Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding
Refill friction stir spot welding is a promising joining process in lightweight design. As lightweight structures react sensitively to cyclic loads, the fatigue life of the joints are of particular interest. In previous studies, attempts have been made to optimize the fatigue properties based on pro...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S223878542500715X |
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| author | Niklaas Becker Daniel Kuhn Jan Piochowiak Benjamin Klusemann |
| author_facet | Niklaas Becker Daniel Kuhn Jan Piochowiak Benjamin Klusemann |
| author_sort | Niklaas Becker |
| collection | DOAJ |
| description | Refill friction stir spot welding is a promising joining process in lightweight design. As lightweight structures react sensitively to cyclic loads, the fatigue life of the joints are of particular interest. In previous studies, attempts have been made to optimize the fatigue properties based on process parameter modification albeit with moderate success. The introduction of post-processing steps such as laser-shock or hammer peening resulted in an improvement but also in a considerable higher effort. In this work, a new approach is pursued, namely to increase the fatigue life properties by manipulating the residual stresses already during the welding process. This is achieved by milling a pocket into one of the joining surfaces prior to the welding process. The pocket and the clamping forces that occur during the welding process cause an elongation of the material. After releasing the clamping force, the elastic springback effect causes compressive forces, leading to compressive residual stresses in the spot weld. This has made it possible to increase the endurance limit for shear-loaded samples by a factor of 40 and for cross-tension-loaded samples by a factor of 18. |
| format | Article |
| id | doaj-art-77c76aa2db9c42ceb5c33a3954cc7b00 |
| institution | OA Journals |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-77c76aa2db9c42ceb5c33a3954cc7b002025-08-20T02:25:35ZengElsevierJournal of Materials Research and Technology2238-78542025-05-01362951295910.1016/j.jmrt.2025.03.205Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot weldingNiklaas Becker0Daniel Kuhn1Jan Piochowiak2Benjamin Klusemann3Helmholtz-Zentrum Hereon, Institute of Materials Mechanics, Solid State Materials Processing, Max–Planck-Straße 1, 21502 Geesthacht, Germany; Corresponding author.Siemens Mobility GmbH, Duisburger Straße 145, 47829 Krefeld, GermanySiemens Mobility GmbH, Duisburger Straße 145, 47829 Krefeld, GermanyHelmholtz-Zentrum Hereon, Institute of Materials Mechanics, Solid State Materials Processing, Max–Planck-Straße 1, 21502 Geesthacht, Germany; Leuphana University of Lüneburg, Institute for Production Technology and Systems, Universitätsallee 1, 21335 Lüneburg, GermanyRefill friction stir spot welding is a promising joining process in lightweight design. As lightweight structures react sensitively to cyclic loads, the fatigue life of the joints are of particular interest. In previous studies, attempts have been made to optimize the fatigue properties based on process parameter modification albeit with moderate success. The introduction of post-processing steps such as laser-shock or hammer peening resulted in an improvement but also in a considerable higher effort. In this work, a new approach is pursued, namely to increase the fatigue life properties by manipulating the residual stresses already during the welding process. This is achieved by milling a pocket into one of the joining surfaces prior to the welding process. The pocket and the clamping forces that occur during the welding process cause an elongation of the material. After releasing the clamping force, the elastic springback effect causes compressive forces, leading to compressive residual stresses in the spot weld. This has made it possible to increase the endurance limit for shear-loaded samples by a factor of 40 and for cross-tension-loaded samples by a factor of 18.http://www.sciencedirect.com/science/article/pii/S223878542500715XRefill friction stir spot weldingFatigue lifeResidual stressAA6005A-T6 |
| spellingShingle | Niklaas Becker Daniel Kuhn Jan Piochowiak Benjamin Klusemann Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding Journal of Materials Research and Technology Refill friction stir spot welding Fatigue life Residual stress AA6005A-T6 |
| title | Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding |
| title_full | Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding |
| title_fullStr | Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding |
| title_full_unstemmed | Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding |
| title_short | Fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding |
| title_sort | fatigue life enhancement via residual stress engineering due to local forming during refill friction stir spot welding |
| topic | Refill friction stir spot welding Fatigue life Residual stress AA6005A-T6 |
| url | http://www.sciencedirect.com/science/article/pii/S223878542500715X |
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