SIMULATION OF FATIGUE CRACK GROWTH IN FRICTION STIR WELDED JOINTS IN 2024-T351 AL ALLOY

Authors

  • Amirreza Fahim Golestaneh Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, University Putra Malaysia, 43400 Serdang, Selangor, Malaysia
  • Aidy Ali Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, University Putra Malaysia, 43400 Serdang, Selangor, Malaysia.
  • Wong Shaw Voon Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, University Putra Malaysia, 43400 Serdang, Selangor, Malaysia.
  • Faizal Mustapha Department of Aerospace Engineering, Faculty of Engineering, University Putra Malaysia, 43400 Serdang, Selangor, Malaysia.
  • Mehdi Zadeh Mohammadi Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, University Putra Malaysia, 43400 Serdang, Selangor, Malaysia.

Keywords:

Simulation, finite element method, fatigue crack growth, Paris model, friction stir welding

Abstract

The aim of the present work is to predict the fatigue life of friction stir welded joints in 2024-T351 Alalloy using the finite element method in the framework of fracture analysis code for two-dimensions(FRANC2D/L). The simulation was conducted under linear elastic fracture mechanics, based on Paris’model and maximum tensile stress and displacement correlation methods were applied to calculate thecrack direction and stress intensity factor, respectively. One strategy has been presented, how crackpropagation was investigated based on the corresponding Paris constants for each FSW zone. Numericalresults were validated with experimental and analytical work.

References

Ali, A., Brown, M.W., and Rodopoulous, C.A.(2008). Modeling of crack coalescence in2024-T351 Al alloy friction stir weldedjoints. Int J Fatigue, 30:2,030-2,043.

Ali, A., Brown, M.W., Rodopoulos, C.A., andGardiner, S. (2006). Characterization of2024-T351 friction stir welding joints. JFailure Anal Prevent, 6(4):41-53.

Alizadeh, H., Simandjutak, S., Smith, D., andPavier, M. (2007). Prediction of fatiguecrack growth rates using crack closurefinite element analysis. Int. J. Fatigue, 29:1,711-1,715.

Barlow, K.W. and Chandra, R. (2005). Fatiguecrack propagation simulation in an aircraftengine fan blade attachment. Int. J. Fatigue,27:1,661-1,668.

Bowness, D. and Lee, M. (1998). Fatigue crackcurvature under the weld toe in an offshoretubular joint. Int. J. Fatigue, 20:481-490.

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.

Corbin, S.F. and Wilkinson, D.S. (1993). Influenceof matrix strength and damage accumulationon the mechanical response of aparticulate metal matrix composite. ActaMetall. Mater, 42(4):1,329-1,335.

Cosenza, C., Fratini, L., Pasta, A., and Micari,F. (2004). Damage and fracture study ofcold extrusion dies. Eng. Fract. Mech., 71:1,021-1,033.

Dusicka, P., Itani, A.M., and Buckle, I.G. (2007).Cyclic response of plate steels under largeinelastic strains. J. Constr. Steel Res., 63:156-164.

Elber, W. (1974). Effect of shot-peening residualstresses on the fracture and crack-growthproperties of D6AC steel. Fracture Toughnessand Slow-Stable Cracking, ASTM STP,559:45-58.

Fersini, D. and Parondi, A. (2007). Fatigue behaviorof Al 2024-T3 friction stir weldedlap joint. Eng. Fract. Mech., 74:468-480.

Fratinia, L., and Zuccarellob, B. (2006). Ananalysis of through-thickness residualstresses in aluminum FSW butt joints. Int.J. Mach. Tool Manu, 46:611-619.

Fulland, M., Sander, M., Kullmer, G., and Richard,H.A. (2008). Analysis of fatigue crackpropagation in the frame of a hydraulicpress. Eng. Fract. Mech., 75:892-900.

Grestle, W. (1986). Finite and boundary elementmodeling of crack propagation in two- andthree-dimensions using interactive computergraphics. Cornell University.

Ingraffea, A.R., Blandford, G., and Liggett, J.A.(1987). Automatic modeling of mixed-modefatigue and quasi-static crack propagationusing the boundary element method. 4thNational Symposium on Fracture, ASTMSTP.

Lie, S., Xiang, Z., Wang, B., and Cen, Z. (2000).Experimental and numerical simulation of3D fatigue crack for plate-to-plate weldedjoints. Int. J. Fatigue, 22:411-424.

Lomolinoa, S., Tovob, R., and dos Santos, J.(2005). On the fatigue behavior and designcurves of friction stir butt-welded Alalloys. Int. J. Fatigue, 27:305-316.

Ragab, A-R.A.F., and Bayoumi, S.E.A. (1999).Engineering solid mechanics: fundamentRagab, A-R.A.F., and Bayoumi, S.E.A. (1999).Engineering solid mechanics: fundamentalsand applications. 2ed: Boca Raton,Fl.: CRC Press.

Rodopoulos, C.A., Romero, J.S., Curtis, S.A.,de los Rios, E.R., and Peyre, P. (2003).Effect of controlled shot peening andlaser shock peening on the fatigue performanceof 2024-T351 aluminum alloy.JMEPEG, 12:414-419.

Scialpi, A., de Filippis, L.A.C., and Cavaliere,P. (2007). Influence of shoulder geometryon microstructure and mechanicalproperties of friction stir welded 6082aluminum alloy. Mater Design, 28:1,124-1,129.

Simandjutak, S., Alizadeh, H., Smith, D.J., andPavier, M.J. (2006). Three dimensionalfinite element prediction of crack closureand fatigue crack growth rate for a cornercrack. Int. J. Fatigue, 28:335-345.

Tanaka, K. Fatigue crack propaagtion from acrack inclined to the cyclic tensile axis.(1974). Eng. Fract. Mech., 6:493-507.

Wang, H., Buchholz, F.G., Richard, H.A., Jagg,S., and Scholtes, B. (1999). Numerical andexperimental analysis of residual stressesfor fatigue crack growth. Comp. MaterSci., 16:104-112.

Xiang, Z., Lie, S.T., Wang, B., and Cen, Z.(2003). A simulation of fatigue crackpropagation in a welded T-joint using 3Dboundary element method. Int. J. Pre.sVes. Pip., 80:111-120.

Yan, X. (2007). Automated simulation of fatiguecrack propagation for two-dimensionallinear elastic fracture mechanics problemsby boundary element method. Eng. Fract.Mech., 74:2,225-2,246.

Zhang, X., Chan, A.S.L., and Davies, G.A.O.(1992). Numerical simulation of fatiguecrack growth under complex loadingsequences. Eng. Fract. Mech., 42:305-321.

Downloads

Published

2026-08-27

How to Cite

Fahim Golestaneh, A., Ali, A., Shaw Voon, W., Mustapha, F., & Zadeh Mohammadi, M. (2026). SIMULATION OF FATIGUE CRACK GROWTH IN FRICTION STIR WELDED JOINTS IN 2024-T351 AL ALLOY. Suranaree Journal of Science and Technology, 15(4), 271–285. retrieved from https://ph04.tci-thaijo.org/index.php/SUJST/article/view/13465

Issue

Section

Research Article