Fatigue Performance and Strength Assessment of AA2024 Alloy Friction Stir Lap Welds

Wang, Ruijie; Kang, Hong Tae; Lei, Xinghai

doi:10.1007/s11665-020-05145-6

Cited by 10 publications

(4 citation statements)

References 31 publications

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“…Subsequent studies delved into fatigue performance [14][15][16], with Takao et al [14] analyzing the fatigue life of non-through cracks in friction stir welded AA2024-T3 joints, noting the influence of welding conditions on fracture locations. As research progressed, fatigue crack growth (FCG) behavior became a prominent topic [17][18][19][20].…”

Section: Introductionmentioning

confidence: 99%

Quasi-In Situ Observation of the Microstructural Response during Fatigue Crack Growth of Friction Stir Welded AA2024-T4 Joint

Yang,

Chen,

Zhao

et al. 2024

Materials

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The reliability of friction stir welded joints is a critical concern, particularly given their potential applications in the aerospace manufacturing industry. This study offers a quasi-in situ observation of the microstructural response during fatigue crack growth (FCG) of a friction stir welded AA2024-T4 joint, aiming to correlate fatigue crack growth behavior with mechanical properties investigated using electron backscatter diffraction (EBSD). Notched compact tension (CT) specimens corresponding to the morphology of the stir zone (SZ), advancing side (AS), and retreating side (RS) were meticulously designed. The findings indicate that the welding process enhances the joint’s resistance to fatigue crack growth, with the base metal exhibiting a shorter fatigue life (i.e., ~105 cycles) compared to the welding zones (SZ ~ 3.5 × 105 cycles, AS ~ 2.5 × 105 cycles, and RS ~ 3.0 × 105 cycles). Crack propagation occurs within the stir zone, traversing refined grains, which primarily contribute to the highest fatigue life and lowest FCG rate. Additionally, cracks initiate in AS and RS, subsequently expanding into the base metal. Moreover, the study reveals a significant release of residual strain at the joint, particularly notable in the Structural-CT-RS (Str-CT-RS) sample compared to the Str-CT-AS sample during the FCG process. Consequently, the FCG rate of Str-CT-AS is higher than that of Str-CT-RS. These findings have significant implications for improving the reliability and performance of aerospace components.

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Section: Introductionmentioning

confidence: 99%

Quasi-In Situ Observation of the Microstructural Response during Fatigue Crack Growth of Friction Stir Welded AA2024-T4 Joint

Yang,

Chen,

Zhao

et al. 2024

Materials

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“…2 The fatigue life of weld mainly determine the fatigue life of welded axle housing. 3,4 At present, the fatigue life calculation of welded structures is mainly based on nominal stress or hot-spot stress method and a series of classified welding S-N curves, [5][6][7][8][9][10] although the fatigue life method based on local stress [11][12][13] provides an alternative method. The results are often problematic because these stresses can be strongly dependent on mesh size and loading patterns.…”

Section: Introductionmentioning

confidence: 99%

Research on fatigue reliability prediction model and structural improvement of welded drive axle housing based on master S‐N Curve method

Tan

Wang

Xie

et al. 2022

Quality & Reliability Eng

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Fatigue reliability prediction of welded structures is mainly based on nominal stress or hot spot stress method, but there are some problems such as grid sensitivity and joint geometry dependence. The Master S-N curve method can solve these problems well, but the corresponding reliability model needs to be studied. In this paper, the fatigue reliability model of welded structures based on the Master S-N curve method is studied. Considering the randomness of life and the correlation of failure, a reliability model is proposed, which reduces the computational burden by establishing a median damage-random threshold rule. Taking the welded drive axle housing as an object, the system reliability is analyzed under the bench test condition, and verified by the experimental data. After the verification, this method is used to predict the reliability of the axle housing under variable amplitude loading collected in the test field, and the results are verified by Monte Carlo (MC) method. When the P-S-N curves are parallel, the model is accurate, which is the characteristic of the Master S-N curve method. This method only needs to input the median damage value of the weak part, which is easy to be applied. This method can speed up the reliability prediction cycle of welded structures, which is beneficial to product innovation and optimal design. Finally, an improved design scheme is proposed for the weak parts of welding, and the effects of welding leg width, welding depth, and closed weld on fatigue life are revealed.

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“…The appearance of these features and characteristics of microstructure and mechanical properties are controlled by welding process parameters and conditions [15][16][17]. Several researches related to FSLW that discuss these variations and control mechanisms are reported, but all are mainly focussed on a single pass or single track FSLW [18][19][20][21][22]. However, lately, the focus is slowly shifting towards research related to multi-pass or multi-track FSLW.…”

Section: Introductionmentioning

confidence: 99%

Multi-Pass Friction Stir Lap Welding of AA 6061-T6: Implication of Tool Pin Overlapping on Microstructure and Mechanical Properties of Joints

et al. 2022

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Fatigue Performance and Strength Assessment of AA2024 Alloy Friction Stir Lap Welds

Cited by 10 publications

References 31 publications

Quasi-In Situ Observation of the Microstructural Response during Fatigue Crack Growth of Friction Stir Welded AA2024-T4 Joint

Quasi-In Situ Observation of the Microstructural Response during Fatigue Crack Growth of Friction Stir Welded AA2024-T4 Joint

Research on fatigue reliability prediction model and structural improvement of welded drive axle housing based on master S‐N Curve method

Multi-Pass Friction Stir Lap Welding of AA 6061-T6: Implication of Tool Pin Overlapping on Microstructure and Mechanical Properties of Joints

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