Fatigue of Friction Stir Welded 2024-T351 Aluminium Alloy

Booth, D.; Sinclair, Ian

doi:10.4028/www.scientific.net/msf.396-402.1671

Cited by 24 publications

(13 citation statements)

References 4 publications

(6 reference statements)

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“…Booth and Sinclair (Ref. 17) found that fatigue failures in the nugget region appear to compromise fatigue life, and that coupons that failed outside of the nugget area were comparable with published parent material data. The failures that occurred in the nugget were "related to the presence of macroscopic discontinuities in the flow pattern of the flow arm," which they showed to have differences in hardness values between the bands.…”

Section: Weld Flaws and Defectssupporting

confidence: 68%

Effect of Fit-Up Tolerances on the Strength of Friction Stir Welds

Widener¹,

Tweedy²,

Burford³

2006

47th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference

6
1
5
0

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Part fit-up variations are critical to the joint quality produced by joining operations like friction stir welding (FSW). Typical fit-up issues may include: gaps, misalignment between the weld path and joint line, setup related variations, voids or holes in the weld path, mismatch between materials being joined, etc. These and other factors potentially result in variations in mechanical properties between the start and finish of the weld as well as lead to the possible formation of defects along the joint line. The purpose of this study was to determine the robustness of the FSW process to selected imperfections in joint fit-up between plates in butt-welding. Specifically, it includes a study of the effect of part fit-up variations on the transverse joint tensile strength of 0.125" thick friction stir butt-welded 7075-T73 aluminum plate. Welds were performed on an MTS® ISTIR™ PDS friction stir weld machine at the National Institute for Aviation Research in Wichita, KS. It was found that the FSW process was capable of creating a sound defect-free joint for a range of typical fit-up discontinuities. The tolerance zone for weld path misalignment to the joint line was related to the formation of fine nugget grain structure at the bottom of the weld, with twothirds of the tolerance zone located on the advancing side of the pin. It was also determined that a certain amount of plate gap or voids in the weld path can be tolerated without a decrease in tensile strength; beyond that point, volumetric defects form in the nugget. Otherwise, there is little variation in tensile properties along the weld joint when care is taken to ensure gap and alignment tolerances are not exceeded. Nomenclature σ= engineering stress HAZ = Heat-Affected Zone TMAZ = Thermo-mechanically Affected Zone FSW = Friction Stir Welding

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Section: Weld Flaws and Defectssupporting
confidence: 68%

Effect of Fit-Up Tolerances on the Strength of Friction Stir Welds
Widener¹,
Tweedy²,
Burford³
2006
47th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference
6
1
5
0
View full text Add to dashboard Cite

show abstract

“…Booth and Sinclair [107] asserted that fatigue failure in FSW 2024-T351 could occur within the weld nugget or at the HAZs (i.e HAZ or TMAZ). Failure in the nugget was linked to discontinuities in the material flow pattern at the surface in the absence of obvious defects.…”

Section: Fractography Of the Surfaces Of Fsw Failed Specimensmentioning
confidence: 99%

Review Paper: Production and Microstructural Phenomena Affecting Friction Stir Welding Mechanical Behaviour and Applications.
Dada
¹

2019
SSRN Journal
1
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Friction stir welding (FSW) is the fastest evolving joining technology and the principal prospective technique for implementing an integral fuselage structure in aircraft manufacturing. The viability of FS welds is dependent upon mechanical properties and production turnovers, which are dependent on welding rates and tool design. Hence this review paper border on the effect of welding parameters, tool designs on microstructure, and mechanical behavior of friction stir welds. The microstructure and micro-hardness which were influenced by the welding rates determined static properties, failure locations, and residual stress minima and maxima. The study reviews the nature and distribution of material flow, grain structure, and precipitates in the aluminum FS welds and their effect on mechanical properties. Advances in the industrial application of Friction Stir Welds and further prospects are critical to this review work.

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“…These differences in hardness value within the nugget have been correlated with the size of the precipitates present in the region (Ref [12][13][14][15]. The 2xxx and 7xxx show the hardness minima within the TMAZ zone (Ref 6,9,16,17). The effect has been attributed to over-aging (Ref 12).…”

Section: Introductionmentioning
confidence: 94%

The Effect of Ultrasonic Impact Treatment on the Fatigue Resistance of Friction Stir Welded Panels
Rodopoulos
¹
,
Pantelakis
²
,
Papadopoulos
³

2009
J. of Materi Eng and Perform
10
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5
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In this work, the results of an experimental study for assessing the effects of Ultrasonic Impact Treatment on the fatigue resistance of Friction Stir Welded aluminum alloy panels are presented. Although the significant compressive residual stress introduced on the material by ultrasonic impact treatment (UIT) was expected to cause retardation in the crack growth rate, this was only noted at low initial DJ values. At high DJ values, the effect of UIT practically diminishes. The phenomenon was attributed to the relaxation/ redistribution of the residual stresses with fatigue damage. This provides an alarming situation where damage tolerance design relies on models where only the initial residual stress profile is taken into account without knowledge of the potential re-distribution of the residual stresses caused by the fatigue damage accumulation. The findings of this work also indicate that any FCG tests performed can only be considered as case-specific and conclusions can only be drawn for the case studied.

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Fatigue of Friction Stir Welded 2024-T351 Aluminium Alloy

Cited by 24 publications

References 4 publications

Effect of Fit-Up Tolerances on the Strength of Friction Stir Welds

Effect of Fit-Up Tolerances on the Strength of Friction Stir Welds

Review Paper: Production and Microstructural Phenomena Affecting Friction Stir Welding Mechanical Behaviour and Applications.

The Effect of Ultrasonic Impact Treatment on the Fatigue Resistance of Friction Stir Welded Panels

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