Fatigue Life of Friction Stir Welded Joints in the Presence of Corrosion Damage: Experiments and Calculations

2005 ◽  
Vol 47 (7-8) ◽  
pp. 456-461 ◽  
Author(s):  
Tommaso Ghidini ◽  
Ulises Alfaro ◽  
C. Dalle Donne
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
Corrosion Damage ◽  
Friction Stir

Corrosion Resistance Evaluation and Effects of Prior Corrosion and Stress on Fatigue Behavior of Friction Stir Welded AA2024-T3

CORROSION ◽  
10.5006/2447 ◽  
2017 ◽  
Vol 74 (2) ◽  
pp. 169-180 ◽  
Author(s):  
Takao Okada ◽  
Shigeru Machida ◽  
Toshiya Nakamura
Keyword(s):  
Corrosion Resistance ◽  
Fatigue Life ◽  
Fatigue Behavior ◽  
Base Material ◽  
Corrosion Damage ◽  
Al Alloy ◽  
Line Energy ◽  
Friction Stir ◽  
Aspect Ratios ◽  
Corrosion Pits

The corrosion resistance of 2024-T3 (UNS A92024) Al alloy with no clad layer and that of friction stir welded (FSW) joint specimens fabricated from the same material were evaluated. The surfaces of both the alloy base material and FSW joint specimens were ground out before being exposed to a 3.0% sodium chloride solution at 60°C for 24, 48, 72, or 96 h. The corrosion pits on the base material samples were found to be randomly distributed, while those on the FSW joint were formed around the edge and center of the weld line. Energy dispersive x-ray spectrometry indicated constituent particles containing Mg at the grain boundaries in the thermomechanically affected zone and stir zone of the FSW joint; this Mg content aggravated the corrosion damage in those regions. The depth and volume of the corrosion pits in the FSW joint were greater than those in the base material. However, the aspect ratios of the corrosion pits in the base material and FSW were similar. Prior-corroded specimens were fatigue tested to evaluate the effect of corrosion damage. The fatigue life of the base material with corrosion damage was slightly shorter than that of the FSW joint specimens with corrosion damage, and the fatigue life of an uncorroded FSW joint specimen was more than 10 times longer than that of a corroded specimen. Thus, corrosion damage has a severely detrimental effect on fatigue life. Further, fracture surface observation revealed that the fracture origins in the FSW joint specimens tended to be multiple corrosion pits; however, the corrosion pits with the greatest depth or volume did not necessarily become fracture origins in the base material or FSW joints.

scholarly journals A Comparative Study on Fatigue Response of Aluminum Alloy Friction Stir Welded Joints at Various Post-Processing and Treatments

2021 ◽  
Vol 5 (3) ◽  
pp. 93 ◽  
Author(s):  
Soran Hassanifard ◽  
Ahmad Varvani-Farahani
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
Solution Treatment ◽  
Welding Process ◽  
Rolling Process ◽  
Alumina Powder ◽  
Post Processing ◽  
Friction Stir ◽  
Copper Foils

The present study examines the fatigue of friction stir welded (FSW) aluminum 6061, 7075, 1060 joints followed by (i) in situ and sequential rolling (SR) processes, (ii) plastic burnishing (iii) solution-treatment artificial aging (STA), (iv) local alloying through depositing thin copper foils, and (v) inserting alumina powder in the weld nugget zone (NZ). The microstructural features and fatigue life of post-processed joints were compared with those of as-welded joints. The in situ rolling technique offered simultaneous rolling and welding operations of aluminum joints, while through the sequential rolling process, the top surface of FSW joints was rolled after the welding process. The fatigue life of in situ rolled samples was increased as the ball diameter of welding tool increased. The fatigue life of friction stir welded joints after a low-plasticity burnishing process was noticeably promoted. The addition of 1 wt.% alumina in the NZ of joints resulted in a significant elevation on fatigue life of friction stir spot welded joints, while an increase in alumina powder to 2.5 wt.% adversely affected fatigue strength. Weld NZ was alloyed through the insertion of copper foils between the faying surfaces of joints. This localized alloy slightly improved the fatigue life of joints; however, its effects on fatigue life were not as influential as STA heat-treated or in situ rolled joints. The microstructure of weld joints was highly affected through post-processing and treatments, resulting in a substantial influence on the fatigue response of FSW aluminum joints.

A novel method for improving fatigue life of friction stir spot welded joints using localized plasticity

2014 ◽  
Vol 53 ◽  
pp. 962-971 ◽  
Author(s):  
Soran Hassanifard ◽  
Masoud Mohammadpour ◽  
Hossein Ahmadi Rashid
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
Friction Stir ◽  
Novel Method ◽  
Spot Welded

scholarly journals Fatigue of Friction Stir Welded Aluminum Alloy Joints: A Review

2018 ◽  
Vol 8 (12) ◽  
pp. 2626 ◽  
Author(s):  
Hongjun Li ◽  
Jian Gao ◽  
Qinchuan Li
Keyword(s):  
Growth Rate ◽  
Fatigue Life ◽  
Crack Growth Rate ◽  
Crack Growth ◽  
Process Parameters ◽  
Welded Joints ◽  
Welding Process ◽  
Life Assessment ◽  
Fatigue Properties ◽  
Friction Stir

The application fields of friction stir welding technology, such as aerospace and transportation, has high safety requirements and fatigue is the dominant failure mode for weldments. It is of great significance to understand the fatigue properties of friction stir welded joints. This paper provides an overview of the fatigue mechanism, influencing factors, crack growth rate, and fatigue life assessment. It is found that the fatigue performance of friction stir welded joints can be affected by welding process parameters, test environment, stress ratio, residual stress, and weld defect. The optimized process parameters can produce high quality weld and increase the weld fatigue life. Laser peening is an effective post weld treatment to decrease fatigue crack growth rate and improve material fatigue life.

scholarly journals Influence of corrosion damage on cyclic fatigue life of tee welded joints treated by high-frequency mechanical peening

2016 ◽  
Vol 2016 (9) ◽  
pp. 46-51
Author(s):  
V.V. Knysh ◽  
◽  
S.A. Solovej ◽  
L.I. Nyrkova ◽  
L.G. Shitova ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
High Frequency ◽  
Corrosion Damage ◽  
Cyclic Fatigue

scholarly journals Influence of corrosion damage on cyclic fatigue life of tee welded joints treated by high-frequency mechanical peening

2016 ◽  
Vol 2016 (9) ◽  
pp. 42-46 ◽  
Author(s):  
V.V. Knysh ◽  
◽  
S.A. Solovej ◽  
L.I. Nyrkova ◽  
L.G. Shitova ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
High Frequency ◽  
Corrosion Damage ◽  
Cyclic Fatigue

Effect of Welding Processes on Fatigue Behaviour of AISI 409M Grade Ferritic Stainless Steel Joints

2013 ◽  
Vol 794 ◽  
pp. 391-412 ◽  
Author(s):  
V. Balasubramanian ◽  
A.K. Lakshminarayanan ◽  
S. Malarvizhi
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Fatigue Crack ◽  
Fatigue Life ◽  
Friction Stir Welding ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Welded Joints ◽  
Friction Stir ◽  
Welding Processes

The present investigation is aimed at to study the effect of four welding processes namely friction stir welding, gas tungsten arc welding, laser beam welding and electron beam welding on fatigue behavior of the ferritic stainless steel conforming to AISI 409M grade. Rolled plates of 4 mm thickness were used as the base material for preparing single pass butt welded joints. The fatigue life and fatigue crack growth behavior were evaluated using hourglass and centre cracked tension (CCT) specimens respectively. A 100 kN servo hydraulic controlled fatigue testing machine was used under constant amplitude uniaxial tensile load with stress ratio of 0.1 and frequency of 15 Hz. Fatigue properties are correlated with the tensile, impact toughness, micro hardness, microstructure, fracture surface morphology and residual stress of the welded joints. It is found that the joint fabricated by friction stir welding process showed superior fatigue life and fatigue crack growth resistance compared to other joints. This is mainly due to the synergetic effect of dual phase ferritic-martensitic microstructure, superior tensile properties and favorable residual stress, which inhibit the growth of cracks compared to other joints.

Predicting the fatigue life of pristine and pre‐corroded friction stir welded joints

2011 ◽  
Vol 2 (2) ◽  
pp. 200-213 ◽  
Author(s):  
T. Ghidini ◽  
C. Dalle Donne ◽  
U. Alfaro Mercado
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
Friction Stir
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