skip to main content
DOE PAGES title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Two-sided friction stir riveting by extrusion: A process for joining dissimilar materials

Abstract

Two-sided friction stir riveting (FSR) by extrusion is an innovative process developed to rapidly, efficiently, and securely join dissimilar materials. This process extends a previously developed one sided friction stir extrusion process to create a strong and robust joint by producing a continuous, rivet-like structure through a preformed hole in one of the materials with a simultaneous, two-sided friction stir spot weld. The two-sided FSR by extrusion process securely joins the dissimilar materials together and effectively locks them in place without the use of any separate materials or fasteners. Lastly, in this paper we demonstrate the process by joining aluminum to steel and illustrate its potential application to automotive and aerospace manufacturing processes.

Authors:
 [1];  [2];  [1];  [1];  [3]
  1. Vanderbilt Univ., Nashville, TN (United States)
  2. Schlumberger, Houston, TX (United States)
  3. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Laboratory Directed Research and Development (LDRD) Program
OSTI Identifier:
1261567
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Journal of Manufacturing Processes
Additional Journal Information:
Journal Volume: 23; Journal Issue: C; Journal ID: ISSN 1526-6125
Publisher:
Society of Manufacturing Engineers; Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 42 ENGINEERING; dissimilar materials joining; aluminum steel welding; friction stir extrusion; friction stir spot welding; friction stir forming; rivet

Citation Formats

Evans, William T., Cox, Chase D., Strauss, Alvin M., Cook, George E., and Gibson, Brian T. Two-sided friction stir riveting by extrusion: A process for joining dissimilar materials. United States: N. p., 2016. Web. https://doi.org/10.1016/j.jmapro.2016.06.001.
Evans, William T., Cox, Chase D., Strauss, Alvin M., Cook, George E., & Gibson, Brian T. Two-sided friction stir riveting by extrusion: A process for joining dissimilar materials. United States. https://doi.org/10.1016/j.jmapro.2016.06.001
Evans, William T., Cox, Chase D., Strauss, Alvin M., Cook, George E., and Gibson, Brian T. Sat . "Two-sided friction stir riveting by extrusion: A process for joining dissimilar materials". United States. https://doi.org/10.1016/j.jmapro.2016.06.001. https://www.osti.gov/servlets/purl/1261567.
@article{osti_1261567,
title = {Two-sided friction stir riveting by extrusion: A process for joining dissimilar materials},
author = {Evans, William T. and Cox, Chase D. and Strauss, Alvin M. and Cook, George E. and Gibson, Brian T.},
abstractNote = {Two-sided friction stir riveting (FSR) by extrusion is an innovative process developed to rapidly, efficiently, and securely join dissimilar materials. This process extends a previously developed one sided friction stir extrusion process to create a strong and robust joint by producing a continuous, rivet-like structure through a preformed hole in one of the materials with a simultaneous, two-sided friction stir spot weld. The two-sided FSR by extrusion process securely joins the dissimilar materials together and effectively locks them in place without the use of any separate materials or fasteners. Lastly, in this paper we demonstrate the process by joining aluminum to steel and illustrate its potential application to automotive and aerospace manufacturing processes.},
doi = {10.1016/j.jmapro.2016.06.001},
journal = {Journal of Manufacturing Processes},
number = C,
volume = 23,
place = {United States},
year = {2016},
month = {6}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Citation Metrics:
Cited by: 7 works
Citation information provided by
Web of Science

Save / Share:

Works referenced in this record:

Growth Manner of Intermetallic Compound Layer Produced at Welding Interface of Friction Stir Spot Welded Aluminum/Steel Lap Joint
journal, January 2011


Dissimilar friction stir spot welding of low carbon steel and Al–Mg alloy by formation of IMCs
journal, April 2009

  • Lee, C. -Y.; Choi, D. -H.; Yeon, Y. -M.
  • Science and Technology of Welding and Joining, Vol. 14, Issue 3
  • DOI: 10.1179/136217109X400439

Intermetallic compounds in Al 6016/IF-steel friction stir spot welds
journal, June 2010

  • Bozzi, S.; Helbert-Etter, A. L.; Baudin, T.
  • Materials Science and Engineering: A, Vol. 527, Issue 16-17
  • DOI: 10.1016/j.msea.2010.03.097

Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate
journal, April 2009


Mechanical Behaviour and Microstructure of Aluminum-Steel Sheets Joined by FSSW
journal, June 2008

  • Bozzi, S.; Etter, A. L.; Baudin, T.
  • Texture, Stress, and Microstructure, Vol. 2008
  • DOI: 10.1155/2008/360617

A Hybrid Joining Technology for Aluminum/Zinc Coated Steels in Vehicles
journal, January 2010


Experimental analysis of friction stir forming for dissimilar material joining application
journal, October 2013


Development of Friction Stir Forming
journal, August 2003


Friction Stir Extrusion: A new process for joining dissimilar materials
journal, August 2015


A New One-Sided Joining Process for Aluminum Alloys: Friction Stir Blind Riveting
journal, November 2009

  • Gao, Dalong; Ersoy, Ugur; Stevenson, Robin
  • Journal of Manufacturing Science and Engineering, Vol. 131, Issue 6
  • DOI: 10.1115/1.4000311

Friction stir blind riveting for aluminum alloy sheets
journal, January 2015


Friction Stir Blind Riveting: A Novel Joining Process for Automotive Light Alloys
journal, April 2011

  • Lathabai, Sri; Tyagi, Vinay; Ritchie, David
  • SAE International Journal of Materials and Manufacturing, Vol. 4, Issue 1
  • DOI: 10.4271/2011-01-0477

A method for double-sided friction stir spot welding
journal, April 2014


    Works referencing / citing this record:

    Processing and tooling considerations in joining by forming technologies; part B—friction-based welding
    journal, January 2020

    • Salamati, Masoud; Soltanpour, Mahdi; Fazli, Ali
    • The International Journal of Advanced Manufacturing Technology, Vol. 106, Issue 9-10
    • DOI: 10.1007/s00170-019-04845-1

    A review on friction-based joining of dissimilar aluminum–steel joints
    journal, October 2018


    Mechanical Properties and Microstructures on Dissimilar Metal Joints of Stainless Steel 301 and Aluminum Alloy 1100 by Micro-Resistance Spot Welding
    journal, December 2018

    • Baskoro, Ario Sunar; Muzakki, Hakam; Kiswanto, Gandjar
    • Transactions of the Indian Institute of Metals, Vol. 72, Issue 2
    • DOI: 10.1007/s12666-018-1500-z

    Joining of aluminum sheet and glass fiber reinforced polymer using extruded pins
    conference, January 2018

    • Conte, Romina; Buhl, Johannes; Ambrogio, Giuseppina
    • PROCEEDINGS OF THE 21ST INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2018, AIP Conference Proceedings
    • DOI: 10.1063/1.5034881