TY - JOUR
T1 - Multiple Crack Growth Prediction in AA2024-T3 Friction Stir Welded Joints, Including Manufacturing Effects
AU - Carlone, Pierpaolo
AU - Citarella, Roberto
AU - Sonne, Mads Rostgaard
AU - Hattel, Jesper Henri
PY - 2016
Y1 - 2016
N2 - A great deal of attention is currently paid by several industries toward the friction stir welding process to realize lightweight structures. Within this aim, the realistic prediction of fatigue behavior of welded assemblies is a key factor. In this work an integrated finite element method - dual boundary element method (FEM-DBEM) procedure, coupling the welding process simulation to the subsequent crack growth assessment, is proposed and applied to simulate multiple crack propagation, with allowance for manufacturing effects. The friction stir butt welding process of the precipitation hardened AA2024-T3 alloy was simulated using a thermo-mechanical FEM model to predict the process induced residual stress field and material softening. The computed stress field was transferred to a DBEM environment and superimposed to the stress field produced by a remote fatigue traction load applied on a notched specimen. The whole procedure was finally tested comparing simulation outcomes with experimental data. The good agreement obtained highlights the predictive capability of the method. The influence of the residual stress distribution on crack growth and the mutual interaction between propagating cracks were analyzed as well.
AB - A great deal of attention is currently paid by several industries toward the friction stir welding process to realize lightweight structures. Within this aim, the realistic prediction of fatigue behavior of welded assemblies is a key factor. In this work an integrated finite element method - dual boundary element method (FEM-DBEM) procedure, coupling the welding process simulation to the subsequent crack growth assessment, is proposed and applied to simulate multiple crack propagation, with allowance for manufacturing effects. The friction stir butt welding process of the precipitation hardened AA2024-T3 alloy was simulated using a thermo-mechanical FEM model to predict the process induced residual stress field and material softening. The computed stress field was transferred to a DBEM environment and superimposed to the stress field produced by a remote fatigue traction load applied on a notched specimen. The whole procedure was finally tested comparing simulation outcomes with experimental data. The good agreement obtained highlights the predictive capability of the method. The influence of the residual stress distribution on crack growth and the mutual interaction between propagating cracks were analyzed as well.
KW - Friction Stir Welding
KW - Residual Stress
KW - Crack propagation
KW - FEM
KW - DBEM
U2 - 10.1016/j.ijfatigue.2016.04.004
DO - 10.1016/j.ijfatigue.2016.04.004
M3 - Journal article
SN - 0142-1123
VL - 90
SP - 69
EP - 77
JO - International Journal of Fatigue
JF - International Journal of Fatigue
ER -