Detailed strain field analyses of fatigue

cracks in friction stir welded joints

ICAF 2009, Rotterdam

H.J.K. Lemmen,
R.C. Alderliesten,
R. Benedictus
Aerospace Structures and Materials, Faculty of Aerospace Engineering

6-7-2009

Delft
University of
Technology

Challenge the future

 Introduction
ICAF 2007: Fatigue crack initiation behaviour of friction stir
welded joints in aluminium alloy
σ∞ Direction of crack growth Hole

Width of
nugget
Fracture

σ∞
Different material flows
Width = 50mm
How affects an FS weld the fatigue crack growth behaviour?

Detailed strain field analyses of fatigue cracks in FS welded joints 2

Contents
• Introduction
• Friction Stir (FS) welding
• Residual stress profiles
• Yield strength profiles
• Fatigue Crack Growth (FCG) test
• Loads & specimen configuration
• Digital Image Correlation (DIC)
• FCG test results
• FCG curves
• Results from DIC
• Conclusions
• Questions

Detailed strain field analyses of fatigue cracks in FS welded joints 3

 Friction Stir Welding
FS welding performed by EADS in Munich

Downward
Welding crown
welding force
Shoulder direction AS RS

Pin Tool rotation HAZ HAZ

TMAZ
L Nugget
LT
root
weld

Advancing Retreating Process parameters: Alloys:

Side (AS) Side (RS) AA2024-T3 AA7075-T6 AA6013-T4
Thickness: 2.5 mm 2.0 mm 1.8 mm
Welding speed: 350 mm/min 300 mm/min 1000 mm/min
Rotational speed: 550 rpm 280 rpm 1500 rpm
Downward force: 19 kN 18 kN 14 kN
Detailed strain field analyses of fatigue cracks in FS welded joints 4
Residual stress profiles in FS welds

Tool shoulder
500
RS Tool Pin AS

400

300 AA7075-T6
stress [MPa]

200

100

AA2024-T3 AA6013-T4
-100
-20 -15 -10 -5 0 5 10 15 20
distance from weld centre [mm]

Residual stresses measured by X-ray diffraction

Detailed strain field analyses of fatigue cracks in FS welded joints 5

Yield strength profiles of FS welds

Tool shoulder
500
RS Tool Pin AS
AA7075-T6
400

300
AA2024-T3
stress [MPa]

200

AA6013-T4
100

-100
-20 -15 -10 -5 0 5 10 15 20
distance from weld centre [mm]

results presented at AIAA/SDM conference 2008

Detailed strain field analyses of fatigue cracks in FS welded joints 6

 FS weld properties & FCG behaviour
yield strength: residual stress: Residual stress
σcrack tip = Kt * σ∞ Profile:
Yield strength profile:
Fatigue σyield, 0.2
crack Undisturbed
plastic zone
Direction of
FS weld
crack growth

σcrack tip

centre
Kt * σ∞

ld
we
σresidual

FS
FCG retardation? ?? FCG Direction in FS weld

Detailed strain field analyses of fatigue cracks in FS welded joints 7

 Fatigue crack growth test
Goal: to repeat and measure the behaviour observed in the FI specimen
Constant amplitude loading; R = 0.1; σa = 60MPa
Three configurations of centre crack FCG test specimen:
0º 45º 90º

LT L LT
AS RS
AS L
a = 2.5mm 2a = 5mm

y
AS
RS
x
y

x
d = 3mm RS

L
y
LT
x

Effect of residual stress Combined effect & Effect of yield strength

Change of FCG direction
Detailed strain field analyses of fatigue cracks in FS welded joints 8
 Digital image correlation
Strains are determined by analysing the images of a test
DIC software has been developed by the author
Images after DIC analyses,
with overlay of strain field
X-Y-Z axes CCT specimen
electronically
controlled rack

Digital
camera

Grid of images

For examples of applications for this DIC tool have a look at the poster presentations of
Mr. Wilson, Mr. Rodi, Mr. Khan, and Mr. Delgrange.

Detailed strain field analyses of fatigue cracks in FS welded joints 9

 Results DIC
Details: alloy = AA2024-T3; 90º configuration; y= 6.5mm;

Centreline FS weld

Centreline FS weld

Centreline FS weld

Detailed strain field analyses of fatigue cracks in FS welded joints 10

 Plastic zone behaviour
550
Y = 6.5 mm AA7075-T6
450

stress [MPa]
350 AA2024-T3
Details:
> AA2024-T3; 250

> 90º conf.; 150 Small butterfly wings AA6013-T4

> y= 6.5mm; -15 -10 -5 0 5
distance from weld centre [mm]
10 15
σ∞

a=6.5mm Weld
σ∞
Crack path centre
a=9mm
a=11mm
Large butterfly wings

Detailed strain field analyses of fatigue cracks in FS welded joints 11

 FCG behaviour 90º conf.

Details: 5.E-03
base AA2024-T3

> AA2024-T3; FS weld, 90º config, spec 1, y = 0.0mm

FS weld, 90º config, spec 2, y = 3.0mm
4.E-03
> 90º conf.; FS weld, 90º config, spec 3, y = 6.5mm
da/dN [mm/cycle]

FS weld, 90º config, spec 4, y = 6.5mm

3.E-03
σ∞

m
m
m m

5
mm 0.0

6.
2.E-03
6.5 e
bas
1.E-03

3.0mm
0.E+00
0 5 10 15 20

σ∞ a [mm]

FCG acceleration
FCG retardation

Detailed strain field analyses of fatigue cracks in FS welded joints 12

 Plastic zone behaviour

Y=3.0mm
Details: Y=0.0mm
> AA2024-T3; base
> 90º conf.;
σ∞

a=5.0mm

a=8.0mm
a=10.5mm
σ∞

Detailed strain field analyses of fatigue cracks in FS welded joints 13

 FCG behaviour 0º configuration

5.E-03
Details:

Tool edge

Weld centre

Weld centre

Tool edge
Tool edge
base AA7075-T6-3, 1 saw cut

> AA7075-T6;
FS welded AA7075-T6; 0º conf; spec 1
4.E-03 FS welded AA7075-T6; 0º conf; spec 2

> 0º conf.;
da/dN [mm/cycle]

σ∞
3.E-03

acceleration
2.E-03

1.E-03 Base material

0.E+00
σ∞ 0 5 10 15 20 25

a [mm] rapid acceleration

retardation

Detailed strain field analyses of fatigue cracks in FS welded joints 14

 FCG behaviour 45º behaviour

Details:
> AA2024-T3;
> 45º conf.;
σ∞

σ∞

Detailed strain field analyses of fatigue cracks in FS welded joints 15

 FCG behaviour 45º behaviour

n
io
ct
Details:

re
di
> AA2024-T3;

ng
di
el
> 45º conf.;

W
σ∞
a=5mm
a=7.5mm

a=20mm
Crack path
a=12mm

σ∞

Tool edge
Weld centre

Detailed strain field analyses of fatigue cracks in FS welded joints 16

 FCG behaviour 45º behaviour
1 2 3 7
4 5 6 8

Details:
> AA7075-T6; Failure after
> 45º conf.; several
centimetres
σ∞

σ∞

Detailed strain field analyses of fatigue cracks in FS welded joints 17

 FCG behaviour 45º behaviour

W Material flows
el
Details: di
ng
in Nugget
> AA7075-T6; di
re
> 45º conf.; W
ct
io
n
el
d
σ∞ ce
nt
re Crack path

To
ol
ed
σ∞ ge

Detailed strain field analyses of fatigue cracks in FS welded joints 18

 FCG behaviour 45º behaviour

Material flows

n
io
ct
in Nugget

re
di
Details:

ng
di
> AA7075-T6;

el
W
> 45º conf.;
σ∞ nt
re
ce

ge
ed
d
el

σ∞
W

Crack path
ol
To

Detailed strain field analyses of fatigue cracks in FS welded joints 19

 Introduction
ICAF 2007: Fatigue crack initiation behaviour of friction stir
welded joints in aluminium alloy
σ∞ Direction of crack growth Hole

Width of
nugget
Fracture

σ∞
Different material flows

How affects an FS weld the fatigue crack growth behaviour?

Detailed strain field analyses of fatigue cracks in FS welded joints 20

Conclusions

• The yield strength affects the FCG rate, depending on the

orientation of the FS weld.

• The residual stresses affect the FCG rate, with the largest effect
found for the 90º configuration

• The micro structure in the nugget of the FS weld provides a path

with low fatigue resistance

• Digital image correlation has a large potential in future research in

fatigue.

Detailed strain field analyses of fatigue cracks in FS welded joints 21

 Questions?

Detailed strain field analyses of fatigue cracks in FS welded joints 22

 FCG behaviour 0º configuration

Details: Weld centre Tool edge

> AA2024-T3; Welding

direction
> 0º conf.;
σ∞ Tool edge

a=5mm

a=7.5mm a=22mm
a=10mm a=15mm
Crack path
σ∞

Detailed strain field analyses of fatigue cracks in FS welded joints 23