The role of residual stress and heat affected zone properties on fatigue crack propagation in friction stir welded 2024-T351 aluminium joints

• Published in: International journal of fatigue Vol. 25; no. 1; pp. 77 - 88
• Main Authors: Bussu, G, Irving, P.E
• Format: Journal Article
• Language: English
• Published: Oxford Elsevier Ltd 01-01-2003; Elsevier Science
• Subjects: Aluminium alloys; Applied sciences; Crack growth; Exact sciences and technology; Fatigue; Friction stir welding; Heat affected zone; Joining, thermal cutting: metallurgical aspects; Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology; Metals. Metallurgy; Residual stress; Welded joints; Welding; Welded joints; Heat affected zone; Aluminium alloys; Friction stir welding; Residual stress; Crack growth; Stress analysis; Aluminium base alloys; Welding; Mechanical properties; Aluminium; Friction welding; Experimental study; Fatigue crack; Crack propagation
• ISSN: 0142-1123; 1879-3452
• DOI: 10.1016/S0142-1123(02)00038-5

The effects of weld residual stress and heat affected zone on the fatigue propagation of cracks parallel and orthogonal to the weld direction in friction stir welded (FSW) 2024-T351 joints were investigated. Crack propagation behaviour was sensitive to both weld orientation and the distance of the crack from the weld line. Growth rates both faster and slower than in the parent material were observed, depending on the crack orientation and distance from the weld. Weld residual stress was mechanically relieved and the effects on crack propagation observed. A comparative analysis of the results indicated that crack growth behaviour in the FSW joints was generally dominated by the weld residual stress and that microstructure and hardness changes in FSWs had a minor influence.