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.; Roosendaal, Timothy; Sun, Xin; Nelaturu, Phalgun; Carlson, Blair

doi:10.1016/j.jmapro.2018.03.030

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

Journal Article · Wed Apr 04 00:00:00 EDT 2018 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2018.03.030· OSTI ID:1435194

^[1]; Upadhyay, Piyush ^[1]; Fifield, Leonard S. ^[1]; Roosendaal, Timothy ^[2]; Sun, Xin ^[2]; Nelaturu, Phalgun ^[3]; Carlson, Blair ^[3]

Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
General Motors Research and Development, Warren, MI (United States)

We present that 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 welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a 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-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725; AC05-76RL01830; EE0007311

OSTI ID:: 1435194

Alternate ID(s):: OSTI ID: 1434847
OSTI ID: 1780260
OSTI ID: 1491237

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Journal Issue: C Vol. 32; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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A review on friction-based joining of dissimilar aluminum–steel joints Mehta, Kush P. Journal of Materials Research, Vol. 34, Issue 1 https://doi.org/10.1557/jmr.2018.332	journal	October 2018
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