Solid-state Joining of Similar and Dissimilar Automotive Sheet

National Laboratory: 
Pacific Northwest National Laboratory
Processing/Manufacturing Class: 
Shaping and forming

Integrating state-of-the-art thermal control strategies with patented solid-state joining techniques, Pacific Northwest National Laboratory provides the largest team of coordinated researchers in friction stir technologies. This includes using high-speed friction stir welding for welding lightweight tailor-welded blanks; dissimilar sheet metal joining of aluminum, magnesium, advanced high strength steel (AHSS), or carbon-fiber–reinforced polymer (CFRP); and other linear combinations. PNNL’s integration of thermal control strategies allows for tailored joining conditions based on the advanced properties of today’s materials.

Capability Bounds: 

The equipment is capable of joining prototypical geometries up to 60 in. with linear and rotational capability for joining any combination of sheet products (including dissimilar thickness, alloy, and materials combinations).

Unique Aspects: 

PNNL offers the only domestic operational capability for integrating thermal control strategies using friction stir welding and friction stir scribe technologies.


Use typically is coordinated with capability experts and via collaborative funding proposals or contracts.

Single Point of Contact: 

Name: Glenn Grant
Phone: 509-375-6890

  1. Hovanski Y, P Upadhyay, J Carsley, T Luzanski, B Carlson, M Eisenmenger, A Soulami, D Marshall, B Landino, and S Hartfield-Wunsch. 2015. “High-Speed Friction-Stir Welding To Enable Aluminum Tailor-Welded Blanks.” JOM. The Journal of the Minerals, Metals and Materials Society 67(5):1045-1053, DOI:10.1007/s11837-015-1384-x. Jana S and Y Hovanski. 2012. “Fatigue Behaviour of Magnesium to Steel Dissimilar Friction Stir Lap Joints.” Science and Technology of Welding and Joining 17(2):141-145, DOI:10.1179/1362171811Y.0000000083.
  2. Hovanski Y, ML Santella, and GJ Grant. 2007. “Friction Stir Spot Welding of Hot-Stamped Boron Steel.” Scripta Materialia 57(9):873-876.
  3. Upadhyay P, Y Hovanski, LS Fifield, and S Jana. 2015. “Joining Dissimilar Materials with Friction Stir Scribe Technology.” In The 4th International Conference on Scientific and Technical Advances on Friction Stir Welding & Processing. PNNL-SA-111642, Pacific Northwest National Laboratory, Richland, WA.
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