Development of technological conditions and applications of friction stir channeling

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Insinööritieteiden korkeakoulu | Master's thesis
Production Engineering
Degree programme
Master’s Programme in Mechanical Engineering
59 + 10
This thesis investigates development of technical conditions of Friction Stir Channeling (FSC) with main focus on industrial Lithium battery cooling applications. Conventional technologies - Electrical Discharge Machining (EDM), Drilling and Milling - have limitations in creating continuous straight or continuous curved internal channels and none of them are capable of producing continuous free-path internal channel in a single step. FSC is an innovative method within solid-state manufacturing technologies which is able to produce continuous internal channels in monolithic plates in a single step. FSC is capable of producing both straight and curved channels in metal plates with control of technical parameters similar to that of Friction Stir Welding (FSW). However, FSC is in initial phases and still more research needs to be done in order to improve FSC tools for producing channels in more diverse metals. This thesis designs and builds new tools for FSC with improved geometrical parameters, and by means of these new tools, performs experiments in order to investigate technical condition of FSC and its capability in various industries. This thesis produces various Friction Stir (FS) channel prototypes in aluminum alloy plates AA6082-T6 and AA5083-H111. This work performs thermal and flow analysis in order to evaluate capability of FSC for battery cooling. Following conclusions are arrived at in this thesis: The experimental results of this work shows that by means of our improved FSC tools and by selecting the right technical parameters, high quality of channel surface finish with low roughness is obtained using position control as opposed to forced control. Moreover, FS tool rotation and travel speed affect the channel size so that channel size increases by increasing travel speed and decreasing rotation speed. Pressure tests conclude that the FS channels produced in this work can endure high pressure levels. Furthermore, investigation and analysis in this thesis concludes that FSC has high potential in heat exchanger industries and conformal cooling channels for mould industries, and results in high productivity and low cost of production. Moreover, our thermal and flow analysis concludes that FSC has a high potential to be applied for cooling of industrial Lithium-ion batteries.
Vilaca, Pedro
Thesis advisor
Minav, Tatiana
friction stir channeling, aluminum alloy AA6082-T6, aluminum alloy AA5083-H111, heat exchanger, conformal cooling
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