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Md. Reza E Rabby

Md. Reza E Rabby

Pacific Northwest National Laboratory
PO Box 999
Richland, WA 99352


Dr. Md Reza-E-Rabby joined at PNNL in 2016 as a Post Doctorate Research Associate and assigned to the task of joining thick section dissimilar material. Following his graduate work at the University of South Carolina in 2015, Dr. Rabby started his career as a Friction Stir Weld (FSW) engineer in a company that provide canister for the nuclear spent fuel in power plants. His expertise in FSW tool design brought him in current position at PNNL for developing new solid state joining technology of dissimilar material such as, Al-steel, Al-Mg, Al/Mg-carbon/glass fiber reinforced polymer(C/G FRP) composites etc. over a range of stack up thicknesses of 1-75 mm. In addition, his research is also focused towards the investigation of solid phase processing of lightweight materials using Shear Assisted Processing and Extrusion (ShAPE™) for enhancing properties with novel microstructures, and the transition the technology from the lab scale manufacturing to the bulk production environment.

Research Interests

  • Developing design criteria for FSW tools
  • Solid phase processing and joining of materials (ShAPE™, FSW)
  • Structural analysis using finite element method (FEM)
  • Metallurgy of aluminum alloys and their metal matrix composites
  • Synthesis and characterization of nanocomposite materials
  • Vacuum assisted resin transfer molding (VARTM) for manufacturing C/G FRP

Education and Credentials

  • Ph.D. Mechanical Engineering, University of South Carolina, 2015
  • M.S. Mechanical Engineering, Tuskegee University, 2010
  • B.Sc. Civil Engineering, Bangladesh University of Engineering and Technology (BUET), 2006

Affiliations and Professional Service

  • The Minerals, Metals and Materials Society (TMS)

Awards and Recognitions

  • Outstanding Performance award, PNNL, 2016
  • Travel Grant Award, the Graduate School at University of South Carolina (2013-2014)

PNNL Patents

PNNL Publications


  • 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


  • 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


  • 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


  • 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

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