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Welding parameter selection and short fatigue crack growth of dissimilar aluminum alloy friction stir welded joint

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Abstract

The welding process parameters of dissimilar 2024-T4 and 7075-T6 aluminum alloy friction stir welded (FSWy) joints are selected by the metallographic microstructure, the mechanical properties, and the hardness distribution. The joints with rotational speed of 900 rpm and advancing speed of 100 mm/min that have the highest tensile strength are used to carry out the experimental fatigue research. The short crack growth behavior of dissimilar FSW joints is analyzed through the replica technique. The stage of the crack initiation and stable growth accounts for about 60~80% of total fatigue life. The short crack grows rapidly once it reaches the crack size of approximately 350~450 μm. The cracks are prone to initiate at the defects of subsurface in the weld nugget zone and propagate in a quasi-cleavage fracture mode.

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Abbreviations

Q :

Heat input per unit length

α :

Heat input efficiency

q :

Heat input

v :

Traverse speed

μ :

Friction coefficient

P :

Pressure

R :

Shoulder radius

ω :

Rotation speed

ΔN :

Increment of cycle numbers

Δa :

Increment of crack length

N i :

Cycle numbers

N f :

Cycle numbers of total fatigue life

a :

Surface crack length

a i :

Surface crack length at Ni cycles

ΔK :

Stress intensity factor range

area :

Projected area of the crack

σ max :

Maximum stress

σ min :

Minimum stress

Δσ :

Stress range

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Funding

This work is financially supported by the National Natural Science Foundation of China (Grant Nos. 11672010, 51535001, 51575012).

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Authors and Affiliations

  1. College of Mechanical Engineering and Applied Electronics Technology, Bei**g University of Technology, Bei**g, 100124, China

    Guo-Qin Sun, Guo-Sheng Xu, De-Guang Shang & Shu-Jun Chen

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  1. Guo-Qin Sun
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  2. Guo-Sheng Xu
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Correspondence to Guo-Qin Sun.

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Recommended for publication by Commission XIII - Fatigue of Welded Components and Structures

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Sun, GQ., Xu, GS., Shang, DG. et al. Welding parameter selection and short fatigue crack growth of dissimilar aluminum alloy friction stir welded joint. Weld World 63, 1761–1769 (2019). https://doi.org/10.1007/s40194-019-00773-6

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