Materials Scientist
Materials Scientist

Biography

Scott Whalen is a Chief Scientist in the Applied Materials and Manufacturing group at Pacific Northwest National Laboratory (PNNL). His research interests focus on developing new manufacturing processes to create materials with exceptional performance. Alloys of aluminum, magnesium, copper, titanium, and bismuth-telluride are currently under investigation by his research teams. Scott is a co-inventor on 28 granted and pending US patents, is the author or co-author on 50+ peer-reviewed publications, and has received two R&D 100 Awards. He was selected as PNNL’s Engineer of the Year in 2022 and Inventor of the Year in 2003 in recognition of his creative innovations and impactful technologies.

Scott received a PhD in Mechanical Engineering from Washington State University in 2004 where he developed the world’s first and only Micro-Electro-Mechanical Systems (MEMS) engine to run on a thermodynamic working cycle. After graduation, he completed a postdoctoral appointment at Sandia National Laboratories investigating micro-scale energy harvesting devices. As a Staff Scientist at Sandia, he performed R&D on all aspects of milliwatt-scale radioisotopic thermoelectric systems and materials. Scott joined PNNL in 2012 where he now develops solid-phase processing techniques for manufacturing novel materials. He is particularly passionate about inventing new technologies that convert domestic scrap metals into high-performance products to reduce our reliance on expensive foreign-made materials.

Research Interest

  • Shear Assisted Processing and Extrusion (ShAPE™)
  • Solid Phase Processing
  • Metal Scrap Upcycling
  • Thermoelectric Materials

Education

  • PhD in Mechanical Engineering, Washington State University, 2004.
  • MS in Safety Engineering, Biomechanics, Texas A&M University, 1997.
  • BS in Mechanical Engineering, University of Idaho, 1996.

Affiliations and Professional Service

  • American Society of Mechanical Engineers.
  • The Minerals, Metals & Materials Society.

Awards and Recognitions

  • PNNL Project Manager of the Year, Energy Process and Materials Division, 2025.
  • PNNL Inventor of the Year, 2024.
  • DOE-VTO Team Award, 2023.
  • PNNL Paper of the Year, Energy and Environment Directorate, 2023.
  • PNNL Paper of the Quarter, Applied Materials and Manufacturing Group, 7 times, 2019-2023.
  • PNNL Director's Award for Exceptional Engineering Achievement, 2022.
  • Association of Washington Business (AWB) Green Manufacturing Award, 2021.
  • R&D 100 Award, PNNL, 2020.
  • PNNL Project of the Year, Energy Process and Materials Division, 2020.
  • PNNL Paper of the Year, Energy and Environment Directorate, 2019.
  • PNNL Core Value Award, Energy and Environment Directorate, 2018.
  • R&D 100 Award, PNNL, 2017.
  • National Nuclear Security Administration (NNSA) Defense Program Award of Excellence, 2011
  • NNSA Defense Program Award of Excellence, 2009.
  • Sandia Award for Individual Technical Excellence, 2008.
  • Sandia Award for Excellence in Research and Development (R&D), 2008.
  • Sandia Center R&D Award, 2007.
  • American Society of Mechanical Engineers (ASME) Best Paper in micro-electromechanical system (MEMS) Division, 2005.
  • Sandia Excellence in Engineering Full Doctoral Fellowship, 2002-2004.
  • Washington State University Doctoral Researcher of the Year, 2002.

Patents

C. Lavender, V. Joshi, G. Grant, S. Jana, S. Whalen, J. Darsell. System and Process for Formation of Extrusion Products. US Patent 10189063-B2, filed 14 November 2016, and issued 29 January 2019.  

S. Whalen, Md. Reza-E-Rabby, K. Ross, A, Rohatgi. Friction Stirring Interlocking of Dissimilar Materials. US Patent 10369748-B2, filed 26 October 2017, and issued 6 August 2019. 

V. Joshi, S. Whalen, C. Lavender, G. Grant, MD. Reza-E-Rabby, A. Rohatgi, J. Darsell. Method for Forming Hollow Profile Non-Circular Extrusions Using Shear Assisted Processing and extrusion (ShAPE™). US Patent 11534811-B2, filed 12 February 2021, and issued 27 December 2022.

S. Whalen, Md. Reza-E-Rabby, Scott Taysom, Curt Lavender. Devices and Methods for Performing Shear-Assisted Extrusion, Extrusion Feedstocks, Extrusion Processes, and Methods for Preparing Metal Sheets. US Patent 11383280-B2, filed 5 September 2019, and issued 12 July 2022. 

V. Joshi, G. Grant, C. Lavender, S. Whalen, S. Jana, D. Catalini, J. Darsell. Functionally Graded Coatings and Claddings. US Patent 2021023596-A1, filed 30 June 2020, and issued 28 January 2021. 

M. Komarasamy, S. Whalen, B. Milligan. Shear-Assisted Extrusion Assemblies and Methods. US Patent 2024307939-A1, filed 2 February 2024, and issued 19 September 2024. 

S. Whalen, T. Wang, P. Upadhyay, K. Kappagantula. Assemblies, Riveted Assemblies, Methods for Affixing Substrates, and Methods for Mixing Materials to Form a Metallurgical Bond. US Patent 2023076727-A1, filed 3 November 2022, and issued 9 March 2023. 

S. Whalen, J. Darsell, MD. Reza-E-Rabby, B. Taysom, T. Wang, D. Herling, X. Li. Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes. US Patent 2021402471-A1, filed 13 September 2021, and issued 30 December 2021.  

S. Whalen, K. Ross, Md. Reza-E-Rabby, Y. Hovanski. System and Process for Joining Dissimilar Materials and Solid-State Interlocking Joint with Intermetallic Interface Formed Thereby. US Patent 2024052862-A1, filed 25 October 2023 , and issued 15 February 2024. 

S. Whalen, Md. Reza-E-Rabby, K. Ross, M. McDonnell, Y. Hovanski. Methods and Devices for Connecting Two Dissimilar Materials. US Patent 2024058891-A1, filed 25 October 2023, and issued 22 February 2024.  

S. Taysom, Md. Reza-E-Rabby, S. Whalen. Shear Assisted Extrusion Apparatus, Tools, and Methods. US Patent 2024009725-A1, filed 5 July 2022, and issued 11 January 2024. 

S. Whalen, D. Herling, X. Li, MD. Reza-E-Rabby, B. Taysom, G. Grant, V. Joshi, R. Kalsar, T. Wang. Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes. US Patent 2023042802-A1, filed 30 September 2022, and issued 9 February 2023.

S. Whalen, J. Darsell, Reza-E-Rabby, Md., B. Taysom, T. Wang, D. Herling, X. Li. Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes. US Patent 4210882-A1, filed 13 September 2021, and issued 19 July 2023.

S. Whalen, D. Herling, X. Li, MD. Reza-E-Rabby, B. Taysom, G. Grant. Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes. US Patent 12186791-B2, filed 27 September 2020, and issued 7 January 2025. 

S. Taysom, S. Whalen. Extrusion with Specifiable or Variable Wall Thickness. US Patent 2024082898-A1, filed 11 September 2023, and issued 14 March 2024.

M. Komarasamy, S. Whalen, G. Grant, B. Taysom. Variable Thickness Extrusion for Variable Extrudate Product Properties. US Patent 2025034572-A2, filed 17 November 2023, and issued 14 March 2024.

S. Taysom, S. Whalen, C. Smith. Multi-Axis Shear-Assisted Extrusion Machine. US Patent Application 18/793,394 file August 2024.

M. Komarasamy, S. Whalen, G. Grant, S. Taysom. Manufacturing components with variable properties via solid phase processing. US Patent Application 18/513,402, filed November 2023.

M. Komarasamy, S. Whalen, G. Grant, S. Taysom. Manufacturing components with variable properties via solid phase processing. US Patent Application 18/513,392 filed November 2023.

B. Taysom, S. Whalen, Md. Reza-E-Rabby. Interruptible Shear-Assisted Extrusion. US Patent Application 18/410,784 filed November 2023.

Publications

2024

  • S. Whalen, N. Overman, B.D. Taysom, B. Milligan, M. Tillman, D. Bishop, P. Renner, Y. Qiao, R. Montgomery, “Fabrication of Bismuth-Telluride Thermoelectric Wires by Friction Extrusion,” Materials & Design, vol. 224, 113527, 2024. doi:10.1016/j.matdes.2024.113527
  • B. Milligan, Md. Reza-E-Rabby, B. Schuessler, T. Roosendaal, T. Lemmon, S. Whalen, “Microstructural Refinement of an Al-Ce-Mg Alloy via Shear Assisted Processing and Extrusion,” Materials Science and Engineering A, vol. 916, 2024, 147328. PNNL-SA-202613. doi:10.1016/j.msea.2024.147328 
  • M. Komarasamy, L. Li, B.S. Taysom, A. Soulami, G. Grant, D. Herling, S. Whalen, “Co-Extrusion of Dissimilar Aluminum Alloys via Shear Assisted Processing and Extrusion,” Coatings, vol. 14, 42, 2024. PNNL-SA-182175. doi:10.3390/coatings14010042
  • H. Das, Md. Reza-E-Rabby, S. Whalen, P. Upadhyay, G. Grant, “Impact of Backing Plate and Thermal Boundary Conditions for High-Speed Friction Stir Welding of 25 mm Thick Aluminum Alloy 7175-T79,” International Journal of Precision Engineering and Manufacturing-Green Technology, vol. 11, 2024, pp. 1757-1767. PNNL-SA-184852. doi:10.1007/s40684-024-00607-x
  • B. Milligan, B.S. Taysom, B. Schuessler, T. Lemmon, S. Whalen, “Upcycling of Mixed Aluminum Alloy Shredder Scrap using Shear Processing,” ASM Advanced Materials and Processes, pp. 15-20, 2024. PNNL-SA-198397. doi:10.31399/asm.amp.2024-05.p015

2023

  • S. Whalen, N. Overman, B.S. Taysom, M. Bowden, Md. Reza-E-Rabby, T. Skszek, M. DiCiano, “Effect of High Iron Content on Direct Recycling of Unhomogenized Aluminum 6063 by Shear Assisted Processing and Extrusion,” Journal of Manufacturing Processes, vol. 97, pp. 115-124, 2023. PNNL-SA-181577. doi:10.1016/j.jmapro.2023.04.067
  • S. Whalen, B.S. Taysom, N. Overman, Md. Reza-E-Rabby, Y. Qiao, T. Richter, T. Skszek, M. DiCiano, “Porthole Die Extrusion of Aluminum 6063 Industrial Scrap by Shear Assisted Processing and Extrusion,“ Manufacturing Letters, vol. 36, pp. 52-56, 2023. PNNL-SA-179478. doi:10.1016/j.mfglet.2023.01.005
  • Md. Reza-E-Rabby, H. Das, T. Wang, M. Komarasamy, S. Whalen, G. Grant, “High-Speed Friction Stir Butt Welding of 25 mm Thick 7175-T79 Aluminum Alloy,” Manufacturing Letters, vol. 38, pp. 1-5, 2023. PNNL-SA-184859. doi:10.1016/j.mfglet.2023.08.140
  • T. Wang, Md. Reza-E-Rabby, H. Das, G. Grant, S. Whalen, “Friction Stir Welding of Thick 7175 Aluminum Alloy Plates for Deepwater Riser Applications,” Science and Technology of Welding and Joining, vol. 28 (8), 2023. doi:10.1080/13621718.2023.2219908
  • B. Milligan, L. Li, M. Komarasamy, T. Roosendaal, S. Whalen, “Cladding and Butt-Joining Dissimilar Aluminum Alloys Simultaneously via Shear Assisted Processing and Extrusion,” The Journal of the Minerals, Metals & Materials Society, vol. 75, pp. 3033-3040, 2023. doi:10.1007/s11837-023-05855-x
  • B.S. Taysom, X. Ma, S. Whalen, “In Situ Measurement of a Deforming Interface with Thermoelectricity,” Transactions of the Institute of Measurement and Control, pp. 1-8, 2023. doi:1177/01423312231169327
  • B. Milligan, X. Ma, B.S. Taysom, S. Whalen, “Solutionization via Severe Plastic Deformation: Effect of Temperature and Quench Method in a ShAPE™-Processed Al-Mg-Si Alloy,” Metallurgical and Materials Transactions, vol. 54, pp. 2576-2584, 2023. doi:10.1007/s11661-023-07034-8
  • W. Frazier, N. Overman, B. Schuessler, S. Niverty, T. Roosendaal, S. Whalen, V. Joshi, “Hot Rolling of ZK60 Magnesium Alloy with Isotropic Tensile Properties from Tubing made by Shear Assisted Processing and Extrusion (ShAPE™),” Applied Sciences, vol. 13 (9), 5343, 2023. PNNL-SA-159102. doi:10.3390/app13095343

2022

  • L. Li, Md. Reza-E-Rabby, N. Overman, T. Wang, S. Whalen, G. Grant, S. Mathaudhu, A. Soulami, “Analysis of Contact Conditions and Microstructure Evolution in Shear Assisted Processing and Extrusion using Smoothed Particle Hydrodynamics Method,” Materials and Design, vol. 221, 111010, 2022. PNNL-SA-173428. doi:10.1016/j.matdes.2022.111010
  • X. Li, T. Wang, X. Ma, N. Overman, S. Whalen, D. Herling, K. Kappagantula, “Manufacture High-Temperature Aluminum Alloy Tube from Powder with a Single-Step Extrusion,” Journal of Manufacturing Processes, vol. 80, pp. 108-115, 2022. PNNL-SA-169412. doi:10.1016/j.jmapro.2022.05.060
  • T. Wang, B. Gwalani, M. Song, X. Ma, T. Liu, H. Das, J. Silverstein, S. Whalen, “Extreme Shear Deformation Enables Ultra-Fast Riveting of High Strength Aluminum Alloys,” Journal of Manufacturing Processes, vol. 75, pp. 814-825, 2022. doi:10.1016/j.jmapro.2022.01.046
  • Komarasamy M., S.A. Whalen, B.S. Taysom, and D.R. Herling. 2022. "Co-extrusion of dissimilar Al alloys via shear assisted processing and extrusion." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition, (Light Metals 2022), February 27-March 2, 2022, Anaheim, CA, edited by D. Eskin, 308-313. Cham:Springer. PNNL-SA-166339. doi:10.1007/978-3-030-92529-1_43
  • Ma X., X. Li, G. Petrossian, A. Ortiz, M. Komarasamy, S.A. Whalen, and G.J. Grant, et al. 2022. "Porosity evolution during heating of copper made from powder by friction extrusion." Materialia 21. PNNL-SA-166323. doi:10.1016/j.mtla.2022.101341
  • Reza E Rabby M., T. Wang, N.L. Canfield, B.S. Taysom, D.R. Herling, D.D. Graff, and T.J. Roosendaal, et al. 2022. "Effect of Post-Extrusion Heat Treatment on Performance of AA2024 Tubes Fabricated by Shear Assisted Processing and Extrusion." CIRP - Journal of Manufacturing Science and Technology 37. PNNL-SA-167732. doi:10.1016/j.cirpj.2022.02.025
  • Reza E Rabby M., T. Wang, N.L. Canfield, D.D. Graff, T.J. Roosendaal, and S.A. Whalen. 2022. "Effect of post-extrusion heat treatment on mechanical property of aluminum alloy 2024 tube produced using Shear Assisted Processing and Extrusion (ShAPE™)." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition (Light Metals 2022), February 27- March 3, 2022, Anaheim, CA, edited by D. Eskin, 301-307. Cham:Springer. PNNL-SA-166238. doi:10.1007/978-3-030-92529-1_42
  • Wang T., J.D. Escobar Atehortua, M. Song, M. Reza E Rabby, B.S. Taysom, J.A. Silverstein, and T.J. Roosendaal, et al. 2022. "Extrusion of Unhomogenized Castings of 7075 Aluminum via ShAPE™." Materials & Design 213. PNNL-SA-167731. doi:10.1016/j.matdes.2021.110374
  • Wang T., S.A. Whalen, X. Ma, J.A. Silverstein, H. Das, M. Pallaka, and A. Ortiz, et al. 2022. "Friction-based riveting technique for AZ31 magnesium alloy." Journal of Magnesium and Alloys 10, no. 1:110 - 118. PNNL-SA-155089. doi:10.1016/j.jma.2021.06.004

2021

  • Komarasamy M., X. Li, S.A. Whalen, X. Ma, N.L. Canfield, M.J. Olszta, and T. Varga, et al. 2021. "Microstructural evolution in Cu-Nb processed via friction consolidation." Journal of Materials Science 56, no. 22:12864-12880. PNNL-SA-158852. doi:10.1007/s10853-021-06093-9
  • Nazaeri Tiji S., A. Asgharzadeh, T. Park, S.A. Whalen, M. Reza E Rabby, M. Eller, and F. Pourboghrat. 2021. "Microstructure and Mechanical Properties of the AA7075 Tube Fabricated using Shear Assisted Processing and Extrusion (ShAPE™)." Archives of Civil and Mechanical Engineering 21, no. 2:44. PNNL-SA-155953. doi:10.1007/s43452-021-00179-6
  • Olszta M.J., N.R. Overman, M. Reza E Rabby, T.J. Roosendaal, M. Mcdonnell, and S.A. Whalen. 2021. "Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer." JOM. The Journal of the Minerals, Metals and Materials Society 73, no. 7:2203-2211. PNNL-SA-155286. doi:10.1007/s11837-021-04668-0
  • Overman N.R., M.J. Olszta, M.E. Bowden, X. Li, A. Rohatgi, S.N. Mathaudhu, and G.J. Grant, et al. 2021. "The Onset of Alloying in Cu-Ni Powders Under High-shear Consolidation." Materials & Design 211. PNNL-SA-165452. doi:10.1016/j.matdes.2021.110151
  • Overman N.R., X. Li, M.J. Olszta, E.K. Nickerson, C.T. Overman, S. Mathaudhu, and G.J. Grant, et al. 2021. "Microstructural Progression of Shear-Induced Mixing in a CuNi Alloy." Materials Characterization 171. PNNL-SA-155870. doi:10.1016/j.matchar.2020.110759
  • Reza E Rabby M., M.J. Olszta, N.R. Overman, M. Mcdonnell, and S.A. Whalen. 2021. "Friction Stir Dovetailing of AA7099 to Steel with AA6061 Interlayer for Reduced Zn Embrittlement at Dissimilar Interface." Journal of Manufacturing Processes 61. PNNL-SA-155326. doi:10.1016/j.jmapro.2020.10.084
  • Reza E Rabby M., T.J. Roosendaal, P. Upadhyay, N.R. Overman, J.A. Silverstein, M. Mcdonnell, and S.A. Whalen. 2021. "Process Robustness of Friction Stir Dovetailing of AA7099 to Steel with In Situ AA6061 Interlayer Linking." In Friction Stir Welding and Processing XI. The Minerals, Metals & Materials Series, edited by Y. Hovanski, et al. Cham:Springer. PNNL-SA-155938. doi:10.1007/978-3-030-65265-4_14
  • Taysom B.S., N.R. Overman, M.J. Olszta, M. Reza E Rabby, T. Skszek, M. Diciano, and S.A. Whalen. 2021. "Shear assisted processing and extrusion of enhanced strength aluminum." International Journal of Machine Tools and Manufacture 169. PNNL-SA-162162. doi:10.1016/j.ijmachtools.2021.103798
  • Taysom B.S., S.A. Whalen, M. Reza E Rabby, M. Diciano, and T. Skszek. 2021. "Shear Assisted Processing and Extrusion of Thin-Walled AA6063 Tubing." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition, March 15-18, 2021. Minerals, Metals and Materials Series, edited by L. Perander, 6, 281 - 285. Cham:Springer. PNNL-SA-156007. doi:10.1007/978-3-030-65396-5_42
  • Wang T., L. Li, M. Pallaka, H. Das, S.A. Whalen, A. Soulami, and P. Upadhyay, et al. 2021. "Mechanical and microstructural characterization of AZ31 magnesium-carbon fiber reinforced polymer joint obtained by friction stir interlocking technique." Materials & Design 198. PNNL-SA-150263. doi:10.1016/j.matdes.2020.109305
  • Wang T., P. Upadhyay, and S.A. Whalen. 2021. "A review of technologies for welding magnesium alloys to steels." International Journal of Precision Engineering and Manufacturing-Green Technology 8, no. 3:1027-1042. PNNL-SA-149896. doi:10.1007/s40684-020-00247-x
  • Whalen S.A., K.S. Kappagantula, M. Reza E Rabby, X. Li, N.R. Overman, M.J. Olszta, and T. Wang, et al. 2021. Shear Assisted Processing and Extrusion (ShAPE™) of Aluminum Alloy 7075, 2024, and Al-12.4TM. PNNL-32387. Richland, WA: Pacific Northwest National Laboratory. 
  • Whalen S.A., M. Reza E Rabby, T. Wang, X. Ma, T.J. Roosendaal, and B.S. Taysom. 2021. "Shear Assisted Processing and Extrusion of Aluminum Alloy 7075 Tubing at High Speed." In Light Metals held at the TMS Annual Meeting and Exhibition, March 15-18, 2021. Minerals, Metals and Materials Series, edited by L. Perander, 6, 277-280. Cham:Springer. PNNL-SA-156009. doi:10.1007/978-3-030-65396-5_41
  • Whalen S.A., M.J. Olszta, M. Reza E Rabby, T.J. Roosendaal, T. Wang, D.R. Herling, and B.S. Taysom, et al. 2021. "High Speed Manufacturing of Aluminum Alloy 7075 Tubing by Shear Assisted Processing and Extrusion (ShAPE™)." Journal of Manufacturing Processes 71. PNNL-SA-164792. doi:10.1016/j.jmapro.2021.10.003

2020

  • Croteau J.R., J. Jung, S.A. Whalen, J.T. Darsell, A. Mello, D. Holstine, and K. Lay, et al. 2020. "Ultrafine-grained Al-Mg-Zr Alloy Processed by Shear-Assisted Extrusion with High Thermal Stability." Scripta Materialia 186. PNNL-SA-151920. doi:10.1016/j.scriptamat.2020.05.051
  • Li Y., S. Hu, E.I. Barker, N.R. Overman, S.A. Whalen, and S. Mathaudhu. 2020. "Effect of grain structure and strain rate on dynamic recrystallization and deformation behavior: a phase field-crystal plasticity model." Computational Materials Science 180. PNNL-SA-144520. doi:10.1016/j.commatsci.2020.109707
  • Reza E Rabby M., K.A. Ross, M. Mcdonnell, and S.A. Whalen. 2020. "Numerical Simulation and Experimental Validation of Joint Performance in Aluminum-Steel Lap Welds Formed by Friction Stir Dovetailing." Journal of Materials Processing Technology 277. PNNL-SA-145070. doi:10.1016/j.jmatprotec.2019.116459
  • Wang T., B. Gwalani, J.A. Silverstein, J.T. Darsell, S. Jana, T.J. Roosendaal, and A. Ortiz, et al. 2020. "Microstructural Assessment of a Multiple-Intermetallic-Strengthened Aluminum Alloy Produced from Gas-Atomized Powder by Hot Extrusion and Friction Extrusion." Materials 13, no. 23:Article No. 5333. PNNL-SA-154087. doi:10.3390/ma13235333
  • Wang T., P. Upadhyay, M. Reza E Rabby, X. Li, L. Li, A. Soulami, and K.S. Kappagantula, et al. 2020. "Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking." International Journal of Advanced Manufacturing Technology 109, no. 3-4:689-698. PNNL-SA-149338. doi:10.1007/s00170-020-05717-9
  • Wang T., S.A. Whalen, P. Upadhyay, and K.S. Kappagantula. 2020. "Joining Dissimilar Materials via Rotational Hammer Riveting Technique." In Magnesium Technology 2020, edited by J. Brian, et al, 207-212. New York, New York:Springer Nature. PNNL-SA-147128. doi:10.1007/978-3-030-36647-6_32

2019

  • Reza E Rabby M., S.A. Whalen, K.A. Ross, and M. Mcdonnell. 2019. "Joining AA7099 to Ni-Cr-Mo Steel using Friction Stir Dovetailing." In Friction Stir Welding and Processing X, edited by Y Hovanksi, et al, 171-180. Cham:Springer. PNNL-SA-138056. doi:10.1007/978-3-030-05752-7_16
  • Ross K.A., M. Reza E Rabby, M. Mcdonnell, and S.A. Whalen. 2019. "Advances in Dissimilar Metals Joining through Temperature Control of Friction Stir Welding." MRS Bulletin 44, no. 8:613-618. PNNL-SA-144347. doi:10.1557/mrs.2019.181
  • Whalen S.A., M.J. Olszta, C. Roach, J.T. Darsell, D.D. Graff, M. Reza E Rabby, and T.J. Roosendaal, et al. 2019. "High Ductility Aluminum Alloy made from Powder by Friction Extrusion." Materialia 6. PNNL-SA-138614. doi:10.1016/j.mtla.2019.100260
  • Whalen S.A., N.R. Overman, V.V. Joshi, T. Varga, D.D. Graff, and C.A. Lavender. 2019. "Magnesium Alloy ZK60 Tubing made by Shear Assisted Processing and Extrusion (ShAPE™)." Materials Science and Engineering. A. Structural Materials: Properties, Microstructure and Processing 755. PNNL-SA-140301. doi:10.1016/j.msea.2019.04.013

2018

  • Darsell J.T., N.R. Overman, V.V. Joshi, S. Mathaudhu, and S.A. Whalen. 2018. "Shear Assisted Processing and Extrusion (ShAPE™) of AZ91E Flake: A Study of Tooling Features and Processing Effects." Journal of Materials Engineering and Performance 27, no. 8:4150-4161. PNNL-SA-129883. doi:10.1007/s11665-018-3509-1
  • Reza E Rabby M., K.A. Ross, N.R. Overman, M.J. Olszta, M. Mcdonnell, and S.A. Whalen. 2018. "Joining Thick Section Aluminum to Steel with Suppressed FeAl Intermetallic Formation via Friction Stir Dovetailing." Scripta Materialia 148. PNNL-SA-131279. doi:10.1016/j.scriptamat.2018.01.026

2017

  • Butzbaugh J.B., E.T. Mayhorn, G. Sullivan, and S.A. Whalen. 2017. Connected Equipment Maturity Model Version 1.0. PNNL-26413. Richland, WA: Pacific Northwest National Laboratory. 
  • Jiang X., S.A. Whalen, J.T. Darsell, S. Mathaudhu, and N.R. Overman. 2017. "Friction Consolidation of Gas-Atomized Fe-Si Powders for Soft Magnetic Applications." Materials Characterization 123. PNNL-SA-120598. doi:10.1016/j.matchar.2016.11.026
  • Overman N.R., S.A. Whalen, M.E. Bowden, M.J. Olszta, K. Kruska, T. Clark, and E.L. Stevens, et al. 2017. "Homogenization and Texture Development in Rapidly Solidified AZ91E Consolidated by Shear Assisted Processing and Extrusion (ShAPE™)." Materials Science and Engineering. A. Structural Materials: Properties, Microstructure and Processing 701. PNNL-SA-122981. doi:10.1016/j.msea.2017.06.062
  • Reza E Rabby M., K.A. Ross, S.A. Whalen, Y. Hovanski, and M. Mcdonnell. 2017. "Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process." In Friction Stir Welding and Processing IX, edited by Y Hovanksi, et al, 67-77. Cham:Springer International Publishing. PNNL-SA-119210. doi:10.1007/978-3-319-52383-5_8
  • Whalen S.A., V.V. Joshi, N.R. Overman, D.D. Caldwell, C.A. Lavender, and T. Skszek. 2017. "Scaled-Up Fabrication of Thin-Walled ZK60 Tubing using Shear Assisted Processing and Extrusion (ShAPE™)." In Magnesium Technology Conference 2017, February 26 - March 2, 2017, San Diego, California, edited by KN Solanki, et al, 315-321. Cham:Springer. PNNL-SA-121164. doi:10.1007/978-3-319-52392-7_45

2016

  • Whalen S.A., S. Jana, D. Catalini, N.R. Overman, and J. Sharp. 2016. "Friction Consolidation Processing of n-Type Bismuth-Telluride Thermoelectric Material." Journal of Electronic Materials 45, no. 7:3390-3399. PNNL-SA-114513.

2015