Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology

doi:10.1007/s11837-017-2334-6

Title: Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology

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Abstract

One challenge in adapting welding processes to dissimilar material joining is the diversity of melting temperatures of the different materials. Although the use of mechanical fasteners and adhesives have mostly paved the way for near-term implementation of dissimilar material systems, these processes only accentuate the need for low-cost welding processes capable of joining dissimilar material components regardless of alloy, properties, or melting temperature. Friction stir scribe technology was developed to overcome the challenges of joining dissimilar material components where melting temperatures vary greatly, and properties and/or chemistry are not compatible with more traditional welding processes. Although the friction stir scribe process is capable of joining dissimilar metals and metal/polymer systems, a more detailed evaluation of several aluminum/steel joints is presented herein to demonstrate the ability to both chemically and mechanically join dissimilar materials.

Authors:

; Upadyay, Piyush; Kleinbaum, Sarah; Carlson, Blair; Boettcher, Eric; Ruokolainen, Robert

Publication Date:: Wed Apr 05 00:00:00 EDT 2017

Research Org.:: Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1415079

Report Number(s):: PNNL-SA-125531
Journal ID: ISSN 1047-4838; VT0505000

DOE Contract Number:: AC05-76RL01830

Resource Type:: Journal Article

Resource Relation:: Journal Name: JOM. Journal of the Minerals, Metals & Materials Society; Journal Volume: 69; Journal Issue: 6

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

Citation Formats


                    Hovanski, Yuri, Upadyay, Piyush, Kleinbaum, Sarah, Carlson, Blair, Boettcher, Eric, and Ruokolainen, Robert. Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology.  United States: N. p., 2017. 
        Web.  doi:10.1007/s11837-017-2334-6.

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                    Hovanski, Yuri, Upadyay, Piyush, Kleinbaum, Sarah, Carlson, Blair, Boettcher, Eric, & Ruokolainen, Robert. Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology.  United States.  doi:10.1007/s11837-017-2334-6.

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                    Hovanski, Yuri, Upadyay, Piyush, Kleinbaum, Sarah, Carlson, Blair, Boettcher, Eric, and Ruokolainen, Robert. Wed .  
        "Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology".  United States.  
        doi:10.1007/s11837-017-2334-6.

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@article{osti_1415079,

  title        = {Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology},

  author       = {Hovanski, Yuri and Upadyay, Piyush and Kleinbaum, Sarah and Carlson, Blair and Boettcher, Eric and Ruokolainen, Robert},

  abstractNote = {One challenge in adapting welding processes to dissimilar material joining is the diversity of melting temperatures of the different materials. Although the use of mechanical fasteners and adhesives have mostly paved the way for near-term implementation of dissimilar material systems, these processes only accentuate the need for low-cost welding processes capable of joining dissimilar material components regardless of alloy, properties, or melting temperature. Friction stir scribe technology was developed to overcome the challenges of joining dissimilar material components where melting temperatures vary greatly, and properties and/or chemistry are not compatible with more traditional welding processes. Although the friction stir scribe process is capable of joining dissimilar metals and metal/polymer systems, a more detailed evaluation of several aluminum/steel joints is presented herein to demonstrate the ability to both chemically and mechanically join dissimilar materials.},

  doi          = {10.1007/s11837-017-2334-6},

  journal      = {JOM. Journal of the Minerals, Metals & Materials Society},

  number       = 6,

  volume       = 69,

  place        = {United States},

  year         = {Wed Apr 05 00:00:00 EDT 2017},

  month        = {Wed Apr 05 00:00:00 EDT 2017}

}

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Journal Article:

DOI: 10.1007/s11837-017-2334-6

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Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology

Hovanski, Yuri ; Upadyay, Piyush ; Kleinbaum, Sarah ; ... - JOM. Journal of the Minerals, Metals & Materials Society

One challenge in adapting welding processes to dissimilar material joining is the diversity of melting temperatures of the different materials. Although the use of mechanical fasteners and adhesives have mostly paved the way for near-term implementation of dissimilar material systems, these processes only accentuate the need for low-cost welding processes capable of impartially joining dissimilar material components regardless of alloy, properties, or melting temperature. Friction stir scribe technology was developed to overcome the challenges of joining dissimilar material components where melting temperatures vary greatly, and properties and/or chemistry are not compatible with more traditional welding processes. Finally, although the frictionmore »« less
DOI: 10.1007/s11837-017-2334-6

Full Text Available
Joining dissimilar materials using Friction Stir scribe technique

Upadhyay, Piyush ; Hovanski, Yuri ; Jana, Saumyadeep ; ... - Journal of Manufacturing Science and Engineering, 139(3):Article No. 034501

The ability to effectively join materials with vastly different melting points like Aluminum-Steel, Polymer composites - metals has been one of the road blocks in realizing multi-material components for light weighting efforts. Friction stir scribe (FSS) technique is a promising method that produces continuous overlap joint between materials with vastly different melting regimes and high temperature flow characteristics. FSS uses an offset cutting tool at the tip of the FSW pin to create an insitu mechanical interlock between material interfaces. With investments from Vehicle Technology office, US DOE and several automotive manufacturers and suppliers PNNL is developing the FSS processmore »« less
DOI: 10.1115/1.4034629
Joining Dissimilar Materials Using Friction Stir Scribe Technique

Upadhyay, Piyush ; Hovanski, Yuri ; Jana, Saumyadeep ; ... - Journal of Manufacturing Science and Engineering

Development of a robust and cost-effective method of joining dissimilar materials could provide a critical pathway to enable widespread use of multi-material designs and components in mainstream industrial applications. The use of multi-material components such as steel-aluminum and aluminum-polymer would allow design engineers to optimize material utilization based on service requirements and could often lead to weight and cost reductions. However, producing an effective joint between materials with vastly different thermal, microstructural, and deformation responses is highly problematic using conventional joining and/or fastening methods. This is especially challenging in cost sensitive, high volume markets that largely rely on low costmore »« less
DOI: 10.1115/1.4034629
Friction stir scribe welding technique for dissimilar joining of aluminium and galvanised steel

Wang, Tianhao ; Sidhar, Harpreet ; Mishra, Rajiv S. ; ... - Science and Technology of Welding and Joining

Friction stir scribe technology, a derivative of friction stir welding, was applied for the dissimilar lap welding of an aluminum alloy and galvanized mild steel sheets. During the process, the rotating tool with a cobalt steel scribe first penetrated the top material — aluminum — and then the scribe cut the bottom material — steel. The steel was displaced into the upper material to produce a characteristic hook feature. Lap welds were shear tested, and their fracture paths were studied. Welding parameters affected the welding features including hook height, which turned out to be highly related to fracture position. Therefore,more »« less
DOI: 10.1080/13621718.2017.1381460
Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

Gupta, Varun ; Upadhyay, Piyush ; Fifield, Leonard S. ; ... - Journal of Manufacturing Processes

The friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For the welds in lap configuration, an enhancement to this technology is made by introducing a short hard insert, referred to as cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanically coupled computational model employing coupled Eulerian-Lagrangian approach is developed to quantitativelymore »« less
DOI: 10.1016/j.jmapro.2018.03.030