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Failure modes and fatigue life estimations of spot friction welds in cross-tension specimens of aluminum 6061-T6 sheets
Affiliation:1. Department of Mechanical & Aerospace Engineering, University of Strathclyde, James Weir Building, 75 Montrose Street, Glasgow G1 1XJ, United Kingdom;2. TWI Ltd., Granta Park, Cambridge CB21 6AL, United Kingdom;3. TWI Technology Centre, Wallis Way, Catcliff, Rotherham, S60 5TZ, United Kingdom;1. Weidlinger Applied Science, Thornton Tomasetti, Inc., New York, NY, United States;2. Survivability, Structures, Materials, and Environmental Department, Naval Surface Warfare Center Carderock Division, West Bethesda, MD, United States;3. School of Engineering and Applied Sciences, Harvard University, Cambridge, MA, United States;1. State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China;2. Shandong Provincial Key Laboratory of Special Welding Technology, Harbin Institute of Technology at Weihai, Weihai 264209, China
Abstract:Failure modes of spot friction welds (SFWs) in cross-tension specimens of aluminum 6061-T6 sheets are investigated. Micrographs of the SFWs before and after failure under quasi-static and cyclic loading conditions are examined. Two different nugget pullout failure modes can be seen. A fatigue crack growth model based on the paths of the dominant kinked fatigue cracks is adopted to estimate the fatigue lives of SFWs. The computational stress intensity factors for finite kinked cracks and the Paris law for fatigue crack propagation are considered. The fatigue life estimations based on this model agree well with the experimental results.
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