Friction Stir Extrusion: A new process for joining dissimilar materials

William T. Evans; Brian T. Gibson; Jay T. Reynolds; Alvin M. Strauss; George E. Cook

doi:10.1016/j.mfglet.2015.07.001

Friction Stir Extrusion: A new process for joining dissimilar materials

William T. Evans, Brian T. Gibson, Jay T. Reynolds, Alvin M. Strauss, George E. Cook

Research output: Contribution to journal › Article › peer-review

58 Scopus citations

Abstract

The need to join dissimilar materials such as aluminum and steel is prevalent in many industries. This paper investigates a new process called Friction Stir Extrusion (FSE) for joining aluminum and steel. The process uses Friction Stir Welding (FSW) to extrude aluminum into a premade concave groove cut into steel. FSE eliminates the concerns of intermetallic compounds and tool wear. This technique leads to a mechanically bound joint whose strength is determined by the mechanical bond between the steel and the extruded aluminum. Successful joints were created showing the FSE process has the potential for application to any combination of dissimilar materials.

Original language	English
Pages (from-to)	25-28
Number of pages	4
Journal	Manufacturing Letters
Volume	5
DOIs	https://doi.org/10.1016/j.mfglet.2015.07.001
State	Published - Aug 1 2015
Externally published	Yes

Funding

This work was supported by the NASA Tennessee Space Grant Consortium.

Funders	Funder number
Rocky Mountain NASA Space Grant Consortium

Keywords

Aluminum steel joining
Dissimilar materials
Extrusion
Friction stir welding
Intermetallic bonds

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10.1016/j.mfglet.2015.07.001

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title = "Friction Stir Extrusion: A new process for joining dissimilar materials",

abstract = "The need to join dissimilar materials such as aluminum and steel is prevalent in many industries. This paper investigates a new process called Friction Stir Extrusion (FSE) for joining aluminum and steel. The process uses Friction Stir Welding (FSW) to extrude aluminum into a premade concave groove cut into steel. FSE eliminates the concerns of intermetallic compounds and tool wear. This technique leads to a mechanically bound joint whose strength is determined by the mechanical bond between the steel and the extruded aluminum. Successful joints were created showing the FSE process has the potential for application to any combination of dissimilar materials.",

keywords = "Aluminum steel joining, Dissimilar materials, Extrusion, Friction stir welding, Intermetallic bonds",

author = "Evans, {William T.} and Gibson, {Brian T.} and Reynolds, {Jay T.} and Strauss, {Alvin M.} and Cook, {George E.}",

note = "Publisher Copyright: {\textcopyright} 2015 Society of Manufacturing Engineers (SME).",

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doi = "10.1016/j.mfglet.2015.07.001",

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T2 - A new process for joining dissimilar materials

AU - Evans, William T.

AU - Gibson, Brian T.

AU - Reynolds, Jay T.

AU - Strauss, Alvin M.

AU - Cook, George E.

PY - 2015/8/1

Y1 - 2015/8/1

N2 - The need to join dissimilar materials such as aluminum and steel is prevalent in many industries. This paper investigates a new process called Friction Stir Extrusion (FSE) for joining aluminum and steel. The process uses Friction Stir Welding (FSW) to extrude aluminum into a premade concave groove cut into steel. FSE eliminates the concerns of intermetallic compounds and tool wear. This technique leads to a mechanically bound joint whose strength is determined by the mechanical bond between the steel and the extruded aluminum. Successful joints were created showing the FSE process has the potential for application to any combination of dissimilar materials.

AB - The need to join dissimilar materials such as aluminum and steel is prevalent in many industries. This paper investigates a new process called Friction Stir Extrusion (FSE) for joining aluminum and steel. The process uses Friction Stir Welding (FSW) to extrude aluminum into a premade concave groove cut into steel. FSE eliminates the concerns of intermetallic compounds and tool wear. This technique leads to a mechanically bound joint whose strength is determined by the mechanical bond between the steel and the extruded aluminum. Successful joints were created showing the FSE process has the potential for application to any combination of dissimilar materials.

KW - Aluminum steel joining

KW - Dissimilar materials

KW - Extrusion

KW - Friction stir welding

KW - Intermetallic bonds

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JO - Manufacturing Letters

JF - Manufacturing Letters

ER -

Friction Stir Extrusion: A new process for joining dissimilar materials

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