Materials Scientist
Materials Scientist

Biography

Scott Whalen is a Senior Research Scientist in the Applied Materials and Manufacturing group at Pacific Northwest National Laboratory (PNNL). His research interests focus on developing high-shear metals manufacturing processes that result in reduced energy usage and carbon emissions while providing improved material properties. Alloys of aluminum, magnesium, copper, and bismuth-telluride are currently under investigation by his research teams. He is a co-inventor on 11 granted and pending patents for Shear Assisted Processing and Extrusion (ShAPE™) and is the author or co-author on 27 peer-reviewed publications.

Whalen received his PhD from Washington State University in 2004 where he developed the world’s first and only Micro-Electro-Mechanical Systems (MEMS) engine to run on a thermodynamic working cycle. After graduation, he completed a postdoctoral appointment at Sandia National Laboratories investigating micro-scale thermoelectric materials and devices. As a Staff Scientist at Sandia, Whalen performed research and development on all aspects of milliwatt-scale radioisotopic thermoelectric systems and materials. 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. Whalen's active area of research involves discerning the ShAPE of various materials that is enabling improved strength, ductility, and throughput compared to conventional extrusion.

Research Interest

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

Education

  • PhD in Mechanical Engineering, Washington State University, 2004.
  • MS in Safety Engineering, Biomechanics, Texas A&M University, 1997.
  • BS in Mechanical Engineering, University of Idaho, 1996.

Affiliations and Professional Service

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

Awards and Recognitions

  • PNNL Paper of the Quarter, Applied Materials and Manufacturing Group, 7 times, 2019-2022.
  • Association of Washington Business (AWB) Green Manufacturing Award, 2021.
  • R&D 100 Award, PNNL, 2020.
  • 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.
  • R&D 100 Award, PNNL, 2017.
  • National Nuclear Security Administration (NNSA) Defense Program Award of Excellence, 2011
  • NNSA Defense Program Award of Excellence, 2009.
  • Sandia Award for Individual Technical Excellence, 2008.
  • American Society of Mechanical Engineers (ASME) Best Paper in micro-electromechanical system (MEMS) Division, 2005.
  • Sandia Excellence in Engineering Full Doctoral Fellowship, 2002-2004.
  • Washington State University Doctoral Researcher of the Year, 2002.

Patents

Publications

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
  • 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
  • Reza E Rabby M., T. Wang, N.L. Canfield, B.S. Taysom, D.R. Herling, D.D. Graff, and T.J. Roosendaal, et al. 2022. "Effect of Post-Extrusion Heat Treatment on Performance of AA2024 Tubes Fabricated by Shear Assisted Processing and Extrusion." CIRP - Journal of Manufacturing Science and Technology 37. PNNL-SA-167732. doi:10.1016/j.cirpj.2022.02.025
  • 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., J.D. Escobar Atehortua, M. Song, M. Reza E Rabby, B.S. Taysom, J.A. Silverstein, and T.J. Roosendaal, et al. 2022. "Extrusion of Unhomogenized Castings of 7075 Aluminum via ShAPE." Materials & Design 213. PNNL-SA-167731. doi:10.1016/j.matdes.2021.110374
  • 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

  • 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., M.J. Olszta, M.E. Bowden, X. Li, A. Rohatgi, S.N. Mathaudhu, and G.J. Grant, et al. 2021. "The Onset of Alloying in Cu-Ni Powders Under High-shear Consolidation." Materials & Design 211. PNNL-SA-165452. doi:10.1016/j.matdes.2021.110151
  • 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., K.S. Kappagantula, M. Reza E Rabby, X. Li, N.R. Overman, M.J. Olszta, and T. Wang, et al. 2021. Shear Assisted Processing and Extrusion (ShAPE) of Aluminum Alloy 7075, 2024, and Al-12.4TM. PNNL-32387. Richland, WA: Pacific Northwest National Laboratory. 
  • 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
  • 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

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. 
  • Jiang X., S.A. Whalen, J.T. Darsell, S. Mathaudhu, and N.R. Overman. 2017. "Friction Consolidation of Gas-Atomized Fe-Si Powders for Soft Magnetic Applications." Materials Characterization 123. PNNL-SA-120598. doi:10.1016/j.matchar.2016.11.026
  • 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.

2015