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Title: Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process

Abstract

Solid-state joining of thick section aluminum to steel plate has been achieved using a new process called Friction Stir Dovetailing (FSD). In FSD, a custom designed pin tool is used to flow a lower melting point material (AA6061) into dovetail grooves machined into the surface of an underlying higher melting point material (Rolled Homogeneous Armor – RHA). Repeating dovetails form a mechanical interlocking structure akin to metallic Velcro. In this study, AA6061 sections ranging in thickness from 1.5” to 3.0” are joined to 0.5” thick RHA plates. The effectiveness of FSD is demonstrated through tensile test data which shows specimens failing in the processed aluminum rather than at the joint interface. Numerical simulations are presented which highlight the importance of optimizing dovetail geometry. The effect of process parameters on joint strength, microstructure, and hardness are also discussed.

Authors:
; ; ; ;
Publication Date:
Research Org.:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1440675
Report Number(s):
PNNL-SA-119210
830403000
DOE Contract Number:  
AC05-76RL01830
Resource Type:
Conference
Resource Relation:
Conference: Friction Stir Welding and Processing IX, 67-77
Country of Publication:
United States
Language:
English
Subject:
Friction Stir; dissimilar metals joining; th; sc; do

Citation Formats

Reza E Rabby, MD, Ross, Kenneth A., Whalen, Scott A., Hovanski, Yuri, and Mcdonnell, Martin. Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process. United States: N. p., 2017. Web. doi:10.1007/978-3-319-52383-5_8.
Reza E Rabby, MD, Ross, Kenneth A., Whalen, Scott A., Hovanski, Yuri, & Mcdonnell, Martin. Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process. United States. doi:10.1007/978-3-319-52383-5_8.
Reza E Rabby, MD, Ross, Kenneth A., Whalen, Scott A., Hovanski, Yuri, and Mcdonnell, Martin. Tue . "Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process". United States. doi:10.1007/978-3-319-52383-5_8.
@article{osti_1440675,
title = {Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process},
author = {Reza E Rabby, MD and Ross, Kenneth A. and Whalen, Scott A. and Hovanski, Yuri and Mcdonnell, Martin},
abstractNote = {Solid-state joining of thick section aluminum to steel plate has been achieved using a new process called Friction Stir Dovetailing (FSD). In FSD, a custom designed pin tool is used to flow a lower melting point material (AA6061) into dovetail grooves machined into the surface of an underlying higher melting point material (Rolled Homogeneous Armor – RHA). Repeating dovetails form a mechanical interlocking structure akin to metallic Velcro. In this study, AA6061 sections ranging in thickness from 1.5” to 3.0” are joined to 0.5” thick RHA plates. The effectiveness of FSD is demonstrated through tensile test data which shows specimens failing in the processed aluminum rather than at the joint interface. Numerical simulations are presented which highlight the importance of optimizing dovetail geometry. The effect of process parameters on joint strength, microstructure, and hardness are also discussed.},
doi = {10.1007/978-3-319-52383-5_8},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2017},
month = {2}
}

Conference:
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Works referenced in this record:

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