Fatigue experimental analysis and numerical simulation of FSW joints for 2219 Al–Cu alloy

Abstract

Fatigue properties of friction stir welding (FSW) butt joints for Al–Cu alloy 2219‐T6 were investigated by experimental analysis and numerical simulation. Microstructure characteristics of FSW butt joints for 2219 aluminium alloy were studied during different fatigue stages. Micro hardness values and grain sizes across the FSW joint at different cycles were measured to study the fatigue properties of the joint. Local mechanical performances of the FSW butt joints were investigated based on the micro tensile tests. Fatigue parameters of different regions in the FSW joints were obtained from the four‐point‐correlation method. The local stress and strain response of the FSW joints were obtained based on mechanical performances of the micro tension specimens. The comparison results between simulation and tests analysis show that the built finite element model is effective for estimating the weak areas for FSW joints.

Influence of Mesh Density on Repeatability of FSW Process Simulation Based on DEFORM

“…According to the research on the microstructure and tensile test by related scholars [6,7], during the FSW process, the intense flow range of the weldment material is located at approximately 2mm on the side of the conical stir pin, and the fracture position of the FSW joint tensile specimen is at TMAZ near NZ or TMAZ near HAZ. The data points on the weldment at AS and RS section and at 2mm on the side of the conical stir pin (Y = 25mm, XOZ section) are selected as feature points, where each feature point is separated by 0.92mm.…”

Influence of Residual Stress on Fatigue Weak Areas and Simulation Analysis on Fatigue Properties Based on Continuous Performance of FSW Joints

“…The fatigue loading parameters and total fatigue lives are available from Ref. [25]. The curve of cyclic stress range versus fatigue lives for the FSW specimens is shown in Figure 3.…”

“…To compare the effectiveness of the continuous performance joint model for the fatigue performance simulation of the FSW joints, the partitioned performance joint model was established according to the metallurgical morphologies, hardness profile of the joints and the material attributes in different regions of the joint [25]. The joint is composed of the WNZ, TMAZ, HHAZ, LHAZ and BM, as shown in Figure 10.…”

Thermo-mechanical analysis of linear welding stage in friction stir welding: Influence of welding parameters

“…However, there are some interesting recent studies showing the application of other mathematical tools, such as cellular automaton model [2], or wavelet analysis [15] in modelling of this welding technique. Simulation of the joint formation is not the only area of application for numerical simulations -they are also applied in fracture and failure analysis of FSW joints [16][17][18].…”