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

Abstract

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.

Authors:
; ; ; ; ;
Publication Date:
Research Org.:
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1502411
Report Number(s):
PNNL-SA-131279
Journal ID: ISSN 1359-6462
DOE Contract Number:  
AC05-76RL01830
Resource Type:
Journal Article
Journal Name:
Scripta Materialia
Additional Journal Information:
Journal Volume: 148; Journal Issue: C; Journal ID: ISSN 1359-6462
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
Friction stir dovetailing, Joining, Intermetallics, Fracture, Friction stir welding

Citation Formats

Reza-E-Rabby, Md., Ross, Kenneth, Overman, Nicole R., Olszta, Matthew J., McDonnell, Martin, and Whalen, Scott A. Joining thick section aluminum to steel with suppressed FeAl intermetallic formation via friction stir dovetailing. United States: N. p., 2018. Web. doi:10.1016/j.scriptamat.2018.01.026.
Reza-E-Rabby, Md., Ross, Kenneth, Overman, Nicole R., Olszta, Matthew J., McDonnell, Martin, & Whalen, Scott A. Joining thick section aluminum to steel with suppressed FeAl intermetallic formation via friction stir dovetailing. United States. doi:10.1016/j.scriptamat.2018.01.026.
Reza-E-Rabby, Md., Ross, Kenneth, Overman, Nicole R., Olszta, Matthew J., McDonnell, Martin, and Whalen, Scott A. Sun . "Joining thick section aluminum to steel with suppressed FeAl intermetallic formation via friction stir dovetailing". United States. doi:10.1016/j.scriptamat.2018.01.026.
@article{osti_1502411,
title = {Joining thick section aluminum to steel with suppressed FeAl intermetallic formation via friction stir dovetailing},
author = {Reza-E-Rabby, Md. and Ross, Kenneth and Overman, Nicole R. and Olszta, Matthew J. and McDonnell, Martin and Whalen, Scott A.},
abstractNote = {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.},
doi = {10.1016/j.scriptamat.2018.01.026},
journal = {Scripta Materialia},
issn = {1359-6462},
number = C,
volume = 148,
place = {United States},
year = {2018},
month = {4}
}