CHARACTERISATION AND FATIGUE OF FRICTION STIR WELDING

Authors

  • Aidy Ali Department of Mechanical and Manufacturing Engineering, University Putra Malaysia, 43400 Serdang, Selangor, Malaysia
  • Omar Suliman Zaroog Department of Mechanical and Manufacturing Engineering, University Putra Malaysia, 43400 Serdang, Selangor, Malaysia

Keywords:

Friction stir welding (FSW), fatigue

Abstract

Previous attempts on the characterisation of Friction Stir Welding (FSW) based on microstructures,hardness, and residual stress distribution have been reviewed. The role of these parameters on fatiguedamage of FSW is then discussed. Relevant conclusions have been drawn to demonstrate the currentissues and the future research potential of these joints.

References

Beghini, M., Bertini, L., and Vitale, E. (1994).Fatigue crack growth in residual stressfields: experimental results and modelling.Fatigue Fract. Eng. Mater. Struct.,17(12):1,433-1,444.

Benavides, S., Li, Y., Murr, L.E., Brown, D., andMcClure, J.C. (1999). Low temperaturefriction stir welding of 2024 aluminium.Scr. Mater., 41(8):809-815.

Booth, D. and Sinclair, I. (2002). Fatigue offriction stir welded 2024-T351 Al-alloy.Mater. Sci. Forum, 396-402:1,671-1,676.

Bussu, G. (2000). Damage tolerance of weldedaluminum aircraft structure, [PhD. thesis].Engineering Faculty, Cranfield University,UK, 287p.

Bussu, G. and Irving, P.E. (2001). Damagetolerance of welded aluminium aircraftstructures. ICAF Design for Durability inthe Digital Age. Proceedings of the 21stSymposium of the International Committeeon Aeronautical Fatigue; June 27-29,2001; Toulouse, France, p. 331-350.

Bussu, G. and Irving, P.E. (2003). The role ofresidual stress and heat affected zoneproperties on fatigue crack propagation infriction stir welded 2024-T351 Aluminumjoints. Int. J. Fatigue, 25:77-88.

Coffin, L.F. (1950.). The flow and fracture of abrittle material. J. Appl. Mech., 17: 233-248.

Dalle Donne, C. and Biallas, G. (1999). Fatigueand fracture performance of friction stirwelded 2024-T3. Proceedings of theEuropean Conference on SpacecraftStructure, Material and Mechanical Testing;November 4-6, 1998; Braunschweig,Germany. 428:309-314.

Dalle Donne, C., Biallas, G., Ghidini, T., andRaimbeaux, G. (2000). Effect of weldimperfections and residual stresses on thefatigue crack propagation in friction stirwelded joints. Proceedings of the 2ndInternational Conference on Friction StirWelding; June 26-28, 2000; Gothenburg,Sweeden, 289p.

Dalle Donne, C., Lima, E., Wegener, J., Pyzalla,A., and Buslaps, T. (2001). Investigationon residual stress in friction stir welds.Proceedings of the 3rd InternationalSymposium on Friction Stir Welding;September 27-28, 2001; Kobe, Japan. TWI(UK), p. 281-291.

Dawes, C.J. (1995). An introduction to frictionstir welding and its development. Weldingand Metal Fabrication, 63(1):13-16.

Dawes, C.J. and Thomas, W.M. (1996). Frictionstir process welds aluminium alloys. Weld.J. (Miami, FL), 75(3):41-45.

de los Rios, E.R. and Navarro, A. (1988).Compact solution for a multizone BCScrack model with bounded or unboundedend conditions. Philos. Mag. A, 57:43-50.

Ericsson, M. and Sandstrom, R. (2000). Fatigueof friction stir welded ALMgSi-alloy 6082.Mater. Sci. Forum, 331-337:1,787-1,792.

Esparza, J.A., Davis, W.C., Trillo, E.A., andMurr, L.E. (2002). Friction stir weldingof magnesium alloy AZ31B. J. Mater. Sci.Lett., 21: 917-920.

Fitzpatrick, M.E. and Edwards, L. (1998). Fatiguecrack residual stress field interactions andtheir implications for damage tolerantdesign. J. Mater. Eng. Perform., 7(2):190-198.

Flores, O.V., Kennedy, C., Murr L.E., Brown, D.,Pappu, S., Nowak, B.M., and McClure,J.C. (1998). Microstructural issues in afriction stir welded aluminum alloy. Scr.Mater., 38 (5):703-708.

Gatolo, R. and Lanciotti, A. (1997). Fatigue crackpropagation in residual stress fields ofwelded plates. Int. J. Fatigue, 19(1):43-49.

Heinz, B., Skrotzki, B., and Eggeler, G. (2000).Microstructural and mechanical characterizationof friction stir welded Al-Alloy.Mater. Sci. Forum, 331-337: 1,757-1,762.

Hobson, P.D., Brown, M.W., and de los Rios,E.R. (1986). Two phases of short crackgrowth in a medium carbon steel. In: TheBehaviour of Short Fatigue Crack. MillerK.J. and de Los Rios E.R. (eds.). mechanicalengineering publication, London, UK,p. 441-459.

Jata, K.V., Sankaran, K.K., and Ruschau, J.J.(2000). Friction stir welding effects onmicrostructure and fatigue of aluminumalloy 7050-T451. Metall. Mater. Trans. A,31(9): 2,181-2,192.

Jata, K.V. (2000). Friction stir welding of highstrength aluminium alloys. Mater.Sci.Forum, 331-337: 1,701-1,712.

Jata, K.V. and Rioja, R.J. (1998). Unpublishedresearch. Air Force Research Laboratory,Material and Manufacturing Directorate,AFRL/MILLLM Wright Patterson Air forceBase, OH, USA.

Kwan, Y.J., Saito, N., and Shigematsu, I. (2002).Friction stir process as a new manufacturingtechnique of ultrafine grainedaluminium alloy. J. Mater. Sci. Lett.,21:1,473-1,476.

Mahoney, M.W., Rhodes, C.G., Flintoff, J.G.,Spurling, R.A., and Bingel, W.H. (1998).Properties of friction stir welded 7075 T651aluminium. Metall. Mater. Trans. A, 29A:1,955-1,964.

Meguid, S.A. and Coufopanos, J.A. (1986).Elasto-plastic finite element study of theeffect of residual stress upon doubleedge-crack plate. Eng. Mater. FractureMechanics, 23: 735-744.

Mendez, P.F. and Eagar, T.W. (2001). Weldingprocesses for aeronautics. Adv. Mater.Processes, 159(5): 39-43.

Miller, K.J., and O’Donnell, W.J. (1999). Thefatigue limit and its elimination. FatigueFract. Eng. Mater. Struct., 22:545-557.

Mohshier, M.A. and Hillberry, B.M. (1999). Theinclusion of compressive residual stresseffects in crack growth modelling. FatigueFract. Eng. Mater. Struct., 22(6):519-526.

Murr, L.E., Li, Y., Trillo, E.A., Flores, R.D., andMcClure, J. C. (1998). Microstructure infriction stir welded metals. J. Mater.Process. Manuf. Sci., 7:145-161.

Navarro, A. and de los Rios, E.R. (1992). Fatiguecrack growth modelling by successiveblocking of dislocations. Proceedings ofthe Royal Society, London, A vol., 437:375-390.

Navarro, A. and de los Rios, E. R. (1988). Amicrostructurally short fatigue crackgrowth equation. Fatigue Fract. Eng. Mater.and Struct., 11(5): 383-396.

Navarro, A., and de los Rios, E.R. (1988). Shortand long fatigue crack growth: A unifiedmodel. Philos. Mag. A, 57: 15-36.

Nicholas, E.D. and Thomas, W.M. (1998).A review of friction processes for aerospaceapplications. Int. J. Mater. Prod.Tech., 13(1-2):45-55.

Oosterkamp, L.D., Webster, P.J., Browne, P.A.,Vaughan, G. B.M., and Withers, P.J. (2000).Residual stress field in a friction stir weldingaluminium extrusion. Mater. Sci. Forum,347-349: 678-683.

Paris, P.C. and Erdogan, F.J. (1963). A criticalanalysis of crack propagation law. Trans.ASME, J. Basic Eng., 85(4): 528-535.

Rhodes, C.G., Mahoney, M.W., and Bingel,W.H. (1997). Effect of friction stir weldingon microstructure of 7075 aluminium.Scr. Materi., 36(1): 69-75.

Sato, Y.S., Park, S.H.C., and Kokawa, H. (2001).Microstructure factors governinghardness in friction stir welds of solidsolution hardened Al alloys. Metall.Mater. Trans. A, 32A,12:3,033-3,042.

Sato, Y.S. and Kokawa, H. (2001). Distribution oftensile property and microstructure infriction stir weld of 6063 aluminum. Metall.Mater. Trans. A, 32A:3,023-3,031.

Schmidt, H.J., Van, C., and Hanson, J. (2001).Tango metallic fuselage barrel validationof advanced technologies. ICAF Designfor Durability in the Digital Age.Proceedings of the 21st Symposium of theInternational Committee on AeronauticalFatigue; June 27-29, 2001; Toulouse,France, p. 273-288.

Strombeck, A., Cam, G., Dos Santos, J.F., Venzke,V., and Kocak, M. (2001). A comparisonbetween microstructure, properties andtoughness behaviour of power beam andfriction stir welds in AL-alloys. Proceedingsof the TMS Annual Meeting, TheMinerals, Metals & Materials Society,p. 249-264.

Sun, W. and Sehitoglu, H. (1992). Residual stressfields during fatigue crack growth. FatigueFract. Eng. Mater. Struct., 15(2):115-128.

Suresh, S. (1998). Fatigue of Materials. 2nd ed.Cambridge University Press, Cambridge,UK, 187p.

Sutton, M.A., Yang, B., Reynolds, A.P., andTaylor, R. (2002). Microstructural studiesof friction stir welds in 2024-T3 aluminum.Mater. Sci. Eng., A, 323:160-166.

Thomas, W.M., Nicholas, E.D., Watts, E.R., andStaines, D.G. (2002). Friction basedwelding technology for aluminium. Mater.Sci. Forum, 396-402(3):1,543-1,548.

Tomkins, B. (1981). High strain fatigue. In: ISPRACourses on Mechanical Science andMaterials. Larsson, L.H. (ed.). Elsevier,London, UK, p. 239-273.

Ulysse, P. (2002). Three-dimensional modellingof the friction stir-welding process. Int. J.Mach. Tool Manufact., 42:1,549-1,557.

Wang, H., Buchholz, F.G., Richard, H.A., Jagg, S.,and Scholtes, B. (1999). Numerical andexperimental analysis of residual stress forfatigue crack growth. Comput. Mater. Sci.,16:104-112.

Webster, P.J., Oosterkamp, L.D., Browne, P.A.,Hughes, D.J., Kang, W.P., Withers, P.J., andVaughan, G.B.M. (2001). SynchrotronX-ray residual strain scanning of a frictionstir weld. The Journal of Strain Analysisfor Engineering design, 36(1):61-70.

Weertman, J. (1979). Fatigue crack propagationtheories. In: Fatigue and Microstructure.ASM Publications, Materials Park, OH,USA, p. 279-306.

Williams, S.W. (2001). Welding airframes usingfriction stir. Air and Space Europe, 3:64-66.

Downloads

Published

2026-08-27

How to Cite

Ali, A., & Suliman Zaroog, O. (2026). CHARACTERISATION AND FATIGUE OF FRICTION STIR WELDING. Suranaree Journal of Science and Technology, 15(2), 95–106. retrieved from https://ph04.tci-thaijo.org/index.php/SUJST/article/view/13392

Issue

Section

Research Article