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

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Friction Stir Welding and Processing IX

Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

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 material that has a higher melting point (rolled homogeneous armor [RHA]) . Repeating dovetails form a mechanical interlocking structure akin to metallic Velcro. In this study, 38.1 mm (1.5 in.) thick AA6061 was joined to 12.7 mm (0.5 in.) thick RHA plates. The effectiveness of FSD is demonstrated through tensile test data that shows specimens failing in the processed aluminum rather than at the joint interface. Numerical simulations that highlight the importance of optimizing dovetail geometry are presented. The effect of process parameters on joint strength and microstructure also are discussed.

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Acknowledgements

This work was supported by the US Army Tank Automotive Research, Development and Engineering Center. The Pacific Northwest National Laboratory is operated by the Battelle Memorial Institute for the United States Department of Energy under contract DE-AC06-76LO1830.

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Authors and Affiliations

  1. Applied Materials and Processing Group, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA, 99352, USA

    Md. Reza-E-Rabby, Ken Ross, Scott Whalen & Yuri Hovanski

  2. U.S. Army Tank Automotive Research Development and Engineering Center, 6501 E 11 Mile Road, Warren, MI, 48397, USA

    Martin McDonnell

Authors
  1. Md. Reza-E-Rabby
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  2. Ken Ross
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  3. Scott Whalen
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  4. Yuri Hovanski
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  5. Martin McDonnell
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Corresponding author

Correspondence to Md. Reza-E-Rabby .

Editor information

Editors and Affiliations

  1. Brigham Young University , Provo, Utah, USA

    Yuri Hovanski

  2. Denton, Texas, USA

    Rajiv Mishra

  3. Tohoku University , Sendai, Japan

    Yutaka Sato

  4. Pacific Northwest National Laboratory , Richland, Washington, USA

    Piyush Upadhyay

  5. University of Wisconsin Green Bay , Green Bay, Wisconsin, USA

    David Yan

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© 2017 The Minerals, Metals & Materials Society

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Reza-E-Rabby, M., Ross, K., Whalen, S., Hovanski, Y., McDonnell, M. (2017). Solid-State Joining of Thick-Section Dissimilar Materials Using a New Friction Stir Dovetailing (FSD) Process. In: Hovanski, Y., Mishra, R., Sato, Y., Upadhyay, P., Yan, D. (eds) Friction Stir Welding and Processing IX. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-319-52383-5_8

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