Synchrotron diffraction measurement of residual stresses in friction stir welded 5383-H321 aluminium butt joints and their modification by fatigue cycling

Abstract

This paper presents two-dimensional information on the residual stresses in 8 mm 5383-H321 aluminium plates joined by double pass (DP) friction stir welding (FSW). It considers the inherent variability in residual stress magnitudes along 0.5 m lengths of weld pass, and their modification under a sequence of applied fatigue loads. This represents one of a planned series of experiments aimed at illuminating the effects of fatigue cycling on residual stress fields. In this particular case, the magnitudes of the bending fatigue loads (R = 0.1) were chosen to correlate with the measured proof strengths of the weld metal (approximately 160 MPa) and the parent plate (approximately 260-270 MPa). In four-point bend S-N tests at R = 0.1 on 40 mm wide FS welded specimens of this alloy and plate thickness, these peak stress levels correspond to lives of around 105 cycles and 107 cycles, respectively. Results from the work indicate that significant variability exists among welded plates in peak compressive stress magnitudes (a range of perhaps - 50 MPa to -140 MPa), although peak tensile stresses were relatively low and more consistent (from around 0 to 30 MPa). Fatigue loading accentuates the peak-to-valley stress change and causes an overall translation of the stresses to become more positive. Peak tensile stresses increase several-fold during fatigue cycling.