Joining thick section aluminum to steel with suppressed FeAl intermetallic formation via friction stir dovetailing

Journal Article · Sun Apr 01 04:00:00 EDT 2018 · Scripta Materialia

DOI:https://doi.org/10.1016/j.scriptamat.2018.01.026· OSTI ID:1434857

Reza-E-Rabby, Md.; Ross, Kenneth; Overman, Nicole R.; Olszta, Matthew J.; McDonnell, Martin; Whalen, Scott A.

A new solid-phase technique called friction stir dovetailing (FSD) has been developed for joining thick section aluminum to steel. In FSD, mechanical interlocks are formed at the aluminum-steel interface and are reinforced by metallurgical bonds where intermetallic growth has been uniquely suppressed. Lap shear testing shows superior strength and extension at failure compared to popular friction stir approaches where metallurgical bonding is the only joining mechanism. High resolution microscopy revealed the presence of a 40-70 nm interlayer having a composition of 76.4 at% Al, 18.4 at% Fe, and 5.2 at% Si, suggestive of limited FeAl3 intermetallic formation.

• Research Organization: Pacific Northwest National Laboratory (PNNL), Richland, WA (US)
• Sponsoring Organization: USDOE
• DOE Contract Number: AC05-76RL01830
• OSTI ID: 1434857
• Report Number(s): PNNL-SA-131279; 453040075
• Journal Information: Scripta Materialia, Journal Name: Scripta Materialia Journal Issue: C Vol. 148; ISSN 1359-6462
• Publisher: Elsevier
• Country of Publication: United States
• Language: English

Related Subjects

Fracture
Friction stir dovetailing
Friction stir welding
Intermetallics
Joining