24 Industry and Government Memberships

DoD Research LabsDoE National Labs

NASA Research CentersFAA Regulatory Entities Aerospace ManufacturersAeronautic ManufacturersAutomotive ManufacturersPrimary Metals ProducersEquipment Manufacturers

Setting Site Specific Focused Research Areas---

Overlap is avoided to maximum research returns

Setting the Research Needs of the IAB ---

Color Coded To Track “SUCCESS”

Preparing a Long Term Technology Development Roadmap

The Over-Riding Issues are Identified and a Technology Development Roadmap is prepared

Multi-Year Projects are developed with IAB

Project Scope and Progress is continuously reviewed during the year

Supplemental, REU / RET, and TIE Programs are used to Meet Industrial Needs

Collaborations are Encouraged and Promoted Collaborations are Encouraged and Promoted Between University SitesBetween University Sites

Funding for Projects can come from multiple sources and is “Booked” separately

Collaborations are Encouraged and Promoted Collaborations are Encouraged and Promoted Between University SitesBetween University Sites

CFSP Research funding is controlled at the CFSP Research funding is controlled at the project level project level ““control pointcontrol point”” using University using University

Site Established ProceduresSite Established Procedures

Specific Multi-Year Projects are Identified and added to the Program Master Schedule

New Projects New Projects are Proposed are Proposed at the Spring at the Spring IAB MeetingIAB Meeting

Authorization Authorization to Proceed to Proceed

Obtained at the Obtained at the Fall IAB Fall IAB MeetingMeeting

Unique Project Numbering System Used to ID Projects

The SDSMT Site also uses PaDMS to Manage Project Documentation

• PaDMS – Paperless Data Management Systems

Each Project is Organized into Formal Tasks, Subtasks, and Experimental Work Orders and entered into PaDMS

The Project Level describes the Top Level Scope and Efforts of the Project – Budgets and Contracts Docs Incl.

The Task and Subtask Levels Describe the HieracherialApproach to the project

Work orders are prepared for ALL individual experiments- Status reports (open and closed, assigned to, etc)

Each Work Order (Experiment) is Completed with a Formal Laboratory Report and electronically submitted

Approved WO Are Closed …

Rejected WO are sent back to student for rework and is electronically resubmitted to PI for approval

All Research Projects are Monitored and Controlled Via the Secure CFSP Website ( http://fspiucrc.mst.edu )

http://fspiucrc.mst.edu/

Searchable CFSP Experiments Database

Searchable CFSP Reference Library

CFSP Reporting and Documentation are available on Website

• CFSP Quarterly Reportsare Posted on the Website for Member Reviews

• CFSP Annual Members Reports is uploaded to website and hardcopies to be distributed after Final Revisions

• CFSP NSF Annual Center Report has been submitted and should be available on the website soon (includes independent evaluators report)

• Spring IAB Meeting Life Form Response and Action Items sent to members and uploaded to Website

Annual Members Report

National Science Foundation

Center for Friction Stir Processing

For the Period

October 2004 through October 2005

Mr. William J. ArbegastAdvanced Materials Processing Center

South Dakota School of Mines and technologyRapid City, SD 57701

605-394-6924



605-394-6924

A Global Research Consortium of University, Government, and Industrial Partners Advancing the Science and Technology of Friction Stir Joining and Processing

Dr. Anthony P. ReynoldsDepartment of Mechanical Engineering

University of South CarolinaColumbia, SC 29208

803- 777- 9548



803- 777- 9548

Dr. Tracy W. NelsonDepartment of Mechanical Engineering

Brigham Young UniversityProvo, UT 84602

801-422-6233



801-422-6233

Dr. Rajiv S. MishraCenter For Friction Stir Processing

University of Missouri - RollaRolla, MO 65409

573-341-6361

Dr. Rajiv S. Mishra


573-341-6361

Dr. Rajiv MishraCenter for Friction Stir Processing

University of Missouri- RollaRolla, MO 65409

573-341-6361

I/UCRC Site:

SDSM&T

Number Title Budget

CFSP04-AMP-01 Design, Analysis and Performance of “Built-Up” Aluminum Friction Stir Welded (FSW) and Friction Stir Spot Welded (FSSW) Structures $89,000 (Year 1)

Status Date Start Date End Date PI and Senior Personnel Students

May 21 , 2005 October 01, 2004 September 30, 2005 Bill Arbegast

Anil K. Patnaik Casey Allen

Travis Reidy (MS) Will Lind (Sr)

Neelima Nagotu (MS) Karl Koch (Sr)

Cassandra Degan (Jr) Objectives • Develop design and analysis methodologies for built-up aluminum FSW beams, skin stiffened panels, and friction stir spot welded structures • Design, fabricate, and test response of aluminum built-up beams, skin stiffened panels and friction stir spot welded panel • Compare test results with the behavior predicted by the models developed • Provide design and analysis guidelines Approach Year 1

Beams: Static response of four types of beams and a box beam Skin stiffened panels: Static response of three types of panels FSSW: Static response of coupons and a skin stiffened panel Theoretical models to develop design equations (derive design

equations, finite element stress analysis, elastic buckling analysis, etc)

Year 2

Dynamic loading on beams, skin stiffened panels and FSSW structures

Fatigue tests on FSW and FSSW structures Year 3

Built-up beams (approximately 10 foot long) and skin stiffened panels (approximately 5 foot x 5 foot), FSSW panel subjected to static and dynamic loading

Progress and Achievements Schedule and Milestones • Training of the graduate students to program and run the FSW machine

(with or without FSSW fixture attached), and to conduct mechanical and metallurgical tests

• Procurement of test equipment and materials for test specimens – in progress

• Preliminary FSW trials for Type 1 beams • An additional built-up beam configuration with two sheets welded to

square tubes to form box beams • Preliminary FSW trials for Type 3 stiffened panel • Preliminary FSSW trials • Design of pin tools for FSSW • Development of optimized process parameters • Development of tooling & fixtures, clamping, and anvil type

Activity Q4 2004

Q1 2005

Q2 2005

Q3 2005

Fabricate FSW Stiffened Beams Structural Test FSW Stiffened Beams

Fabricate FSW Stiffened Panels Structural Test FSW Stiffened Panels

Fabricate FSSW Stiffened Panels Structural Test FSSW Stiffened Panels

Year 1 Status Report

Documents and Publications Additional Information and Issues Yet to be produced.

Note: Actual research started in January 2005

For further information contact: Mr. Bill Arbegast, Center Director Email: [email protected] Phone: 605-394-6924



605-394-6924



803- 777- 9548



801-422-6233

Dr. Rajiv S. MishraCenter For Friction Stir Processing


573-341-6361



605-394-6924



803- 777- 9548



801-422-6233

Dr. Rajiv S. Mishra


573-341-6361

STRICTLY CONFIDENTIAL: CFSP PROPRIETARY INFORMATIONCenter for Friction Stir Processing 2006 Spring IAB LIFE ResponsesReport Date: April 21, 2006

Released To CFSP Members under the terms of theNSF IUCRC Collaboration (Membership) Agreement

of October 1, 2004. Distribution Limited.

STRICTLY CONFIDENTIAL: CFSP PROPRIETARY INFORMATIONCenter for Friction Stir Processing 2006 Spring IAB LIFE ResponsesReport Date: April 21, 2006

Released To CFSP Members under the terms of theNSF IUCRC Collaboration (Membership) Agreement

of October 1, 2004. Distribution Limited.

National Science Foundation Center for Friction Stir Processing

LIFEFORM RESPONSE

And Action Items

2006 Spring IAB Meeting

April 19-20, 2006 Provo, Utah

Approved by:

William J. Arbegast

CFSP Center Director South Dakota School of Mines and Technology

Quarterly Reports are Prepared For Each Project and Uploaded for Sponsor Review

Each Current Project has a QTR Report Prepared every 3 months

1 Page Max

Annual Members Report is Prepared with Standardized Executive Summaries Formats

Annual Members Report is Prepared with Standardized Technical Report Formats

Life Form Responses from All Sites are Summarized and uploaded to Website

• Life Form Comments are CLASSIFIED AS “IN SCOPE” OR “OUT OF SCOPE”

• PI Answers Comments during IAB Meeting

Papers and Publications are Uploaded for Sponsor Review

• Papers are prepared and Uploaded to Website For IAB Member Review and Approval to Publish –

• Sponsors are notified by e-mail when new papers are uploaded

• 13 CFSP papers were published in 2006

Action Items from IAB Meetings are Tracked and Controlled on the Website

Need IAB Commitments

Completed

CompleteNot Practical Due to

Accounting Systems at each University

In – ProgressSite Member Specific

Meetings at UMR- BYU- USCE-mail Requests by SDSMT

CompleteSuggest allowing Access to

previous information by new members- Information to be

published

Center Performance Metrics Per NSF Best Practices are Tracked

NSF IUCRC “Best Practices”

NSF IUCRC BEST PRACTICES Red

Yello

w

Gre

en Comments

Implements NSF I/UCRC structure and protocols Member Agreement, Bylaws, and Center Structure

Critical mass of members/support and fees as recommended by the I/UCRC program $150K min at each site

Intellectual property (patent) protocols in place Has not been tested yet

Publication review policies and delays in place Has not been tested yet

Clearly defined research scope and execution strategy Agreed to at IAB Meetings

IAB members co-design research goals and program Agreed to at IAB Meetings

Clearly defined program deliverables and milestones with technology transfer mechanisms in place Needs better definition of deliverables

Create and quantify value and formally evaluate the impact of center research

CFSP Center Evaluator Survey and Annual Report

Communicate success stories regularly to point out concrete examples of industry implementing and benefiting from center research projects/products Needs to be addressed

Conduct semi-annual technical review, research planning and IAB meetings Spring and Fall IAB Meetings

Create center developed business, operations and marketing plans in place and in-sink with industry needs (this is in addition to mission and vision Needs to be addressed

Develop an organizational structure Center Director, Site Director, Project Investigator, Students

Have a center developed strategy for recruiting members in place Needs to be addressed

Center have guests sign confidentially statements Planned for 2006 Spring Meeting, Provo

Make provisions for center research staff and students to work at member company sites DOE Interns- Needs to be addressed

Student involvement and poster sessions during each IAB meeting Maximum use of posters at host site- increased offsite posters

LIFE forms used appropriately and feedback discussed during the IAB meeting

Electronic Lifeforms to be evaluated at 2006 Spring IAB

University supports faculty and student recruitment and capital funding Equipment, Space, and Infrastructure available, New equipment has been

A NDA MAY BE signed by non-members attending IAB Meetings

• Not Required for Government Employees

• Prospective Members are Invited to Meeting with Prior IAB Approval and

• If They Sign the NDA

Technical Presentations for IAB Workshop Follow Standardized Format – 10 minutes typical

Life Form Reviews NOT Done on Workshop Presentations

Technical Presentations for IAB Management Review Follow Standardized Format (Limit 5 – 8 pages)

Life Form Reviews ARE Done on Workshop Presentations

Posters in Standardized Format are prepared for Each Project by each site during IAB

The CFSP hosts various activities to ensure student participation – and have FUN

B-Day Parties Industrial Speakers Annual Picnics

More CFSP Picnics

AMP StockNative American Outreach Undergraduate Capstone Design

”Marketing -- hey- I got pictures- Wanna Join the CFSP ?”

”Wait –there is more ----

Chris Cody (Soph)

Matt Desenfants (Fr)

Jordan Ritz (Soph)

Under a IUCRC REU Supplement “Team Bob”is Automating the AMP and CFSP Website and Standardized Documents Forms and Reports–

Matt will tell you more ..