Multiple crack growth prediction in AA2024-T3 friction stir welded joints, including manufacturing effects

Carlone, Pierpaolo; Citarella, Roberto; Sonne, Mads Rostgaard; Hattel, Jesper Henri

doi:10.1016/j.ijfatigue.2016.04.004

Cited by 41 publications

(22 citation statements)

References 36 publications

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“…In the welded specimen, the equilibrium condition is achieved by combining the stresses in the areas immediately surrounding the weld bead. This peculiarity of the welding process can be clearly distinguished from the observation of the residual stress distribution shown in Figure , where the numerical and experimental residual stress profiles are reported in the midline of the thickness, at the end of the releasing step, and for the uncracked model configuration.…”

Section: Resultsmentioning

confidence: 71%

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Crack closure in friction stir weldment using non‐linear model for fatigue crack propagation

Lepore

Maligno

Berto³

2019

Fatigue Fract Eng Mat Struct

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The fatigue crack propagation in a friction stir‐welded sample has been simulated herein by means of two 3‐dimensional finite element method (FEM)‐based analyses. Numerical simulations of the fatigue crack propagation have been carried out by assuming a residual stress field as a starting condition. Two initial cracks, observed in the real specimen, have been assessed experimentally by performing fatigue tests on the welded sample. Hence, the same cracks have been placed in the corresponding FE model, and then a remote load with boundary conditions has been applied on the welded specimen. The material behaviour of the welded joint has been modelled by means of the Ramberg‐Osgood equation, while the non‐linear Kujawski‐Ellyin (KE) model has been adopted for the fatigue crack propagation under small‐scale yielding (SSY) conditions. Owing to the compressive nature of the residual stress field that acts on a part of the cracked regions, the crack closure phenomenon has also been considered. Then, the original version of the KE law has been modified to fully include the closure effect in the analysis. Later, the crack closure effect has also been assessed in the simulation of fatigue propagation of three cracks. Finally, an investigation of the fracture process zone (FPZ) extension as well as the cyclic plastic zone (CPZ) and monotonic plastic zone (MPZ) extensions have been assessed.

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Section: Resultsmentioning

confidence: 71%

“…It is worth noting that the residual stress field obtained from the elastic–plastic simulation of the FSW process is reported only in the longitudinal direction of the specimen because the corresponding experimental results are calculated by using the contour method.…”

Section: Resultsmentioning

confidence: 99%

Crack closure in friction stir weldment using non‐linear model for fatigue crack propagation

Lepore

Maligno

Berto³

2019

Fatigue Fract Eng Mat Struct

View full text Add to dashboard Cite

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“…However, he was in agreement with Hibbit and Marcal [67] that a fine mesh with linear elements is preferred since brick or hexahedral elements, in three dimensions, are the recommended elements in solving problems of plasticity [68,69]. On the other hand, Citarella et al [13,14] and Carlone et al [15] modelled the residual stresses induced during the Friction Stir Welding (FSW) process in order to study the crack growth. In this work, a thermo-mechanical FEM model with three-dimensional eight-node hexahedral elements (linear elements) with an average element size that was set at 0.5 mm at the cutting surface was created to predict the process-induced residual stress field.…”

Section: Angular Distortion and Residual Stresses Of The Proposed Fe mentioning

confidence: 82%

Residual Stresses with Time-Independent Cyclic Plasticity in Finite Element Analysis of Welded Joints

Lostado-Lorza

Bobadilla

Calvo

et al. 2017

Metals

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Due to the intense concentration of heat in a reduced area when Gas Metal Arc Welding (GMAW) is used to join mechanical components, the regions near the weld bead are subjected to severe thermal cycles. Firstly, the region close to the weld bead that is heated tends to be in compression and, when it cools, tends to be in tension. According to Pilipenko, the material is exposed to elastic compression and, then, reaching the yield limit, undergoes plastic deformation with the appearance of residual stresses followed by elastic-plastic unloading. This could be considered as a strain-stress cycle. This paper applies plastic-strain-range memorization based on time-independent cyclic plasticity theory for butt joints with single V-groove Finite Element (FE) models that were manufactured by GMAW. The theory combines both the isotropic hardening and the nonlinear kinematic hardening rule (Chaboche model) to reproduce the behavior of cyclic plasticity and thus to obtain the residual stresses in welded joint FE models. As a practical example, the proposed theory is validated by three welded joint specimens that were manufactured with different input parameters of speed, voltage, and current. An agreement between the residual stresses obtained by the FE model proposed and those obtained experimentally by the hole drilling method at different depths demonstrates that the proposed theory could be valid for modelling the residual stresses in welded joints when cyclic plasticity is considered over the range of speed, voltage, and current studied.

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“…The welding procedure has briefly been described in [12,13], but will be recapitulated in the following section. Two rolled 2024-T3 plates with the dimensions of 200 × 30 × 4 mm are clamped to a backing plate on a CNC milling machine (MCX 600 ECO, FAMUP, Budoia, Italy), see Figure 2.…”

Section: The Fsw Experimentsmentioning

confidence: 99%

Assessment of the Contour Method for 2-D Cross Sectional Residual Stress Measurements of Friction Stir Welded Parts of AA2024-T3—Numerical and Experimental Comparison

Sonne

Carlone

Hattel

2017

Metals

Self Cite

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Abstract:The contour method is one of the newest techniques for obtaining residual stress fields from friction stir welded (FSW) parts, experimentally. This method has many advantages; however, edge effects coming from the process itself might introduce artifacts in the obtained results, and this was slightly touched upon in the very first paper on the method. This concern is further assessed in the present work, where the contour method is compared with the results that were obtained numerically via a thermomechanical model and experimentally via the cut-compliance method. For the two-dimensional (2-D) cross sectional map obtained by the method, peak stresses in tension are observed in the mid-section of the FSW butt-welded plates at the distance of the tool radius from the centerline. The corresponding numerical simulation indicates the same behavior because of the particular clamping conditions, and consequently this should not be interpreted as a misleading result of the contour method. Edge effects from the cutting process involved in the contour method should, however, be taken into consideration, most likely resulting in the residual stresses observed near the surfaces of the cross section being less extreme in reality than observed.

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Multiple crack growth prediction in AA2024-T3 friction stir welded joints, including manufacturing effects

Cited by 41 publications

References 36 publications

Crack closure in friction stir weldment using non‐linear model for fatigue crack propagation

Crack closure in friction stir weldment using non‐linear model for fatigue crack propagation

Residual Stresses with Time-Independent Cyclic Plasticity in Finite Element Analysis of Welded Joints

Assessment of the Contour Method for 2-D Cross Sectional Residual Stress Measurements of Friction Stir Welded Parts of AA2024-T3—Numerical and Experimental Comparison

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