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Friction stir process models are typically validated by tuning heat transfer and friction coefficients until measured temperatures in either the tool or workpiece, but rarely in both, match simulated results. A three-dimensional finite element model for a tool plunge in an AA 6061-T6 is validated for temperature predictions in both the tool and workpiece using a friction coefficient that varies with time. Peak workpiece temperatures were within 1.5% of experimental temperatures and tool temperatures were off by 80 ∘C. The sensitivity of the predicted temperatures with respect to the workpiece/tool heat transfer coefficient was shown to be high for the tool and low for the workpiece, while the spindle torque was slightly underpredicted in the best case. These results show that workpiece/tool interface properties must be tuned by considering predictions on both sides of the heat generation interface in order to ensure a reliable process simulation.

Microglia transform in response to changes in sensory or neural activity, such as sensory deprivation. However, little is known about how specific frequencies of neural activity, or brain rhythms, affect microglia and cytokine signaling. Using visual noninvasive flickering sensory stimulation (flicker) to induce electrical neural activity at 40 hertz, within the gamma band, and 20 hertz, within the beta band, we found that these brain rhythms differentially affect microglial morphology and cytokine expression in healthy animals. Flicker induced expression of certain cytokines independently of microglia, including interleukin-10 and macrophage colony-stimulating factor. We hypothesized that nuclear factor κB (NF-κB) plays a causal role in frequency-specific cytokine and microglial responses because this pathway is activated by synaptic activity and regulates cytokines. After flicker, phospho–NF-κB colabeled with neurons more than microglia. Inhibition of NF-κB signaling down-regulated flicker-induced cytokine expression and attenuated flicker-induced changes in microglial morphology. These results reveal a mechanism through which brain rhythms affect brain function by altering microglial morphology and cytokines via NF-κB.