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Meeting 2017 TMS Annual Meeting & Exhibition
Symposium Friction Stir Welding and Processing IX
Presentation Title Solid-State Joining of Thick-Section Dissimilar Materials Using a New Friction Stir Dovetailing (FSD) Process
Author(s) Scott A. Whalen, Md. Reza-E-Rabby, Ken Ross, Yuri Hovanski, Martin McDonnell
On-Site Speaker (Planned) Md. Reza-E-Rabby
Abstract Scope 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.
Proceedings Inclusion? Planned: Stand-alone book in which only your symposium’s papers would appear (indicate title in comments section below)


A-84: Effect of Morphological Characteristics of Intermetallic Compounds on Mechanical and Metallurgical Properties of Aluminium A6061- 304 Steel Joint
A-86: Effect of Tool Shoulder Feature on Heat Generation and Material Flow of Friction Stir Welded Al-Mg-Si Alloy
A-87: Fabrication and Characterization of Al/Al2O3-SiC Hybrid Surface Nano Composite by Friction Stir Process
A-88: Fatigue-Strength Increase by Friction Stir Processing between Different Strength Grades of Butt-Welded High-Tensile Steels
A-89: Friction Stir Welding of Dissimilar Metals
A-90: Effect of Heat Treatment on Friction-stir-processed Nanodispersed AA7075 and 2024 Al Alloys
A-91: Circumferential Tool Path Control for Friction Stir Spot Welding of Thin Al/Fe Dissimilar Metal Joint
A-92: Numerical Analysis of FSW Employing Discrete Element Method
A Novel Approach for Joining EN AW 1070 Stranded Wire and EN CW 004A Contact Elements by Friction Stir Spot Bonding
A Numerical Simulation for Dissimilar Aluminum Alloys Joined by Friction Stir Welding
Automated Optical Visualization of Materials Flow in Dissimilar Metal Friction Stir Welds
Avoiding Melting in Friction Stir Welds of Highly Dissimilar Melting Temperature Materials
Corrosion Fatigue Performance of Friction Stir Processed Magnesium Alloy AZ31B-H24: A Comparative Evaluation
Depth and Temperature Control during Friction Stir Welding of 5 cm Thick Copper Canisters
Development of Friction Stir Processing for Repair of Nuclear Dry Cask Storage System Canisters
Direct Pin Tool Temperature Measurements in Friction Stir Welding
Dissimilar Metal T-Joint Formed by Friction Stir Extrusion
Effect of Friction Stir Processing on Microstructure and Mechanical Properties of Cast Eglin Steel (ES-1)
Effect of Friction Stir Processing on the Damage Resistance of 6xxx Series Aluminium Alloys
Effect of Hydrogenation on Superplastic Behavior of Nugget in Friction Stir Welded Ti-6Al-4V Joints
Effect of Pin Tool Profile on Metal Flow, Torque and Forces during Friction Stir Welding-limiting Friction Cases
Effect of Process Parameters on the Residual Stress Distribution in Stationary Shoulder T-Joints
Effect of Thermal Aging on the Corrosion and Mechanical Properties of Friction Stir Welded 250 Grade Maraging Steel
Effect of Tool Runout in Friction Stir Welding of Aluminum Alloy for Structural Applications
Evaluation of Ausformed H13 Tool Steel for FSW Tools
Feasibility of Iridium Containing Nickel Base Superalloy Tool to Friction Stir Spot Welding of High Strength Steel
Flow Features in Shoulder Zone during Scroll Tool Friction Stir Welding Thick 6061 Aluminum Plates
Friction-Stir-Processing Microstructure Improvement Related to Fatigue-strength and Charpy-absorbed-Energy Increase of TIG-welded SS400 Steels
Friction Stir Processing of 2507 Super Duplex Stainless Steel: Microstructure and Corrosion Behaviour
Friction Stir Processing of 304L Stainless Steel for Crack Repair
Friction Stir Weld Lap Joint Properties in Aeronautic Aluminum Alloys
Friction Stir Welding – A Closer Examination
Friction Stir Welding of Steel-two Innovative Welding Methods
Friction Stir Welding of Thick Aluminium Welds – Challenges and Perspectives
Friction Stir Welding of Thick Section Aluminium Alloys - New Techniques
Friction Stir Welding Parameter Development of AA7075 for Hot Stamping Applications
FSW Studies to Achieve High Charpy Impact Energy in 19 mm Thick ASTM-A6 Steel
Growth of Friction Stir Welding and Processing: Contributions of Murray W. Mahoney
High-speed FSW Aluminum Alloy 7075 Microstructure and Corrosion Properties
High Temperature Properties and Microstructures of ODS and RAFM Alloys FSW
Industrial Application of FSW at HFW
Influence of Stir Flow on Joint Quality during Friction Stir Lap Al-to-Cu Welding
Influence of Underwater Operation on Friction Stir Welding of Medium Carbon Steel
Intermetallic Phase Formation at Al-steel Solid-state Joints – A Comparison between FSW and VFAW Processes
Investigation of Process Parameters for Friction Stir Processing (FSP) of Ti-6Al-4V Alloy
Joining Aerospace Aluminum 2024-T4 to Titanium by Friction Stir Extrusion
Joining Al 6061 to ZE41A Mg Alloy by Friction Stir Welding Using a Cold Spray Transition Joint
Joining Aluminum Alloys to High Strength Steels by Friction Spot Welding
Joining Dissimilar Material Using Friction Stir Scribe Technique
Measuring the Advancing Side Separation Forces during Self-reacting FSW of Al
Micro-mechanical Testing of Magnesium Based Composites Reinforced by Carbon Fibers Manufactured by Friction Stir Processing
Microscopic Evaluation of Friction Plug Welds– Correlation to a Processing Analysis
Microstructural Analysis and Mechanical Properties of Friction Stir Back Extruded/Aged 7075 Aluminum Alloy
Microstructure and Mechanical Properties of Beta-type Ti-15V-3Cr-3Al-3Sn Alloy Joints Fabricated by Friction Stir Welding
Performance of Tungsten-based Alloy Tool Developed for Friction Stir Welding of Austenitic Stainless Steel
Predicting Friction Pull Plug Welding Results
Predicting Lap Shear Strength for Friction Stir Scribe Joining of Dissimilar Materials
Prediction of Mechanical Properties of Friction Stir Welds through Microstructural Data
Process Force Reduction during Robotic Friction Stir Welding of Aluminium Alloys with Reduced Tool Aspect Ratios
Realization of Ultrasound Enhanced Friction Stir Welded (USE-FSW) Al/Mg- and Al/Steel-Joints: Process and Robustness, Mechanical and Corrosive Properties
Refill Friction Stir Spot Welding Aerospace Aluminum Alloys
Round Material Flow in Friction Stir Welding of Aluminum Alloy
Simultaneous Independent Control of Tool Axial Force and Temperature in Friction Stir Processing
Solid-State Joining of Thick-Section Dissimilar Materials Using a New Friction Stir Dovetailing (FSD) Process
Solid State Additive Manufacturing Using FSW and Low-cost Precursors

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