Granted Patent
B2
US 12,460,664 · App. 18/494,629 · Granted Nov 4, 2025
Process for welding dissimilar materials with nested dovetails
Inventors:
Scott A. Whalen (West Richland, WA); Kenneth A. Ross (West Richland, WA); M. D. Reza-E-Rabby (Richland, WA); Yuri Hovanski (Mapleton, UT)
Assignee:
Battelle Memorial Institute
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Abstract
A method for connecting two dissimilar materials having different melting points is described wherein a the materials are heated together to obtain plasticization of the lower melting point material within a prefigured geometry within a first material in such a way so as to form intermetallic features within a solid state joint.
Claims (17)
1 . A method, comprising:
engaging a first surface of a first material having a higher melting temperature with a second surface of a second material having a lower melting temperature, wherein:
the first surface defines nested dovetail grooves in the first material;
a first dovetail groove of the nested dovetail grooves defines a base and sidewalls in a vertical cross-section; and
a second dovetail groove of the nested dovetail grooves defined within the base of the first dovetail groove;
wherein the method comprises friction stir welding the second material and the first material with a friction stir welding tool that:
plunges to a depth greater than a thickness of the second material; and
plunges into the second dovetail groove such that edges of the tool contact corners of the second dovetail groove resulting in formation of hooks of the first material that extend upward into the second material.
2 . The method of claim 1 , wherein the first material is a steel material and the first surface is a steel surface.
3 . The method of claim 1 , wherein the second material is an aluminum material and the second surface is an aluminum surface.
4 . The method of claim 1 , wherein the friction stir welding creates sufficient heat to bring the first material to a temperature to increase an area of intermetallic contact at an interface with the second material.
5 . The method of claim 1 , wherein the friction stir welding creates sufficient heat to plasticize the first material.
6 . The method of claim 5 , wherein the heat is created through friction.
7 . The method of claim 1 , wherein the friction stir welding tool has a scrolled shoulder and a frustum shaped threaded and flatted pin.
8 . The method of claim 1 , wherein:
the friction stir welding is performed using a tool rotational speed between 50 and 5000 RPM and a welding speed ranging between 1-5000 mm/min.
9 . The method of claim 8 , wherein the friction stir welding is performed using a tool rotational speed between 200 and 400 RPM and welding speed ranging between 25-50 mm/min.
Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded Oct 27, 2023
From: WHALEN, SCOTT A.; ROSS, KENNETH A.; REZA-E-RABBY, M.D.; HOVANSKI, YURI
To: BATTELLE MEMORIAL INSTITUTE
Reel/Frame 065368/0499 →
Continuity (4)
Provisional Application
62533851
· Jul 18, 2017
Provisional Application
62393409
· Sep 12, 2016
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