Abstract
An equivalent damage model was established to study the fatigue damage behavior of steel–aluminum friction stir welding (FSW) joints. Internal defects of friction stir welding joint under various cyclic loading stages were observed by X-ray microcomputed tomography (X-CT). For the characteristics of defects of the steel–aluminum FSW joints, a simplified method of defects considering key parameters is proposed, and then, the defect model is established. The FSW joint model was established based on the steel–aluminum boundary contour identified by using image processing techniques. Based on the defect model and the FSW joint model, the equivalent damage model was developed. The equivalent damage model was subjected to finite element analysis and compared with the test using strain amplitude as the damage variable. The equivalent damage model can be used to assess fatigue damage in steel–aluminum FSW joints, which provides some theoretical basis for fatigue life prediction.
Issue Section:
Research Papers
References
1.
Safeen
, M. W.
, and Spena
, P. R.
, 2019
, “Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets
,” Metals
, 9
(5
), p. 610
. 2.
Zandsalimi
, S.
, Heidarzadeh
, A.
, and Saeid
, T.
, 2019
, “Dissimilar Friction-Stir Welding of 430 Stainless Steel and 6061 Aluminum Alloy: Microstructure and Mechanical Properties of the Joints
,” Proc. Inst. Mech. Eng. Pt. L-J. Mater.: Des. Appl.
, 233
(9
), pp. 1791
–1801
. 3.
Schjodt-Thomsen
, J.
, and Andreasen
, J. H.
, 2018
, “Low Cycle Fatigue Behaviour of Welded T-Joints in High Strength Steel
,” Eng. Fail. Anal.
, 93
, pp. 38
–43
. 4.
Uematsu
, Y.
, Kakiuchi
, T.
, Ogawa
, D.
, and Hashiba
, K.
, 2020
, “Fatigue Crack Propagation Near the Interface Between Al and Steel in Dissimilar Al/Steel Friction Stir Welds
,” Int. J. Fatigue
, 138
, p. 105706
. 5.
Vishnuvardhan
, S.
, Raghava
, G.
, Saravanan
, M.
, and Gandhi
, P.
, 2016
, “Fatigue Life Evaluation of Fillet Welded Cruciform Joints With Load-Carrying Welds
,” Trans. Indian Inst. Met.
, 69
(2
), pp. 585
–589
. 6.
Cui
, C.
, Xu
, Y.-L.
, and Zhang
, Q.-H.
, 2021
, “Multiscale Fatigue Damage Evolution in Orthotropic Steel Deck of Cable-Stayed Bridges
,” Eng. Struct.
, 237
, p. 112144
. 7.
Remes
, H.
, Gallo
, P.
, Jelovica
, J.
, Romanoff
, J.
, and Lehto
, P.
, 2020
, “Fatigue Strength Modelling of High-Performing Welded Joints
,” Int. J. Fatigue
, 135
, p. 105555
. 8.
Yuan
, D.
, Cui
, C.
, Zhang
, Q.
, Li
, Z.
, and Ye
, Z.
, 2022
, “Fatigue Damage Evaluation of Welded Joints in Steel Bridge Based on Meso-Damage Mechanics
,” Int. J. Fatigue
, 161
, p. 106898
. 9.
Wu
, S. C.
, Yu
, C.
, Zhang
, W. H.
, Fu
, Y. N.
, and Helfen
, L.
, 2015
, “Porosity Induced Fatigue Damage of Laser Welded 7075-T6 Joints Investigated via Synchrotron X-ray Microtomography
,” Sci. Technol. Weld. Join.
, 20
(1
), pp. 11
–19
. 10.
Mahto
, R. P.
, Kumar
, R.
, and Pal
, S. K.
, 2020
, “Characterizations of Weld Defects, Intermetallic Compounds and Mechanical Properties of Friction Stir Lap Welded Dissimilar Alloys
,” Mater. Charact.
, 160
, p. 110115
. 11.
Dezecot
, S.
, Maurel
, V.
, Buffiere
, J.-Y.
, Szmytka
, F.
, and Koster
, A.
, 2017
, “3D Characterization and Modeling of Low Cycle Fatigue Damage Mechanisms at High Temperature in a Cast Aluminum Alloy
,” Acta Mater.
, 123
(16
), pp. 24
–34
. 12.
Li
, Z.
, Limodin
, N.
, Tandjaoui
, A.
, Quaegebeur
, P.
, Witz
, J.-F.
, and Balloy
, D.
, 2020
, “In-Situ 3D Characterization of Tensile Damage Mechanisms in A319 Aluminium Alloy Using X-Ray Tomography and Digital Volume Correlation
,” Mater. Sci. Eng. A
, 794
, p. 139920
. 13.
Xu
, S.
, Chen
, H.
, Yang
, Y. L.
, and Gao
, K.
, 2020
, “Fatigue Damage of Aluminum Alloy Spot-Welded Joint Based on Defects Reconstruction
,” ASME J. Eng. Mater. Technol.
, 142
(2
), p. 021001
. 14.
Li
, P.
, Lee
, P. D.
, Maijer
, D. M.
, and Lindley
, T. C.
, 2009
, “Quantification of the Interaction Within Defect Populations on Fatigue Behavior in an Aluminum Alloy
,” Acta Mater.
, 57
(12
), pp. 3539
–3548
. 15.
Bao
, Y. Q.
, Yang
, Y. L.
, Chen
, H.
, Li
, Y. F.
, Shen
, J.
, and Yang
, S. W.
, 2019
, “Multiscale Damage Evolution Analysis of Aluminum Alloy Based on Defect Visualization
,” Appl. Sci.-Basel
, 9
(23
), p. 5251
. 16.
Ben Ahmed
, A.
, Nasr
, A.
, and Fathallah
, R.
, 2017
, “Probabilistic High Cycle Fatigue Behavior Prediction of A356-T6 Alloy Considering the SDAS Dispersion
,” Int. J. Adv. Manuf. Technol.
, 90
(9–12
), pp. 3275
–3288
. 17.
Gao
, Y. X.
, Yi
, J. Z.
, Lee
, P. D.
, and Lindley
, T. C.
, 2004
, “A Micro-Cell Model of the Effect of Microstructure and Defects on Fatigue Resistance in Cast Aluminum Alloys
,” Acta Mater.
, 52
(19
), pp. 5435
–5449
. 18.
Nadot
, Y.
, and Billaudeau
, T.
, 2006
, “Multiaxial Fatigue Limit Criterion for Defective Materials
,” Eng. Fract. Mech.
, 73
(1
), pp. 112
–133
. 19.
Zhang
, W.
, Jing
, H.
, Xu
, L.
, Zhao
, L.
, Han
, Y.
, and Li
, C.
, 2015
, “Numerical Investigation of Creep Crack Initiation in P92 Steel Pipes With Embedded Spherical Defects Under Internal Pressure at 650 Degrees C
,” Eng. Fract. Mech.
, 140
, pp. 40
–55
. 20.
Le
, V. D.
, Saintier
, N.
, Morel
, F.
, Bellett
, D.
, and Osmond
, P.
, 2018
, “Investigation of the Effect of Porosity on the High Cycle Fatigue Behaviour of Cast Al-Si Alloy by X-Ray Micro-Tomography
,” Int. J. Fatigue
, 106
, pp. 24
–37
. 21.
Nadot
, Y.
, Nadot-Martin
, C.
, Kan
, W. H.
, Boufadene
, S.
, Foley
, M.
, Cairney
, J.
, Proust
, G.
, and Ridosz
, L.
, 2020
, “Predicting the Fatigue Life of an AlSi10Mg Alloy Manufactured via Laser Powder Bed Fusion by Using Data From Computed Tomography
,” Addit. Manuf.
, 32
, p. 100899
. 22.
Chen
, H.
, Yang
, Y. L.
, Cao
, S. L.
, Gao
, K.
, Xu
, S.
, Li
, Y. F.
, and Zhang
, R. P.
, 2021
, “Fatigue Life Prediction of Aluminum Alloy 6061 Based on Defects Analysis
,” Int. J. Fatigue
, 147
, p. 106189
. 23.
Taxer
, T.
, Schwarz
, C.
, Smarsly
, W.
, and Werner
, E.
, 2013
, “A Finite Element Approach to Study the Influence of Cast Pores on the Mechanical Properties of the Ni-Base Alloy MAR-M247
,” Mater. Sci. Eng. A
, 575
, pp. 144
–151
. 24.
Wu
, Z. K.
, Wu
, S. C.
, Bao
, J. G.
, Qian
, W. J.
, Karabal
, S.
, Sun
, W.
, and Withers
, P. J.
, 2021
, “The Effect of Defect Population on the Anisotropic Fatigue Resistance of AlSi10Mg Alloy Fabricated by Laser Powder Bed Fusion
,” Int. J. Fatigue
, 151
, p. 106317
. 25.
Tammas-Williams
, S.
, Withers
, P. J.
, Todd
, I.
, and Prangnell
, P. B.
, 2017
, “The Influence of Porosity on Fatigue Crack Initiation in Additively Manufactured Titanium Components
,” Sci. Rep.
, 7
(1
), p. 7308
. 26.
Peng
, X.
, Wu
, S.
, Qian
, W.
, Bao
, J.
, Hu
, Y.
, Zhan
, Z.
, Guo
, G.
, and Withers
, P. J.
, 2022
, “The Potency of Defects on Fatigue of Additively Manufactured Metals
,” Int. J. Mech. Sci.
, 221
, p. 107185
. 27.
Romano
, S.
, Brandao
, A.
, Gumpinger
, J.
, Gschweitl
, M.
, and Beretta
, S.
, 2017
, “Qualification of AM Parts: Extreme Value Statistics Applied to Tomographic Measurements
,” Mater. Des.
, 131
, pp. 32
–48
. 28.
Evdokimov
, A.
, Springer
, K.
, Doynov
, N.
, Ossenbrink
, R.
, and Michailov
, V.
, 2017
, “Heat Source Model for Laser Beam Welding of Steel-Aluminum Lap Joints
,” Int. J. Adv. Manuf. Technol.
, 93
(1–4
), pp. 709
–716
. 29.
Hynes
, N. R. J.
, and Velu
, P. S.
, 2017
, “Simulation of Friction Welding of Alumina and Steel With Aluminum Interlayer
,” Int. J. Adv. Manuf. Technol.
, 93
(1–4
), pp. 121
–127
. 30.
Kimthong
, P.
, Wattanapornphan
, P.
, Phongphisutthinan
, C.
, and Uthaisangsuk
, V.
, 2021
, “Experimental Investigations and FE Modeling Considering Microstructural Inhomogeneity of Laser Welded Steel-Aluminum Joints
,” Arch. Civ. Mech. Eng.
, 22
(1
), pp. 1
–31
. 31.
Gao
, K.
, Zhang
, S.
, Mondal
, M.
, Basak
, S.
, Hong
, S.-T.
, and Shim
, H.
, 2021
, “Friction Stir Spot Butt Welding of Dissimilar S45C Steel and 6061-T6 Aluminum Alloy
,” Metals
, 11
(8
), p. 1252
. 32.
Arghavani
, M. R.
, Movahedi
, M.
, and Kokabi
, A. H.
, 2016
, “Role of Zinc Layer in Resistance Spot Welding of Aluminium to Steel
,” Mater. Des.
, 102
, pp. 106
–114
. 33.
Suzuki
, S.
, and Abe
, K.
, 1985
, “Topological Structural Analysis of Digitized Binary Images by Border Following
,” Comput. Vis. Graph. Image Process.
, 30
(1
), pp. 32
–46
. 34.
Douglas
, D. H.
, and Peucker
, T. K.
, 1973
, “Algorithms for the Reduction of the Number of Points Required to Represent a Digitized Line or Its Caricature
,” Cartographica: Int. J. Geogr. Inf. Geovis.
, 10
(2
), pp. 112
–122
. 35.
Liu
, X.-G.
, Guo
, H.-D.
, Wang
, B.-Z.
, Li
, J.-W.
, and Wu
, B.
, 2011
, “Study on High Cycle Fatigue Fractal Damage Model of TC11 Alloy Welded Joint
,” Hangkong Dongli Xuebao/J. Aerosp. Power
, 26
(2
), pp. 355
–361
. Copyright © 2023 by ASME
You do not currently have access to this content.
