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.
Revised: June 5, 2018 |
Published: February 7, 2017
Citation
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