PNNL-13501 - Pacific Northwest National Laboratory

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(Johnson 1999; Colligan 1999; Gould et al. 1998; Kallee and Nicholas 1998; Thomas and Nicholas 1997; Liu et al. 1997; Rhodes et al. 1997). Most of the efforts have focused on welding wrought and extruded materials. Single-pass butt-weld joints with aluminum alloys have been made in thickness ranging from 1.2 mm to 50 mm without the need for a weld preparation. Parameters for butt-welding of most similar aluminum alloys have been developed in a thickness range from 1.6 mm to 10 mm. The process has been shown to produce welds of the highest quality, and has led to the development of a number of new product designs previously not possible. The fine microstructure created via friction stir welding also has shown the ability to create weld materials with higher strength and resistance to failure during uniaxial tensile tests. Friction stir is revolutionizing the welding of aluminum in industry. Friction stir already produces costeffective welds in aluminum alloy plates with higher quality and lower distortion than is possible using fusion welding techniques. Friction stir also can weld aluminum alloys that are virtually unweldable by conventional techniques. Results and Accomplishments We investigated existing dissimilar joining technologies, and identified potential research areas at <strong>PNNL</strong>. After identifying technologies of interest, research and development was conducted to investigate the joining of dissimilar materials using friction stir welding methods. Friction stir welding was conducted on three main materials: wrought aluminum sheet materials, wrought and cast magnesium alloys, and aluminum metal matrix composites. An illustration of a friction stir welding tool, dissimilar aluminum sheet butt-welds, and magnesium sheet butt-welds is shown in Figure 2. These welds were produced on conventional milling machines. The aluminum sheet weld consists of several welds produced between dissimilar aluminum alloys of potential automotive interest, as well as Sky 5083 alloy conventionally used for superplastic forming applications. The weld on the right side of the aluminum coupon is between a 5754 alloy 2 mm thick and two 6111 alloy sheets stacked to create a total 2 mm thickness. We also investigated the ability to friction stir weld aluminum metal matrix composites. A micrograph of a typical aluminum-SiC metal matrix composites joint is shown in Figure 3. Fusion welding of aluminum metal matrix composites is typically very difficult and/or undesirable due to particle pushing and subsequent Figure 2. A friction stir welding tool together with dissimilar aluminum and magnesium welds Figure 3. Cross section through an aluminum-SiC metal matrix composite weld joint processed through friction stir welding particle segregation, and formation of undesirable aluminum carbide and aluminum oxycarbides. The friction stir welds exhibited no particle segregation and resulted in continuous welds. However, the tool steel used to construct the welding tool deteriorated at a relatively high rate, resulting in tool debris in the weldment microstructure. Summary and Conclusions Solid-state friction stir welding methods were investigated for potential application to lightweight and hybrid material automotive structures. The weld methods produce joints between dissimilar materials not normally possible using fusion welding techniques. The weld methods also show promise for potential metal matrix composite joints not normally possible using fusion welding methods. References Colligan K. 1999. “Material flow behavior during friction stir welding of aluminum.” Supplement to the Welding Journal pp.229-s-237-s. Design and Manufacturing Engineering 187
Gould JE, Z Feng, and T Lienert. 1998. “Recent developments in friction stir welding.” SAE paper no. 981875, Aerospace Manufacturing Technology Conference & Exposition, Long Beach, California. Johnson MR. 1999. “Friction stir welding takes off at Boeing.” Welding Journal pp. 35-39. Kallee S and D Nicholas. 1998. “Application of friction stir welding to lightweight vehicles.” SAE paper no. 982362, International Body Engineering Conference & Exposition, Detroit. 188 FY 2000 <strong>Laboratory</strong> Directed Research and Development Annual Report Liu G, LE Murr, C-S Niou, JC McClure, and FR Vega. 1997. “Microstructural aspects of the friction-stir welding of 6061-T6 aluminum.” Scripta Materialia, Issue: 3, 37:245-384. Rhodes CG, MW Mahoney, WH Bingel, RA Spurling, and CC Bampton. 1997. “Effects of friction stir welding on microstructure of 7075 aluminum.” Scripta Materialia, Issue 1, 36:1-144. Thomas WM and ED Nicholas. 1997. “Friction stir welding for the transportation industries.” Materials And Design, Issue: 4-6, 18:203-414.
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Laboratory Directed Research and De
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Laboratory Directed Research and De
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Computational Science and Engineeri
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Policy and Management Sciences Asse
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Introduction Department of Energy O
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5. After reviews by the Technical a
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• The Technical Council peer revi
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methods applicable to combustion, s
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Summary Each national laboratory mu
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Study Control Number: PN0004/1411 A
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Table 1. Positive and negative ions
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m/z Arbitrary Units Figure 1. Mass
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introduce low-volatility compounds
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arrangement, but the charge is reta
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two liquid chromatographic gradient
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Integrated Microfabricated Devices
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Matrix Assisted Laser Desorption/Io
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Molecular Beam Synthesis and Charac
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temperature distribution of the des
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expected to result in significant a
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Study Control Number: PN99069/1397
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Seuss DT and KA Prather. 1999. “M
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Analysis of Receptor-Modulated Ion
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laboratory (Lu and Xie 1997; Lu et
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Automated DNA Fingerprinting Microa
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Comparison of 4 Xanthomonas Isolate
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Approach Hematopoietic (bone marrow
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Anti-Human lgG Human lgG Protein G
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Characterization of Global Gene Reg
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PCR products for immobilization on
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identify novel proteins of importan
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Immunoprecipitaton of tyrosinephosp
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Coupled NMR and Confocal Microscopy
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In the optical microscopy image, th
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Development and Applications of a M
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Figure 3. Hepa-1 cells undergoing a
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cellular processing (such as post-t
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8. Initial demonstration of an off-
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expression systems for several year
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accumulation of protein products, i
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Fungal Conversion of Agricultural W
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Fungal Conversion of Waste Glucose/
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Summary and Conclusions We demonstr
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are shown in Figure 1(a) and 1(b),
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Anchorage-Independent Growth (% con
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selection of seedlings demonstratin
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NMR-Based Structural Genomics Micha
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Solution-State Structure and Fold-C
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Plant Root Exudates and Microbial G
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98 99 100 6 7 10 3 1 12 11 15 16 17
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Summary and Conclusions • The gre
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Jones-Oliveira JB, JS Oliveira, HE
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• securely moves files to a targe
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Plenary invited lecture, “The Ele
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Figure 1. X3DGEN tetrahedral mesh o
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Figure 5a. OSO volume rendering of
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Development of Models of Cell-Signa
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SOS p 23 EGFR Professor Rodland at
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Oliveira JS, JB Jones-Oliveira, and
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Figure 2. Associating a dataset mar
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to 1) incorporate three-dimensional
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shown in Figure 1. Simulated result
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HostBuilder: A Tool for the Combina
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Invariant Discretization Methods fo
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Application of a Crop Model The res
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The Nature, Occurrence, and Origin
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Particle number concentration, 1/cm
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geometry optimized AlOOH and FeOOH
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allowable parameters using thermody
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TCE + 3H + + 3Fe 2+ Fe)=> acetylene
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Use of Shear-Thinning Fluids for In
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concentration of 0.5% AMX was the m
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Roberts AL, LA Totten, WA Arnold, D
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tetra-scale computing, envisioned a
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Energy Technology and Management
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Figure 2. Setup for the second expe
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phase. The algorithms will be teste
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[Pb-212]/[Pb-212] final 100 10 1 0.
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Plasma Particle Dielectric Fiber El
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(species, sub-species, and sex), sp
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Figure 3. Relative risk of bone and
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Development of a Preliminary Physio
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Development of a Virtual Respirator
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Figure 3. Use of the chest cavity a
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Examination of the Use of Diazolumi
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Indoor Air Pathways to Nuclear, Che
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Source Building Release Observed re
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To illustrate the potential impact
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Non-Invasive Biological Monitoring
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Materials Science and Technology
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Figure 1. (a) - (c) Successive magn
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Component Fabrication and Assembly
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Development of a Low-Cost Photoelec
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elaxations, indicating the adequacy
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Promising chemical durability, as m
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Study Control Number : PN98028/1274
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High Power Density Solid Oxide Fuel
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Hybrid Plasma Process for Vacuum De
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Matson DW, PM Martin, WD Bennett, J
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We showed the proof-of-principle ap
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Bandgap Energy (eV) 2.9 2.85 2.8 2.
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Ultrathin Electrolyte Test Results
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Detailed Investigations on Hydrogen
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identified low energy step structur
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Development of Novel Photo-Catalyst
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-2 -1 Energy (eV) 0 1 2 Cu2O SrTiO3
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Here, we perform adsorption and des
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exceed those in the all-metal devic
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Intensity (a.u.) 0 100 200 300 400
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integrated voltage (V) 0.10 0.08 0.
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The first step was to implement thi
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Spontaneous Formation of Cu2O Nano-
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Actinide Chemistry at the Aqueous-M
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Figure 5. Close-up atomic force mic
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to 300°C and 400°C. Unfortunately
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Summary and Conclusions Transmutati
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Advanced Calibration/Registration T
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Figure 1a. Violet filter Figure 1b.
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Autonomous Ultrasonic Probe for Pro
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containing nitrous oxide, an optica
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Chemical Detection Using Cavity Enh
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Figure 3 is a color rendered simula
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appropriate study has been performe
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Exploitation of Conventional Chemic
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Figures 3 and 4 illustrate the impa
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enefits of using a modified spread-
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Single Channel Signal 0.0025 0.0020
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Therefore, in order to extract the
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A next-generation technology is nee
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Wind Dir. Figure 2. Negative ion co
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Volumetric Imaging of Materials by
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amplitude and peak frequency change
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Figure 3. 13 C NMR spectrum of corn
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Approach Two flow loops, one that o
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Modification of Ion Exchange Resins
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Permanganate Treatment for the Deco
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minimized by medium exchange. After
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Figure 1. Thermogravimetric analysi
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Validation and Scale-Up of Monosacc
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Concentration (g/100g solution) Con
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Analysis of High-Volume, Hyper-Dime
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ecent figure of merit values. Shoul
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Probabilistic Methods Development f
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a) Traditional PCA-based process co
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Acronyms and Abbreviations 2-D two-
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PNNL-13501 - Pacific Northwest National Laboratory

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