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Scott Whalen

Pacific Northwest National Laboratory
PO Box 999
Richland, WA 99352
(509) 372-6084
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Biography

Dr. Whalen received his PhD from Washington State University in 2004 where he developed the world’s first, and still only, Micro-Electro-Mechanical Systems (MEMS) engine to run on a thermodynamic working cycle. After graduation, he completed a post-doctoral appointment at Sandia National Laboratories investigating micro-scale thermoelectric materials and devices. As a staff scientist at Sandia, Dr. Whalen performed R&D on all aspects of milliwatt-scale radioisotopic thermoelectric systems and materials. Dr. Whalen joined PNNL in 2012 where he now investigates solid-phase processing techniques to achieve novel microstructures and improved material properties that cannot be realized by conventional means. Areas of particular interest include extrusion of lightweight structural metals, friction stir welding of dissimilar materials and fabrication of nanocomposites in bulk form. Dr. Whalen is actively researching Shear Assisted Processing and Extrusion (ShAPE™) of various materials that is enabling improved strength, ductility, and throughput compared to conventional extrusion.

Research Interests

• Solid Phase Processing
• Shear Assisted Processing and Extrusion (ShAPE™)
• Friction Stir Welding
• Thermoelectric Materials

Education and Credentials

• Ph.D. Mechanical Engineering, - Washington State University, 2004
• M.S. Safety Engineering - Biomechanics, Texas A&M University, 1997
• B.S Mechanical Engineering, University of Idaho, 1996

Affiliations and Professional Service

• American Society of Mechanical Engineers
• The Minerals, Metals & Materials Society

Awards and Recognitions

• R&D 100 Award, 2020
• R&D 100 Award, 2017
• PNNL Project of the Year, Energy Process and Materials Division, 2020
• PNNL Paper of the Year, Energy and Environment Directorate, 2019
• PNNL Core Value Award, Energy and Environment Directorate, 2018
• NNSA Defense Program Award of Excellence, 2011
• NNSA Defense Program Award of Excellence, 2009
• Sandia Award for Individual Technical Excellence, 2008
• ASME Best Paper in MEMS Division, 2005
• Sandia Excellence in Engineering Full Doctoral Fellowship, 2002-2004
• Washington State University Doctoral Researcher of the Year, 2002

PNNL Patents

• U.S. Patent No. 12,186,791, January 7, 2025, "DEVICES AND METHODS FOR PERFORMING SHEAR-ASSISTED EXTRUSION PROCESSES".
• U.S. Patent No. 11,946,504, April 2, 2024, "Assemblies, Riveted Assemblies, Methods for Affixing Substrates, and Methods for Mixing Materials to Form a Metallurgical Bond (iEdison No. 0685901-22-0263)".
• U.S. Patent No. 11,919,061, March 5, 2024, "SHEAR-ASSISTED EXTRUSION ASSEMBLIES AND METHODS (iEdison No. 0685901-21-0123)".
• U.S. Patent No. 11,684,959, June 27, 2023, "DEVICES AND METHODS FOR PERFORMING SHEAR-ASSISTED EXTRUSION, EXTRUSION FEEDSTOCKS, EXTRUSION PROCESSES, AND METHODS FOR PREPARING METAL SHEETS (iEdison No. 0685901-13-0018)".
• U.S. Patent No. 11,549,532, January 10, 2023, "Assemblies, Riveted Assemblies, Methods for Affixing Substrates, and Methods for Mixing Materials to Form a Metallurgical Bond (iEdison No. 0685901-22-0263)".
• U.S. Patent No. 11,534,811, December 27, 2022, " Method for Forming Hollow Profile Non-Circular Extrusions Using Shear Assisted Processing and Extrusion (ShAPE) ".
• U.S. Patent No. 11,517,952, December 6, 2022, "SHEAR ASSISTED EXTRUSION PROCESS".
• U.S. Patent No. 11,383,280, July 12, 2022, "DEVICES AND METHODS FOR PERFORMING SHEAR-ASSISTED EXTRUSION, EXTRUSION FEEDSTOCKS, EXTRUSION PROCESSES, AND METHODS FOR PREPARING METAL SHEETS".
• U.S. Patent No. 11,045,851, June 29, 2021, " Method for Forming Hollow Profile Non-Circular Extrusions Using Shear Assisted Processing and Extrusion (ShAPE) ".
• U.S. Patent No. 10,695,811, June 30, 2020, "FUNCTIONALLY GRADED COATINGS AND CLADDINGS ".
• U.S. Patent No. 10,369,748, August 6, 2019, "FRICTION STIRRING INTERLOCKING OF DISSIMILAR MATERIALS ".
• U.S. Patent No. 10,189,063, January 29, 2019, "CURRENT COLLECTOR FOR METAL ANODE, METHOD OF MAKING, AND BATTERY USING".

PNNL Publications

2024

• Das H., M. Reza E Rabby, S.A. Whalen, P. Upadhyay, and G.J. Grant. 2024. "Impact of backing plate and thermal boundary conditions for high-speed friction stir welding of 25-mm thick aluminum alloy 7175-T79." International Journal of Precision Engineering and Manufacturing-Green Technology. PNNL-SA-184852. doi:10.1007/s40684-024-00607-x
• Wang T., Z. Lu, T. Liu, H. Park, D. Garcia, D. Li, and S.A. Whalen. 2024. Achieving high-ZT in Te/Se-based thermoelectric materials via volume-constrained shear-induced plastic deformation. PNNL-36668. Richland, WA: Pacific Northwest National Laboratory. Achieving high-ZT in Te/Se-based thermoelectric materials via volume-constrained shear-induced plastic deformation
• Whalen S.A. 2024. Metal Scrap Upcycling with Shear Assisted Processing and Extrusion (ShAPE). PNNL-36520. Richland, WA: Pacific Northwest National Laboratory. Metal Scrap Upcycling with Shear Assisted Processing and Extrusion (ShAPE)
• Whalen S.A. 2024. Non-Rare Earth Magnesium Bumper Beams - CRADA 418 (Abstract). PNNL-35288. Richland, WA: Pacific Northwest National Laboratory.
• Whalen S.A. 2024. Process Intensification for Nanostructure Aluminum Extrusions - CRADA 411 (Abstract). PNNL-35289. Richland, WA: Pacific Northwest National Laboratory.
• Whalen S.A., A.P. Reynolds, D.K. Chouhan, M. Komarasamy, B.S. Taysom, N.R. Overman, and N.L. Canfield, et al. 2024. Recycling of Titanium Scrap by Shear Assisted Processing and Extrusion (ShAPE). PNNL-36607. Richland, WA: Pacific Northwest National Laboratory. Recycling of Titanium Scrap by Shear Assisted Processing and Extrusion (ShAPE)
• Whalen S.A., M. Reza E Rabby, B.K. Milligan, B.J. Schuessler, T.J. Roosendaal, and T.L. Lemmon. 2024. Wrought Aluminum-Cerium Alloys by Shear Assisted Processing and Extrusion. PNNL-36591. Richland, WA: Pacific Northwest National Laboratory. Wrought Aluminum-Cerium Alloys by Shear Assisted Processing and Extrusion

2023

• Escobar J.D., B.S. Taysom, G.J. Grant, S.A. Whalen, A. Soulami, and L. Li. 2023. Sensing and Control During Bulk SPP. PNNL-34995. Richland, WA: Pacific Northwest National Laboratory. Sensing and Control During Bulk SPP
• Frazier W.E., N.R. Overman, B.J. Schuessler, S. Niverty, T.J. Roosendaal, S.A. Whalen, and V.V. Joshi. 2023. "Hot rolling of ZK60 magnesium alloy with isotropic tensile properties from tubing made by Shear Assisted Processing and Extrusion (ShAPE)." Applied Sciences 13, no. 9:Art. No. 5343. PNNL-SA-159102. doi:10.3390/app13095343
• Milligan B.K., B.S. Taysom, X. Ma, and S.A. Whalen. 2023. "Solutionization via Severe Plastic Deformation: Effect on Natural Aging in an Al-Mg-Si-(Mn) Alloy." In Light Metals 2023: TMS Annual Meeting & Exhibition, edited by S. Broek, 333-338. Cham:Springer. PNNL-SA-177682. doi:10.1007/978-3-031-22532-1_46
• Reza E Rabby M., H. Das, T. Wang, M. Komarasamy, S.A. Whalen, and G.J. Grant. 2023. "High-Speed Friction Stir Butt Welding of 25.4 mm Thick 7175-T79 Aluminum Alloy." Manufacturing Letters 38. PNNL-SA-184859. doi:10.1016/j.mfglet.2023.08.140
• Whalen S.A., B.S. Taysom, M. Reza E Rabby, N.R. Overman, and T.W. Skszek. 2023. Shear Assisted Processing and Extrusion (ShAPE) of Lightweight Automotive Components (CRADA 418). PNNL-33766. Richland, WA: Pacific Northwest National Laboratory. Shear Assisted Processing and Extrusion (ShAPE) of Lightweight Automotive Components (CRADA 418)
• Whalen S.A., B.S. Taysom, N.R. Overman, M. Reza E Rabby, Y. Qiao, T. Richter, and T.W. Skszek, et al. 2023. "Porthole Die Extrusion of Aluminum 6063 Industrial Scrap by Shear Assisted Processing and Extrusion." Manufacturing Letters 36. PNNL-SA-179478. doi:10.1016/j.mfglet.2023.01.005
• Whalen S.A., N.R. Overman, B.S. Taysom, M. Reza E Rabby, T.W. Skszek, and M. Diciano. 2023. "Shear Assisted Processing and Extrusion of Unhomogenized Aluminum Alloy 6063 Castings with High Iron Content." In Light Metals 2023: TMS Annual Meeting & Exhibition, edited by S. Broek, 327-332. PNNL-SA-177354. doi:10.1007/978-3-031-22532-1_45
• Whalen S.A., N.R. Overman, B.S. Taysom, M.E. Bowden, M. Reza E Rabby, T.W. Skszek, and M. Diciano. 2023. "Effect of High Iron Content on Direct Recycling of Unhomogenized Aluminum 6063 Scrap by Shear Assisted Processing and Extrusion." Journal of Manufacturing Processes 97. PNNL-SA-181577. doi:10.1016/j.jmapro.2023.04.067

2022

• Komarasamy M., S.A. Whalen, B.S. Taysom, and D.R. Herling. 2022. "Co-extrusion of dissimilar Al alloys via shear assisted processing and extrusion." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition, (Light Metals 2022), February 27-March 2, 2022, Anaheim, CA, edited by D. Eskin, 308-313. Cham:Springer. PNNL-SA-166339. doi:10.1007/978-3-030-92529-1_43
• Li L., M. Reza E Rabby, N.R. Overman, T. Wang, S.A. Whalen, G.J. Grant, and S.N. Mathaudhu, et al. 2022. "Analysis of contact conditions and microstructure evolution in shear assisted processing and extrusion using smoothed particle hydrodynamics method." Materials & Design 221. PNNL-SA-173428. doi:10.1016/j.matdes.2022.111010
• Li X., T. Wang, X. Ma, N.R. Overman, S.A. Whalen, D.R. Herling, and K.S. Kappagantula. 2022. "Manufacture aluminum alloy tube from powder with a single-step extrusion via ShAPE." Journal of Manufacturing Processes 80. PNNL-SA-169412. doi:10.1016/j.jmapro.2022.05.060
• Ma X., E.K. Nickerson, T. Wang, D. Zhang, T. Pelletirers, S.A. Whalen, and X. Li. 2022. "Friction extrusion of ODS copper rod made from powder." Journal of Manufacturing Processes 84. PNNL-SA-174770. doi:10.1016/j.jmapro.2022.10.003
• Ma X., X. Li, G. Petrossian, A. Ortiz, M. Komarasamy, S.A. Whalen, and G.J. Grant, et al. 2022. "Porosity evolution during heating of copper made from powder by friction extrusion." Materialia 21. PNNL-SA-166323. doi:10.1016/j.mtla.2022.101341
• Peles A., S.A. Whalen, and G.J. Grant. 2022. Sparse Data Machine Learning Integration with Theory, Experiment and Uncertainty Quantification: Process-Structure-Property-Performance of Friction Deformation Processing. PNNL-32875. Richland, WA: Pacific Northwest National Laboratory. Sparse Data Machine Learning Integration with Theory, Experiment and Uncertainty Quantification: Process-Structure-Property-Performance of Friction Deformation Processing
• Reza E Rabby M., T. Wang, N.L. Canfield, D.D. Graff, T.J. Roosendaal, and S.A. Whalen. 2022. "Effect of post-extrusion heat treatment on mechanical property of aluminum alloy 2024 tube produced using Shear Assisted Processing and Extrusion (ShAPE)." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition (Light Metals 2022), February 27- March 3, 2022, Anaheim, CA, edited by D. Eskin, 301-307. Cham:Springer. PNNL-SA-166238. doi:10.1007/978-3-030-92529-1_42
• Wang T., S.A. Whalen, X. Ma, J.A. Silverstein, H. Das, M. Pallaka, and A. Ortiz, et al. 2022. "Friction-based riveting technique for AZ31 magnesium alloy." Journal of Magnesium and Alloys 10, no. 1:110 - 118. PNNL-SA-155089. doi:10.1016/j.jma.2021.06.004

2021

• Frazier W.E., V.V. Joshi, N.R. Overman, M.A. Rhodes, T.J. Roosendaal, R.J. Seffens, and E.K. Nickerson, et al. 2021. Hot rolling of ZK60 magnesium sheet with isotropic tensile properties from tubing made by Shear Assisted Processing and Extrusion (ShAPE). PNNL-32477. Richland, WA: Pacific Northwest National Laboratory. Hot rolling of ZK60 magnesium sheet with isotropic tensile properties from tubing made by Shear Assisted Processing and Extrusion (ShAPE)
• Komarasamy M., X. Li, S.A. Whalen, X. Ma, N.L. Canfield, M.J. Olszta, and T. Varga, et al. 2021. "Microstructural evolution in Cu-Nb processed via friction consolidation." Journal of Materials Science 56, no. 22:12864-12880. PNNL-SA-158852. doi:10.1007/s10853-021-06093-9
• Nazaeri Tiji S., A. Asgharzadeh, T. Park, S.A. Whalen, M. Reza E Rabby, M. Eller, and F. Pourboghrat. 2021. "Microstructure and Mechanical Properties of the AA7075 Tube Fabricated using Shear Assisted Processing and Extrusion (ShAPE)." Archives of Civil and Mechanical Engineering 21, no. 2:44. PNNL-SA-155953. doi:10.1007/s43452-021-00179-6
• Olszta M.J., N.R. Overman, M. Reza E Rabby, T.J. Roosendaal, M. Mcdonnell, and S.A. Whalen. 2021. "Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer." JOM. The Journal of the Minerals, Metals and Materials Society 73, no. 7:2203-2211. PNNL-SA-155286. doi:10.1007/s11837-021-04668-0
• Overman N.R., X. Li, M.J. Olszta, E.K. Nickerson, C.T. Overman, S. Mathaudhu, and G.J. Grant, et al. 2021. "Microstructural Progression of Shear-Induced Mixing in a CuNi Alloy." Materials Characterization 171. PNNL-SA-155870. doi:10.1016/j.matchar.2020.110759
• Reza E Rabby M., M.J. Olszta, N.R. Overman, M. Mcdonnell, and S.A. Whalen. 2021. "Friction Stir Dovetailing of AA7099 to Steel with AA6061 Interlayer for Reduced Zn Embrittlement at Dissimilar Interface." Journal of Manufacturing Processes 61. PNNL-SA-155326. doi:10.1016/j.jmapro.2020.10.084
• Reza E Rabby M., T.J. Roosendaal, P. Upadhyay, N.R. Overman, J.A. Silverstein, M. Mcdonnell, and S.A. Whalen. 2021. "Process Robustness of Friction Stir Dovetailing of AA7099 to Steel with In Situ AA6061 Interlayer Linking." In Friction Stir Welding and Processing XI. The Minerals, Metals & Materials Series, edited by Y. Hovanski, et al. Cham:Springer. PNNL-SA-155938. doi:10.1007/978-3-030-65265-4_14
• Taysom B.S., N.R. Overman, M.J. Olszta, M. Reza E Rabby, T. Skszek, M. Diciano, and S.A. Whalen. 2021. "Shear assisted processing and extrusion of enhanced strength aluminum." International Journal of Machine Tools and Manufacture 169. PNNL-SA-162162. doi:10.1016/j.ijmachtools.2021.103798
• Taysom B.S., S.A. Whalen, M. Reza E Rabby, M. Diciano, and T. Skszek. 2021. "Shear Assisted Processing and Extrusion of Thin-Walled AA6063 Tubing." In Light Metals Symposium held at the TMS Annual Meeting and Exhibition, March 15-18, 2021. Minerals, Metals and Materials Series, edited by L. Perander, 6, 281 - 285. Cham:Springer. PNNL-SA-156007. doi:10.1007/978-3-030-65396-5_42
• Wang T., L. Li, M. Pallaka, H. Das, S.A. Whalen, A. Soulami, and P. Upadhyay, et al. 2021. "Mechanical and microstructural characterization of AZ31 magnesium-carbon fiber reinforced polymer joint obtained by friction stir interlocking technique." Materials & Design 198. PNNL-SA-150263. doi:10.1016/j.matdes.2020.109305
• Wang T., P. Upadhyay, and S.A. Whalen. 2021. "A review of technologies for welding magnesium alloys to steels." International Journal of Precision Engineering and Manufacturing-Green Technology 8, no. 3:1027-1042. PNNL-SA-149896. doi:10.1007/s40684-020-00247-x
• Whalen S.A., M. Reza E Rabby, T. Wang, X. Ma, T.J. Roosendaal, and B.S. Taysom. 2021. "Shear Assisted Processing and Extrusion of Aluminum Alloy 7075 Tubing at High Speed." In Light Metals held at the TMS Annual Meeting and Exhibition, March 15-18, 2021. Minerals, Metals and Materials Series, edited by L. Perander, 6, 277-280. Cham:Springer. PNNL-SA-156009. doi:10.1007/978-3-030-65396-5_41
• Whalen S.A., M.J. Olszta, M. Reza E Rabby, T.J. Roosendaal, T. Wang, D.R. Herling, and B.S. Taysom, et al. 2021. "High Speed Manufacturing of Aluminum Alloy 7075 Tubing by Shear Assisted Processing and Extrusion (ShAPE)." Journal of Manufacturing Processes 71. PNNL-SA-164792. doi:10.1016/j.jmapro.2021.10.003

2020

• Croteau J.R., J. Jung, S.A. Whalen, J.T. Darsell, A. Mello, D. Holstine, and K. Lay, et al. 2020. "Ultrafine-grained Al-Mg-Zr Alloy Processed by Shear-Assisted Extrusion with High Thermal Stability." Scripta Materialia 186. PNNL-SA-151920. doi:10.1016/j.scriptamat.2020.05.051
• Li Y., S. Hu, E.I. Barker, N.R. Overman, S.A. Whalen, and S. Mathaudhu. 2020. "Effect of grain structure and strain rate on dynamic recrystallization and deformation behavior: a phase field-crystal plasticity model." Computational Materials Science 180. PNNL-SA-144520. doi:10.1016/j.commatsci.2020.109707
• Reza E Rabby M., K.A. Ross, M. Mcdonnell, and S.A. Whalen. 2020. "Numerical Simulation and Experimental Validation of Joint Performance in Aluminum-Steel Lap Welds Formed by Friction Stir Dovetailing." Journal of Materials Processing Technology 277. PNNL-SA-145070. doi:10.1016/j.jmatprotec.2019.116459
• Taysom B.S., and S.A. Whalen. 2020. Thermoelectric Temperature Measurement of Deforming Solids. PNNL-30513. Richland, WA: Pacific Northwest National Laboratory. Thermoelectric Temperature Measurement of Deforming Solids
• Wang T., B. Gwalani, J.A. Silverstein, J.T. Darsell, S. Jana, T.J. Roosendaal, and A. Ortiz, et al. 2020. "Microstructural Assessment of a Multiple-Intermetallic-Strengthened Aluminum Alloy Produced from Gas-Atomized Powder by Hot Extrusion and Friction Extrusion." Materials 13, no. 23:Article No. 5333. PNNL-SA-154087. doi:10.3390/ma13235333
• Wang T., P. Upadhyay, M. Reza E Rabby, X. Li, L. Li, A. Soulami, and K.S. Kappagantula, et al. 2020. "Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking." International Journal of Advanced Manufacturing Technology 109, no. 3-4:689-698. PNNL-SA-149338. doi:10.1007/s00170-020-05717-9
• Wang T., S.A. Whalen, P. Upadhyay, and K.S. Kappagantula. 2020. "Joining Dissimilar Materials via Rotational Hammer Riveting Technique." In Magnesium Technology 2020, edited by J. Brian, et al, 207-212. New York, New York:Springer Nature. PNNL-SA-147128. doi:10.1007/978-3-030-36647-6_32
• Whalen S.A., S. Jana, J.T. Darsell, T. Wang, and J.A. Silverstein. 2020. Process Intensification for Nanocomposite Aluminum Extrusions - CRADA 411 (Final Report). PNNL-30643. Richland, WA: Pacific Northwest National Laboratory. Process Intensification for Nanocomposite Aluminum Extrusions - CRADA 411 (Final Report)

2019

• Reza E Rabby M., S.A. Whalen, K.A. Ross, and M. Mcdonnell. 2019. "Joining AA7099 to Ni-Cr-Mo Steel using Friction Stir Dovetailing." In Friction Stir Welding and Processing X, edited by Y Hovanksi, et al, 171-180. Cham:Springer. PNNL-SA-138056. doi:10.1007/978-3-030-05752-7_16
• Ross K.A., M. Reza E Rabby, M. Mcdonnell, and S.A. Whalen. 2019. "Advances in Dissimilar Metals Joining through Temperature Control of Friction Stir Welding." MRS Bulletin 44, no. 8:613-618. PNNL-SA-144347. doi:10.1557/mrs.2019.181
• Whalen S.A., M.J. Olszta, C. Roach, J.T. Darsell, D.D. Graff, M. Reza E Rabby, and T.J. Roosendaal, et al. 2019. "High Ductility Aluminum Alloy made from Powder by Friction Extrusion." Materialia 6. PNNL-SA-138614. doi:10.1016/j.mtla.2019.100260
• Whalen S.A., N.R. Overman, V.V. Joshi, T. Varga, D.D. Graff, and C.A. Lavender. 2019. "Magnesium Alloy ZK60 Tubing made by Shear Assisted Processing and Extrusion (ShAPE)." Materials Science and Engineering A. Structural Materials: Properties, Microstructure and Processing 755. PNNL-SA-140301. doi:10.1016/j.msea.2019.04.013

2018

• Darsell J.T., N.R. Overman, V.V. Joshi, S. Mathaudhu, and S.A. Whalen. 2018. "Shear Assisted Processing and Extrusion (ShAPE) of AZ91E Flake: A Study of Tooling Features and Processing Effects." Journal of Materials Engineering and Performance 27, no. 8:4150-4161. PNNL-SA-129883. doi:10.1007/s11665-018-3509-1
• Reza E Rabby M., K.A. Ross, N.R. Overman, M.J. Olszta, M. Mcdonnell, and S.A. Whalen. 2018. "Joining Thick Section Aluminum to Steel with Suppressed FeAl Intermetallic Formation via Friction Stir Dovetailing." Scripta Materialia 148. PNNL-SA-131279. doi:10.1016/j.scriptamat.2018.01.026

2017

• Butzbaugh J.B., E.T. Mayhorn, G. Sullivan, and S.A. Whalen. 2017. Connected Equipment Maturity Model Version 1.0. PNNL-26413. Richland, WA: Pacific Northwest National Laboratory. doi:10.2172/1355100.Connected Equipment Maturity Model Version 1.0
• Overman N.R., S.A. Whalen, M.E. Bowden, M.J. Olszta, K. Kruska, T. Clark, and E.L. Stevens, et al. 2017. "Homogenization and Texture Development in Rapidly Solidified AZ91E Consolidated by Shear Assisted Processing and Extrusion (ShAPE)." Materials Science and Engineering A. Structural Materials: Properties, Microstructure and Processing 701. PNNL-SA-122981. doi:10.1016/j.msea.2017.06.062
• Reza E Rabby M., K.A. Ross, S.A. Whalen, Y. Hovanski, and M. Mcdonnell. 2017. "Solid-State Joining of Thick-Section Dissimilar Materials using a New Friction Stir Dovetailing (FSD) Process." In Friction Stir Welding and Processing IX, edited by Y Hovanksi, et al, 67-77. Cham:Springer International Publishing. PNNL-SA-119210. doi:10.1007/978-3-319-52383-5_8
• Whalen S.A., V.V. Joshi, N.R. Overman, D.D. Caldwell, C.A. Lavender, and T. Skszek. 2017. "Scaled-Up Fabrication of Thin-Walled ZK60 Tubing using Shear Assisted Processing and Extrusion (ShAPE)." In Magnesium Technology Conference 2017, February 26 - March 2, 2017, San Diego, California, edited by KN Solanki, et al, 315-321. Cham:Springer. PNNL-SA-121164. doi:10.1007/978-3-319-52392-7_45

2016

• Whalen S.A., S. Jana, D. Catalini, N.R. Overman, and J. Sharp. 2016. "Friction Consolidation Processing of n-Type Bismuth-Telluride Thermoelectric Material." Journal of Electronic Materials 45, no. 7:3390-3399. PNNL-SA-114513.

Selected Publications

2021

• Md. Reza-E-Rabby, M. Olszta, Nicole Overman, M. McDonnell, S. Whalen, “Friction Stir Dovetailing of AA7099 to Steel with AA6061 Interlayer for Reduced Zn Embrittlement at dissimilar Interface,” Journal of Manufacturing Processes, 61, pg. 25-34, 2021.
• N. Overman, X. Li, M. Olszta, E. Nickerson, C. Overman, S. Mathaudhu, G. Grant, S. Whalen, “Microstructural Progression of Shear Induced Mixing in a CuNi Alloy,” Materials Characterization, 171, 110759, 2021.
• T. Wang, L. Lei, M. Pallaka, H. Das, S. Whalen, A. Soulami, P. Upadhyay, K. Kappagantula, “Mechanical and Microstructural Characterization of AZ31 Magnesium-Carbon Fiber Reinforced Polymer Joint Obtained by Friction Stir Interlocking Technique,” Materials and Design, 198, 109325, 2021.

2020

• J. Croteau, J. Jung, S. Whalen, J. Darsell, A. Mello, D. Holstine, K. Lay, M. Hansen, D. Dunand, N. Vo, “Ultra-Fine Grained Al-Zr Processed by Shear Assisted Processing and Extrusion with High Thermal Stability,” Scripta Materialia, vol. 186, pp. 326-330, 2020.
• Md. Reza-E-Rabby, K. Ross, M. McDonnell, S. Whalen, “Numerical Simulation and Experimental Validation of Joint Performance in Aluminum-Steel Lap Welds Performed by Friction Stir Dovetailing,” Journal of Materials Processing Technology, vol. 277, 116459, 2020.
• T. Wang, B. Gwalani, J. Silverstein, J. Darsell, S. Jana, T. Roosendaal, A. Ortiz, W. Daye, T. Pelletiers, S. Whalen, “Microstructural Assessment of a Multiple-Intermetallic-Strengthened Aluminum Alloy Produced from Gas-Atomized Powder by Hot Extrusion and Friction Extrusion,” Materials, 13(23) , 5333, 2020.
• T. Wang, P. Upadhyay, Md. Reza-E-Rabby, X. Li K. Kappagantula, S. Whalen, “Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Alloy Sheet by Friction Stir Interlocking,” International Journal of Advanced Manufacturing Technology, vol. 109, pp. 689-698, 2020.
• T. Wang, P. Upadhyay, S. Whalen, “A Review of Technologies for Welding Magnesium Alloys to Steels,” International Journal of Precision Engineering and Manufacturing-Green Technology, 2020.
• Y. Li, S. Hu, E. Barker, N. Overman, S. Whalen, S. Mathaudhu, “Effect of Grain Structure and Strain Rate on Dynamic Recrystallization and Deformation Behavior: A Phase Field Crystal Plasticity Model,” Computational Materials Science, vol. 180, 10907, 2020.

2019

• K. Ross, Md. Reza-E-Rabby, M. McDonnell, S. Whalen, “Advances in Dissimilar Metals Joining through Temperature Control of Friction Stir Welding,” MRS Bulletin, vol. 44 (3), pp. 613-618, 2019.
• S. Whalen, N. Overman, V. Joshi, T. Varga, D. Graff, C. Lavender, “Magnesium Alloy ZK60 Tubing made by Shear Assisted Processing and Extrusion (ShAPE),” Materials Science and Engineering A, 755 (7), 278-288, 2019.

2018

• J. Darsell, N. Overman, V. Joshi, S. Mathaudhu, S. Whalen, “Shear Assisted Processing and Extrusion (ShAPE) of AZ91E Flake: A Study of Tooling Features and Processing Effects,” Materials Engineering and Performance, 27(8), 4150-4161, 2018.
• Md. Reza-E-Rabby, K. Ross, N. Overman, M. Olszta, M. McDonnell, S. Whalen, “Joining Thick Section Aluminum to Steel with Suppressed FeAl Intermetallic Formation via Friction Stir Dovetailing,” Scripta Materialia, 148, 63-67, 2018.

2017

• N. Overman, S. Whalen, M. Olszta, K. Kruska, J. Darsell, V. Joshi, X. Jiang, K. Mattlin, E. Stephens, T. Clark, S. Mathaudhu, “Homogenization and Texture Development in Rapidly Solidified AZ91E Consolidated by Shear Assisted Processing and Extrusion (ShAPE),” Materials Science and Engineering A, 701, 56-68, 2017.
• X. Jiang, S. Whalen, J. Darsell, S. Mathaudhu, N. Overman, “Friction Consolidation of Gas-Atomized Fe-Si Powders for Soft Magnetic Applications,” Materials Characterization, 123, 166-172, 2017.

2016

• S. Whalen, S. Jana, D. Catalini, N. Overman, J. Sharp, “Friction Consolidation Processing of n-Type Bismuth-Telluride Thermoelectric Material,” Journal of Electronic Materials, 45 (7), pp. 3390-3399, 2016.