Friction Stir Dovetailing

Researchers at Pacific Northwest National Laboratory have developed and successfully tested a novel process—called Friction Stir Dovetailing—that joins thick plates of aluminum to steel. The new process will be used to make lighter-weight military vehicles that are more agile and fuel efficient.

In woodworking, dovetails and glue are used to securely join pieces of wood together. Friction Stir Dovetailing is a similar approach for metals. Using a specially designed tool, aluminum is deformed into a steel dovetail groove to form a mechanical interlock. At the same time, the tool rubs along the bottom of the dovetail to form a thin metallurgical bond—or intermetallic compound—which “glues” the metals together within the dovetail.