Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6
Friction stir welding has demonstrated significant efficacy as a solid-state welding methodology for aluminum alloys, including AA6061-T6, and is extensively utilized within automotive and aerospace engineering domains. Nonetheless, conventional FSW methods often lead to uneven residual stress distr...
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Elsevier
2025-06-01
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| Series: | Journal of Advanced Joining Processes |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666330925000214 |
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| author | Hendrato Muizuddin Azka M.Refai Muslih Rifky Apriansyah Nidya Jullanar Salman Sulardjaka Ilhamdi Jos Istiyanto Guino Verma Andik Dwi Kurniawan Irfan Ansori Lukman Shalahuddin Jean Mario Valentino Yohanes Pringeten Dilianto Sembiring Depari Triyono |
| author_facet | Hendrato Muizuddin Azka M.Refai Muslih Rifky Apriansyah Nidya Jullanar Salman Sulardjaka Ilhamdi Jos Istiyanto Guino Verma Andik Dwi Kurniawan Irfan Ansori Lukman Shalahuddin Jean Mario Valentino Yohanes Pringeten Dilianto Sembiring Depari Triyono |
| author_sort | Hendrato |
| collection | DOAJ |
| description | Friction stir welding has demonstrated significant efficacy as a solid-state welding methodology for aluminum alloys, including AA6061-T6, and is extensively utilized within automotive and aerospace engineering domains. Nonetheless, conventional FSW methods often lead to uneven residual stress distributions, compromising the material's resistance to fatigue cracking. Simultaneous Double-sided Friction Stir Welding (SDFSW) was introduced to overcome this limitation, offering enhanced welding quality by welding from both sides. This study examines the influence of tool rotational velocity on the fatigue crack growth and the distribution of residual stresses in the SDFSW process applied to AA6061-T6 aluminum. Several rotational velocity combinations were employed to assess their effect on joint quality, encompassing residual stress distribution and cyclic load performance. Based on previous experiments, the SDFSW process uses upper and lower tool speeds. These are 965/965 rpm, 967/1251 rpm and 965/1555 rpm. Fatigue crack growth testing complied with ASTM E647 standards, and the residual stress distribution was assessed through the X-ray diffraction cos α method. Additional mechanical property assessments were performed, including radiographic analysis, examination of the macrostructure and microstructure, microhardness testing, evaluation of tensile strength, and fracture characterization. The findings reveal that the rotational velocity of the tool significantly impacts the weld zone's microstructure, influencing mechanical properties, residual stress distribution, and crack growth behaviors. Among the tested conditions, the tool's rotational speed of 965/1555 rpm yielded the highest tensile strength of approximately 179.82 MPa, representing about 53 % of the strength of the base material and the greatest microhardness of 85 HV. This velocity combination also demonstrated a low fatigue crack growth rate, with Paris law coefficients C and n measured at 2E-08 and 3.6931, respectively, along with a more favorable residual stress distribution. |
| format | Article |
| id | doaj-art-ef26b79cd0c746a192e98a8866ed04fe |
| institution | DOAJ |
| issn | 2666-3309 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
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| series | Journal of Advanced Joining Processes |
| spelling | doaj-art-ef26b79cd0c746a192e98a8866ed04fe2025-08-20T03:10:01ZengElsevierJournal of Advanced Joining Processes2666-33092025-06-011110030010.1016/j.jajp.2025.100300Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 Hendrato0Muizuddin Azka1M.Refai Muslih2Rifky Apriansyah3Nidya Jullanar Salman4 Sulardjaka5 Ilhamdi6Jos Istiyanto7Guino Verma8Andik Dwi Kurniawan9Irfan Ansori10Lukman Shalahuddin11Jean Mario Valentino12Yohanes Pringeten Dilianto Sembiring Depari13 Triyono14Research Canter for Transportation Technology, BRIN, Jakarta, IndonesiaResearch Canter for Process and Manufacturing Industry Technology, BRIN, Jakarta, IndonesiaResearch Canter for Nuclear Beam Analysis Technology, BRIN, Jakarta, IndonesiaDirectorate of Nuclear Energy Facilities Management, BRIN, Jakarta, IndonesiaDepartment of Mechanical Engineering, Universitas Sebelas Maret, Surakarta, IndonesiaDepartment of Mechanical Engineering, Universitas Diponegoro, Semarang, IndonesiaDepartment of Mechanical Engineering, Universitas Andalas, Padang, IndonesiaDepartment of Mechanical Engineering, Universitas Indonesian, Depok, IndonesiaResearch Canter for Transportation Technology, BRIN, Jakarta, IndonesiaResearch Canter for Transportation Technology, BRIN, Jakarta, IndonesiaResearch Canter for Transportation Technology, BRIN, Jakarta, IndonesiaResearch Canter for Transportation Technology, BRIN, Jakarta, IndonesiaResearch Canter for Transportation Technology, BRIN, Jakarta, IndonesiaResearch Canter for Transportation Technology, BRIN, Jakarta, IndonesiaDepartment of Mechanical Engineering, Universitas Sebelas Maret, Surakarta, Indonesia; Corresponding author.Friction stir welding has demonstrated significant efficacy as a solid-state welding methodology for aluminum alloys, including AA6061-T6, and is extensively utilized within automotive and aerospace engineering domains. Nonetheless, conventional FSW methods often lead to uneven residual stress distributions, compromising the material's resistance to fatigue cracking. Simultaneous Double-sided Friction Stir Welding (SDFSW) was introduced to overcome this limitation, offering enhanced welding quality by welding from both sides. This study examines the influence of tool rotational velocity on the fatigue crack growth and the distribution of residual stresses in the SDFSW process applied to AA6061-T6 aluminum. Several rotational velocity combinations were employed to assess their effect on joint quality, encompassing residual stress distribution and cyclic load performance. Based on previous experiments, the SDFSW process uses upper and lower tool speeds. These are 965/965 rpm, 967/1251 rpm and 965/1555 rpm. Fatigue crack growth testing complied with ASTM E647 standards, and the residual stress distribution was assessed through the X-ray diffraction cos α method. Additional mechanical property assessments were performed, including radiographic analysis, examination of the macrostructure and microstructure, microhardness testing, evaluation of tensile strength, and fracture characterization. The findings reveal that the rotational velocity of the tool significantly impacts the weld zone's microstructure, influencing mechanical properties, residual stress distribution, and crack growth behaviors. Among the tested conditions, the tool's rotational speed of 965/1555 rpm yielded the highest tensile strength of approximately 179.82 MPa, representing about 53 % of the strength of the base material and the greatest microhardness of 85 HV. This velocity combination also demonstrated a low fatigue crack growth rate, with Paris law coefficients C and n measured at 2E-08 and 3.6931, respectively, along with a more favorable residual stress distribution.http://www.sciencedirect.com/science/article/pii/S2666330925000214Fatigue crack growthResidual StressSDFSWAA6061-T6 |
| spellingShingle | Hendrato Muizuddin Azka M.Refai Muslih Rifky Apriansyah Nidya Jullanar Salman Sulardjaka Ilhamdi Jos Istiyanto Guino Verma Andik Dwi Kurniawan Irfan Ansori Lukman Shalahuddin Jean Mario Valentino Yohanes Pringeten Dilianto Sembiring Depari Triyono Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 Journal of Advanced Joining Processes Fatigue crack growth Residual Stress SDFSW AA6061-T6 |
| title | Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 |
| title_full | Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 |
| title_fullStr | Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 |
| title_full_unstemmed | Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 |
| title_short | Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 |
| title_sort | fatigue crack growth and residual stress in simultaneous double sided friction stir welded aluminum alloy aa6061 t6 |
| topic | Fatigue crack growth Residual Stress SDFSW AA6061-T6 |
| url | http://www.sciencedirect.com/science/article/pii/S2666330925000214 |
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