Frank Pfefferkorn

Associate Professor

1031 Mechanical Engineering Building
1513 University Avenue
Madison, WI 53706

Ph: (608) 263-2668
Fax: (608) 265-2316
pfefferk@engr.wisc.edu


Profile Summary

I am an Associated Professor of Mechanical Engineering at the University of Wisconsin-Madison. My teaching and research are focused on manufacturing processes and heat transfer as it applies to manufacturing processes. My work goals are to: (1) educate/develop manufacturing and heat transfer engineers/workforce, and (2) help move thermally-assisted manufacturing, friction stir welding, micro end milling, and pulsed laser polishing from arts to science-based technologies that will help innovate manufacturing.

In addition to being an Associate Professor in the Department of Mechanical Engineering I serve as the Director of the Manufacturing Systems Engineering Program and on the Executive Committee of the Center for German and European Studies.

Education

  • B.S.M.E., University of Illinois Urbana-Champaign, 1994
  • M.S.M.E., Purdue University, 1997
  • Ph.D., Purdue University, 2002

Research Interests

  • Pulsed laser polishing
  • Friction stir welding (FSW)
  • Micro end milling
  • Energy efficiency in manufacturing
  • Thermally-assisted manufacturing
  • Temperature measurement and control in manufacturing
  • Heat and mass transfer

Awards, Honors and Societies

  • Awards:
    • 2007 Society of Manufacturing Engineers K.K. Wang Outstanding Young Manufacturing Engineer
    • 2011 International Conference on MicroManufacturing (ICOMM) Outstanding Paper Award
    • 2012 Best Reviewer for ASME Journal of Manufacturing Science and Engineering
  • Member:
    • American Society of Mechanical Engineers (ASME)
    • Society of Manufacturing Engineers (SME)
    • International Institute of MicroManufacturing (I2M2)

Publications

[38] Cole, E.G., A. Fehrenbacher, N.A. Duffie, M.R. Zinn, F.E. Pfefferkorn, N.J. Ferrier, 2014, “Weld Temperature Effects during Friction Stir Welding of Dissimilar Aluminum Alloys 6061-T6 and 7075-T6,” International Journal of Advanced Manufacturing Technology, DOI: 10.1007/s00170-013-5485-9.

[37] Fehrenbacher, A., C.B. Smith, N.A. Duffie, N.J. Ferrier, F.E. Pfefferkorn, M.R. Zinn, 2014, “Combined Temperature And Force Control For Robotic Friction Stir Welding,” ASME Journal of Manufacturing Science and Engineering, 136(2), DOI: 10.1115/1.4025912.

 [36] Fehrenbacher, A., J.R. Schmale, M.R. Zinn, F.E. Pfefferkorn, 2014, “Measurement of Tool-Workpiece Interface Temperature Distribution in Friction Stir Welding,” ASME Journal of Manufacturing Science and Engineering, 136(2), DOI: 10.1115/1.4026115.

[35] Fehrenbacher, A., N.A. Duffie, N.J. Ferrier, F.E. Pfefferkorn, M.R. Zinn, 2014, “Effects of toolworkpiece interface temperature on weld quality and quality improvements through temperature control in friction stir welding,” International Journal of Advanced Manufacturing Technology, DOI: 10.1007/s00170-013-5364-4.

[34] Ma, C., M. Vadali, N.A. Duffie, F.E. Pfefferkorn, X. Li, submitted 2013, “Numerical Simulation of Melt Pool Flow and Surface Evolution during Pulsed Laser Micro Polishing,” ASME Journal of Manufacturing Science and Engineering, 135(6), DOI: 10.1115/1.4025819.

[33] Pfefferkorn, F.E., N.A. Duffie, X. Li, M. Vadali, C. Ma, 2013, “Improving surface finish in pulsed laser micro polishing using thermocapillary flow,” CIRP Annals Manufacturing Technology, 62(1), 203-206.

[32] Vadali, M., C. Ma, N.A. Duffie, X. Li, F.E. Pfefferkorn, 2013, “Effects of Pulse Duration on Laser Micro Polishing,” ASME Journal of Micro and Nano-Manufacturing, DOI: 10.1115/1.4023756.

[31] Ma, C., L. Chen, J. Xu, A. Fehrenbacher, Y. Li, F.E. Pfefferkorn, N.A. Duffie, J. Zheng, X. Li, submitted 2013, “Effects of Fabrication and Processing Technology on the Biodegradability of Magnesium Nanocomposite: Friction Stir Processing, Ultrasonic Processing and Laser Surface Melting,” Journal of Biomedical Materials Research: Part B Applied Biomaterials, 101(5), 870-877, DOI: 10.1002/jbm.b.32891.

[30] Shultz, E.F., A. Fehrenbacher, F.E. Pfefferkorn, M.R. Zinn, N.A. Duffie, N.J. Ferrier, 2013, “Shared Control of Robotic Friction Stir Welding in the Presence of Imperfect Joint Fit-up,” SME Journal of Manufacturing Processes, 15(1), 25-33 [4th most popular download from this journal in 2013]

[29] Chen, L.-Y., H. Konishi, A. Fehrenbacher, C. Ma, J.-Q. Xu, H. Choi, H.-F. Xu, F.E. Pfefferkorn, X. Li, 2012, “Novel Nanoprocessing Route for Bulk Graphene Nanoplatelets Reinforced Metal Matrix Nanocomposites,” Scripta Materialia, DOI: 10.1016/j.scriptamat.2012.03.013.

[28] Vadali, M., C. Ma, N.A. Duffie, X. Li, F.E. Pfefferkorn, 2012, “Pulsed Laser Micro Polishing: Surface Prediction Model,” SME Journal of Manufacturing Processes, 14, 307-315. 

[27] Cole E.G., A. Fehrenbacher, E.F. Shultz, C.B. Smith, N.J. Ferrier, M.R. Zinn, F.E. Pfefferkorn, 2012, “Stability of Friction Stir Welding Process in Presence of Manufacturing Tolerances,” The International Journal of Advanced Manufacturing Technology, 63: 583-593. DOI 10.1007/s00170-012-3946-1

[26] Fehrenbacher, A., N.A. Duffie, N.J. Ferrier, F.E. Pfefferkorn, M.R. Zinn, 2011, “Towards Automation of Friction Stir Welding Through Temperature Measurement and Closed-Loop Control”, ASME Journal of Manufacturing Science and Engineering, 133: 051008.

[25] Shultz E.F., E.G. Cole, C.B. Smith, M.R. Zinn, N.J. Ferrier, and F.E. Pfefferkorn, 2010 “Effect of Compliance and Travel Angle on Friction Stir Welding with Gaps,” ASME Journal of Manufacturing Science and Engineering, 132(4), 041010 (9 pp.).

[24] Jasperson, B.A., Y. Jeon, K.T. Turner, W. Qu, and F.E. Pfefferkorn, 2010, “Comparison Study of Micro-Pin-Fin and Micro-Channel Heat Sinks Considering Thermal-Hydraulic Performance and  Manufacturability,” IEEE Trans. on Components and Packaging Technologies, 33(1), pp. 148-160. 

[23] Pfefferkorn, F.E., D. Bello, J.Y. Park, M. Powell, G. Haddad, J. McCarthy, M. Hoover, K.L. Bunker, G. Gruetzmacher, A. Fehrenbacher, and Y. Jeon, 2010, “Characterization of Exposures to Nanoscale Particles during Friction Stir Welding of Aluminum,” Annals of Occupational Hygiene, DOI:10.1093/annhyg/meq037, free download available. 

[22] J.J. McCarthy, F.E. Pfefferkorn, D. Bello, G. Haddad and K.L. Bunker, 2009, “Electron Microscopy and EDS of Nanoparticles Generated During Friction Stir Welding,” Microscopy and Microanalysis, 15 (Suppl. 2), pp. 1270-1271, doi:10.1017/S1431927609094471.

[21] Perry, T.L., D. Werschmoeller, X. Li, F.E. Pfefferkorn, and N.A. Duffie, 2009, “Pulsed Laser Polishing of Micromilled Ti6Al4V Samples,” SME Journal of Manufacturing Processes, 11, pp. 74-81. 

[20] Wissmiller, D.L., and F.E. Pfefferkorn, 2009, “Micro End Mill Tool Temperature Measurement and Prediction,” SME Journal of Manufacturing Processes, 11, pp. 45-53. 

[19] Torres, C.D., P.J. Heaney, A.V. Sumant, M.A. Hamilton, R.W. Carpick, and F.E. Pfefferkorn, 2009, “Analyzing the Performance of Diamond Coated Micro End Mills,” International Journal of Machine Tools and Manufacturing, 49, pp. 599-612.

[18] Perry, T.L., D. Werschmoeller, X. Li, F.E. Pfefferkorn, and N.A. Duffie, 2009, “The Effect of Laser Pulse Duration and Feed Rate on Pulsed Laser Polishing of Microfabricated Nickel Samples,” ASME Journal of Manufacturing Science and Engineering, 131, 031002 (June Issue). 

[17] Konishi, C.A., W. Qu, and F.E. Pfefferkorn, 2009, “Experimental Study of Water Liquid-Vapor Two-Phase Pressure Drop Across an Array of Staggered Micro-Pin-Fins,” ASME Journal of Electronics Packaging, 131: 021010. 

[16] Perry, T.L., D. Werschmoeller, N.A. Duffie, X. Li, and F.E. Pfefferkorn, 2009, “Examination of Selective Pulsed Laser Micro Polishing on Microfabricated Nickel Samples Using Spatial Frequency Analysis,” ASME Journal of Manufacturing Science and Engineering, 131, 021002 (April Issue). 

[15] Pfefferkorn, F.E., S. Lei, G. Haddad, and Y. Jeon, 2009, \"A New Metric for Defining the Efficiency of Thermally-Assisted Machining,\" International Journal of Machine Tools and Manufacture, 49(5), pp. 357-365.

[14] Heaney, P.J., A.V. Sumant, C.D. Torres, R.W. Carpick, and F.E. Pfefferkorn, 2008, “Diamond Coatings for Micro End Mills: Enabling the Dry Machining of Aluminum at the Micro-Scale,” Diamond and Related Materials, 17(3), pp. 223-233. 

[13] Jeon, Y., and F.E. Pfefferkorn, 2008, \"Effect of Laser Preheating the Workpiece on Micro-End Milling of Metals,\" ASME Journal of Manufacturing Science and Engineering, 130(1), 011004, DOI: 10.1115/1.2783219. 

[12] Siu-Ho, A., W. Qu, and F.E. Pfefferkorn, 2007, “Experimental Study of Pressure Drop and Heat Transfer in a Single-Phase Micro-Pin-Fin Heat Sink,” ASME Journal of Electronics Packaging, 129(4), pp. 479-487. 

[11] Westover, T., T.S. Fisher, and F. Pfefferkorn, 2007, \"Experimental Characterization of Anode Heating by Electron Emission from a Multi-Walled Carbon Nanotube,\" International Journal of Heat and Mass Transfer, 50(3-4), pp. 595-604. 

[10] Zhang, X.R., T.S. Fisher, Y.C. Shin, E.D. Hirleman, and F.E. Pfefferkorn, 2005, \"Integration of Microscale Fabrication in an Undergraduate Manufacturing Elective,\" International Journal of Engineering Education, 22(2), pp. 343-9. 

[9] Pfefferkorn, F.E., F.P. Incropera, and Y.C. Shin, 2005, \"Heat Transfer Model of Semi-Transparent Ceramics undergoing Laser-Assisted Machining,\" International Journal of Heat and Mass Transfer, 48, pp. 1999-2012. 

[8] Pfefferkorn, F.E., Y.C. Shin, F.P. Incropera, and Y. Tian, 2004, \"Laser-Assisted Machining of Magnesia-Partially-Stabilized Zirconia,\" ASME Journal of Manufacturing Science and Engineering, 126(1), pp. 42-51. 

[7] Pfefferkorn*, F.E., F.P. Incropera, and Y.C. Shin, 2003, \"Surface Temperature Measurement of Semi-Transparent Ceramics by Long-Wavelength Pyrometry,\" ASME Journal of Heat Transfer, 125(1), pp. 48-56. 

[6] Rebro, P.A., F.E. Pfefferkorn, Y.C. Shin, and F.P. Incropera, 2002, \"Comparative Assessment of Laser-Assisted Machining for Various Ceramics,\" Transactions of NAMRI/SME, 30, pp. 153-160. 

[5] Bowman, K.J., F.E. Pfefferkorn, and Y.C. Shin, 2002, \"Recrystallization Textures during Laser-Assisted Machining of Zirconia Ceramics,\" Materials Science Forum, 408-412, pp. 1669-1674. 

[4] Rozzi, J.C., F.E. Pfefferkorn, Y.C. Shin, and F.P. Incropera, 2000, “Experimental Evaluation of the Laser Assisted Machining of Silicon Nitride Ceramics,” ASME Journal of Manufacturing Science and Engineering, 122(4), pp. 666-670. 

[3] Rozzi, J.C., F.E. Pfefferkorn, F.P. Incropera, and Y.C. Shin, 2000, “Transient, three-dimensional Heat Transfer Model for the Laser Assisted Machining of Silicon Nitride: I-Comparison of Predictions with Measured Surface Temperature Histories,” International Journal of Heat and Mass Transfer, 43, pp. 1409-1424. 

[2] Rozzi, J.C., F.E. Pfefferkorn, F.P. Incropera, and Y.C. Shin, 1998, “Transient Thermal Response of a Rotating Cylindrical Silicon Nitride Workpiece Subjected to a Translating Laser Heat Source: I - Comparison of Surface Temperature Measurements with Theoretical Results,” ASME Journal of Heat Transfer, 120(4), pp. 899-906. 

[1] Pfefferkorn, F.E., J.C. Rozzi, F.P. Incropera, and Y.C. Shin, 1997 “Surface Temperature Measurement in Laser Assisted Machining Processes,” Experimental Heat Transfer, 10(4), pp. 291-313.  

Links

Patents

2011

US Patent 7,947,329 B2: “Methods of Applying A Nanocrystalline Diamond Film to a Cutting Tool.” Inventors: Anirudha V. Sumant, Robert W. Carpick, Frank E. Pfefferkorn. IP handled by Wisconsin Alumni Research Foundation (WARF).

2013

US Patent Application (serial number 13/749426) filed on Janaury 24, 2013: “Reducing Surface Asperities,” Inventors: Frank E. Pfefferkorn, Neil A. Duffie, Xiaochun Li, Madhu Vadali, Chao Ma. IP handled by Wisconsin Alumni Research Foundation (WARF).

Languages

  • English - native speaker
  • German - fluent

Courses I Regularly Teach

  • ME 313 - Manufacturing Processes (Metals)
    • One half of the semester covers Metals Processing
    • One half of the semester covers Polymers Processing
  • ME 314 - Manufacturing Fundamentals (Automation & Control)
    • One half of the semester covers Manufacturing Automation & Control
    • One half of the semester covers Modeling of Manufacturing Processes
  • ME 364 - Elementary Heat Transfer
  • ME 429 - Metal Cutting
  • ME 601 - Design & Prototype Fabrication

Courses

Fall 2014-2015

  • ME 291 - Ungergraduate Mechanical Engineering Projects
  • ME 699 - Advanced Independent Study
  • ME 492 - Mechanical Engineering Projects II
  • ME 491 - Mechanical Engineering Projects I
  • ME 429 - Metal Cutting
  • ME 990 - Dissertator Research and Thesis
  • ME 890 - PhD Research and Thesis
  • ME 790 - Master\'s Research and Thesis
  • Profile Summary

    I am an Associated Professor of Mechanical Engineering at the University of Wisconsin-Madison. My teaching and research are focused on manufacturing processes and heat transfer as it applies to manufacturing processes. My work goals are to: (1) educate/develop manufacturing and heat transfer engineers/workforce, and (2) help move thermally-assisted manufacturing, friction stir welding, micro end milling, and pulsed laser polishing from arts to science-based technologies that will help innovate manufacturing.

    In addition to being an Associate Professor in the Department of Mechanical Engineering I serve as the Director of the Manufacturing Systems Engineering Program and on the Executive Committee of the Center for German and European Studies.


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