Fatigue and Fracture Behavior of Joining Methods for Lightweight and High Strength Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (30 November 2018) | Viewed by 10555

Special Issue Editor

School of Engineering and Computer Science, Baylor University, Waco, TX, USA
Interests: fatigue; fracture; welding: joining; solid-state additive manufacturing; mechanical properties; microstructure characterization

Special Issue Information

Dear Colleagues,

The recent push for lightweight and high-strength materials has put renewed interest on joining technologies. Traditional welding and joining methods face significant barriers in joining new materials with advanced physical and mechanical properties. As such, this Special Issue will focus on advancements in the field of fatigue and fracture behavior of joining methods. This special issue will provide a platform intended to present the state-of-the art regarding development of modeling techniques and novel experimental quantification of failure behavior of advanced welding and joining methods. Modeling and experimental studies on the fatigue and fracture of the following are welcome, though the topics are not limited to what follows:

  • Friction stir welding and processing 

  • Fusion welding 

  • Riveting
  • Fasteners 

  • Hybrid joining 

  • Brazing 

  • Mixed-metal joining 

  • Metal-composite joining
  • Additive manufacturing repair 

Prof. J. Brian Jordon
Guest Editor

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Keywords

  • friction stir welding
  • resistance spot welding
  • self-pierce riveting
  • brazing
  • dissimilar metal welding
  • fatigue
  • fracture

Published Papers (3 papers)

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Research

9 pages, 2149 KiB  
Article
Structural Stress Method to Evaluate Fatigue Properties of Similar and Dissimilar Self-Piercing Riveted Joints
by Harish M. Rao, Jidong Kang, Garret Huff and Katherine Avery
Metals 2019, 9(3), 359; https://doi.org/10.3390/met9030359 - 20 Mar 2019
Cited by 4 | Viewed by 3547
Abstract
In this paper, we discuss the application of a simple Battelle structural stress model to evaluate the fatigue life of a self-piercing riveted (SPR) carbon-fiber-reinforced polymer (CFRP) composite to aluminum AA6111. The analytical model accounts for the forces and moments acting on the [...] Read more.
In this paper, we discuss the application of a simple Battelle structural stress model to evaluate the fatigue life of a self-piercing riveted (SPR) carbon-fiber-reinforced polymer (CFRP) composite to aluminum AA6111. The analytical model accounts for the forces and moments acting on the rivets to determine the structural stresses which were then plotted against the laboratory-generated fatigue life data. The master S-N curve determined in this study thus accounts for various factors such as the stacking configuration, rivet head height, and fatigue load ratios. The analytical model used in this study was able to collapse a large number of fatigue life data into one master S-N curve irrespective of stack-ups, rivet head height, and load ratios. Thus, the master S-N curve derived from the model can be used to predict the fatigue life of the SPR joints. Full article
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20 pages, 13762 KiB  
Article
Experiments and Modeling of Fatigue Behavior of Friction Stir Welded Aluminum Lithium Alloy
by Abby R. Cisko, James B. Jordon, Dustin Z. Avery, Tian Liu, Luke N. Brewer, Paul G. Allison, Ricolindo L. Carino, Youssef Hammi, Timothy W. Rushing and Lyan Garcia
Metals 2019, 9(3), 293; https://doi.org/10.3390/met9030293 - 05 Mar 2019
Cited by 17 | Viewed by 3911
Abstract
An extensive experimental and computational investigation of the fatigue behavior of friction stir welding (FSW) of aluminum–lithium alloy (AA2099) is presented. In this study, friction stir butt welds were created by joining AA2099 using two different welding parameter sets. After FSW, microstructure characterization [...] Read more.
An extensive experimental and computational investigation of the fatigue behavior of friction stir welding (FSW) of aluminum–lithium alloy (AA2099) is presented. In this study, friction stir butt welds were created by joining AA2099 using two different welding parameter sets. After FSW, microstructure characterization was carried out using microhardness testing, scanning electron microscopy, and transmission electron microscopy techniques. In particular, the metastable strengthening precipitates T1 (Al2CuLi) and δ’(Al3Li) seen in the base metal were observed to coarsen and dissolve due to the FSW process. In order to evaluate the static and fatigue behavior of the FSW of the AA2099, monotonic tensile and fully-reversed strain-controlled fatigue testing were performed. Mechanical testing of the FSW specimens found a decrease in the ultimate tensile strength and fatigue life compared to the base metal. While the process parameters had an effect on the monotonic properties, no significant difference was observed in the number of cycles to failure between the FSW parameters explored in this study. Furthermore, post-mortem fractography analysis of the FSW specimens displayed crack deflection, transgranular fracture, and delamination failure features commonly observed in other parent Al–Li alloys. Lastly, a microstructurally-sensitive fatigue model was used to elucidate the influence of the FSW process on fatigue life based on variations in grain size, microhardness, and particle size in the AA2099 FSW. Full article
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12 pages, 31064 KiB  
Article
Microstructure and Fracture Behavior of Refill Friction Stir Spot Welded Joints of AA2024 Using a Novel Refill Technique
by Lipeng Deng, Shuhan Li, Liming Ke, Jinhe Liu and Jidong Kang
Metals 2019, 9(3), 286; https://doi.org/10.3390/met9030286 - 03 Mar 2019
Cited by 10 | Viewed by 2683
Abstract
Keyhole at the end of a conventional friction stir welded (FSW) joint is one of the major concerns in certain applications. To address this issue, a novel keyhole refilling technique was developed for conventional friction stir spot welding (FSSW) using resistance spot welding [...] Read more.
Keyhole at the end of a conventional friction stir welded (FSW) joint is one of the major concerns in certain applications. To address this issue, a novel keyhole refilling technique was developed for conventional friction stir spot welding (FSSW) using resistance spot welding (RSW). A three-phase secondary rectifier resistance welder was adapted for the refill of the keyhole in the 1.5 mm + 1.5 mm friction stir spot welded 2024-T4 aluminum alloy joint. The microstructure and tensile shear fracture behavior were compared for both the unfilled and refilled specimens. The results show that the plug and keyhole are dominated by solid state welding with some localized zones by fusion welding. The refill process significantly improved the maximum load capacity in tensile shear testing as the corona ring is enlarged leading to a larger bonding area. Moreover, the tensile shear fracture occurs in the refilled FSSW specimens at the corona bonding zone, while the fracture occurs at the hook zone in the unfilled keyhole. Full article
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