Analysis of Multi-zone Fatigue Crack Growth Behavior of Friction Stir Welded 5083 Aluminum Alloy

Huang, Binghan; Wang, Lei; Li, Hui; Jiahui, Cong; Zhou, Song

doi:10.1007/s11665-021-06191-4

Cited by 5 publications

(5 citation statements)

References 22 publications

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“…Under cyclic loading, the crack tip was constantly opened and passivated, extending and sharpening, thereby leaving traces at the fracture point, called fatigue speckles; moreover, the direction of fatigue speckles was perpendicular to the direction of crack propagation. As shown in Figures 9a and 10a, numerous fatigue striations, fracture steps, and river morphologies [22,23] were present in the fracture points of NZ and HAZ samples. On comparing the two specimens, the crack propagation rate of the NZ specimen was higher than that of the HAZ specimen due to the larger spacing between the cracks.…”

Section: Analysis and Discussionmentioning

confidence: 90%

Fatigue Crack Propagation Behavior and Life Prediction of Welded Joints of SMA490BW Steel for Bogies

Xie

Zhou

et al. 2023

Processes

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In this paper, the precrack propagation behavior of an SMA490BW welded joint in the core zone and heat-affected zone was analyzed through experiments based on the FRANC 3D and ABAQUS cosimulation method, and life prediction of these cracks was also investigated. The results show that the experimental crack propagation path and crack propagation rate in the weld core zone and heat-affected zone agree well with the simulation results, with a small relative error. The life span of the prefabricated crack in the heat-affected zone was higher than that in the core zone. Furthermore, regarding the life prediction results for the two samples, the relative error obtained using FRANC 3D was about 5%, which was verified using the method of joint simulation of crack propagation behavior in the zone simulation and their life prediction with accurate feasibility.

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Section: Analysis and Discussionmentioning

confidence: 90%

Fatigue Crack Propagation Behavior and Life Prediction of Welded Joints of SMA490BW Steel for Bogies

Xie

Zhou

et al. 2023

Processes

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“…As can be seen from the figure, although the SZ region has fine grains, its hardness (∼120 HV) is significantly lower than that of the TMAZ (∼140 HV), HAZ (∼135 HV), and BM (∼135 HV) regions. This decrease in hardness is due to the dissolution of strengthening phases in the SZ during the welding process [11][12][13]. Figure 4 compares the tensile properties of the base metal and the welded joint.…”

Section: Fatigue Crack Growth Behavior With Different Notch Locationsmentioning

confidence: 99%

“…Several research studies have been conducted to explore the fatigue behavior of FSW joints in various aluminum alloys [6][7][8][9][10]. Huang et al [11] studied the microstructure, hardness, tensile properties, and crack growth behavior of a 12-mm 5083 aluminum-alloy bobbin tool for friction stir welding joint. They noticed decreased mechanical properties after welding, with the heat-affected zone showing lower tensile strength and elongation compared to the base material.…”

Section: Introductionmentioning

confidence: 99%

Quasi-in-situ observation of fatigue crack growth behavior of friction stir welded 2024-T4 joint

Yang,

Samiuddin,

Chen

et al. 2024

Mater. Res. Express

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This study presents a quasi-in-situ observation of the fatigue crack growth behavior in a friction stir welded 2024-T4 joint. The microstructure and fatigue properties of the joint were investigated using electron backscatter diffraction (EBSD) technique, scanning electron microscopy (SEM), and fatigue crack growth tests. The fatigue crack growth behavior of the joint was examined by conducting fatigue crack growth tests with different notch locations. The results show that the sample with the notch in the stir zone (SZ) exhibited the highest resistance to fatigue crack growth, followed by the notched samples of the Advancing side (AS) and Retreating side (RS) weldments. Microstructural observations showed a homogeneous microstructure with a fine grain size in SZ and it was observed that this fine-grained structure significantly enhanced the material's resistance to fatigue crack growth. The experimental results were further analyzed using the Paris model to provide a quantitative understanding of the crack growth behavior. The study underlines the impact of microstructural characteristics and notch location on the fatigue performance of the weldment. Overall, the quasi-in-situ observations and experimental findings contribute to a comprehensive understanding of the fatigue crack growth behavior in friction stir welded 2024-T4 joints.

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“…The reliability of FSW joints is particularly crucial for aerospace applications [10], with research traditionally focused on microstructural and tensile properties [11][12][13]. For instance, Malopheyev et al [11] noted that higher welding speeds improved the uniformity of precipitation distribution in the SZ during subsequent aging, enhancing joint performance.…”

Section: Introductionmentioning

confidence: 99%

“…For instance, Malopheyev et al [11] noted that higher welding speeds improved the uniformity of precipitation distribution in the SZ during subsequent aging, enhancing joint performance. Huang et al [12] investigated the microstructure, hardness, and tensile characteristics of AA5083 friction stir welded joints, observing diminished mechanical qualities post-welding, particularly in the heat-affected zone (HAZ), which exhibited reduced tensile strength and elongation compared to the BM.…”

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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Analysis of Multi-zone Fatigue Crack Growth Behavior of Friction Stir Welded 5083 Aluminum Alloy

Cited by 5 publications

References 22 publications

Fatigue Crack Propagation Behavior and Life Prediction of Welded Joints of SMA490BW Steel for Bogies

Fatigue Crack Propagation Behavior and Life Prediction of Welded Joints of SMA490BW Steel for Bogies

Quasi-in-situ observation of fatigue crack growth behavior of friction stir welded 2024-T4 joint

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

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