Fatigue in Friction Stir Welding provides knowledge on how to design and fabricate high performance, fatigue resistance FSW joints. It summarizes fatigue characterizations of key FSW configurations, including butt and lap-shear joints. The book's main focus is on fatigue of aluminum alloys, but discussions of magnesium, steel, and titanium alloys are also included. The FSW process-structure-fatigue performance relationships, including tool rotation, travel speeds, and pin tools are covered, along with sections on extreme fatigue conditions and environments, including multiaxial, variable amplitude, and corrosion effects on fatigue of the FSW. From a practical design perspective, appropriate fatigue design guidelines, including engineering and microstructure-sensitive modeling approaches are discussed. Finally, an appendix with numerous representative fatigue curves for design and reference purposes completes the work. - Provides a comprehensive characterization of fatigue behavior for various FSW joints and alloy combinations, along with an in-depth presentation on crack initiation and growth mechanisms - Presents the relationships between process parameters and fatigue behavior - Discusses modeling strategies and design recommendations, along with experimental data for reference purposes

This volume contains the proceedings of the XIX International Colloquium on Mechanical Fatigue of Metals, held at the Faculty of Engineering of the University of Porto, Portugal, 5-7 September 2018. This International Colloquium facilitated and encouraged the exchange of knowledge and experiences among the different communities involved in both basic and applied research in the field of the fatigue of metals, looking at the problem of fatigue exploring analytical and numerical simulative approaches. Fatigue damage represents one of the most important types of damage to which structural materials are subjected in normal industrial services that can finally result in a sudden and unexpected abrupt fracture. Since metal alloys are still today the most used materials in designing the majority of components and structures able to carry the highest service loads, the study of the different aspects of metals fatigue attracts permanent attention of scientists, engineers and designers.

This book covers the rapidly growing area of friction stir welding. It also addresses the use of the technology for other types of materials processing, including superplastic forming, casting modification, and surface treatments. The book has been prepared to serve as the first general reference on friction stir technology,. Information is provided on tools, machines, process modeling, material flow, microstructural development and properties. Materials addressed include aluminum alloys, titanium alloys, steels, nickel-base alloys, and copper alloys. The chapters have been written by the leading experts in this field, representing leading industrial companies and university and government research insititutions.

Friction Stir Welding of High Strength 7XXX Aluminum Alloys is the latest edition in the Friction Stir series and summarizes the research and application of friction stir welding to high strength 7XXX series alloys, exploring the past and current developments in the field. Friction stir welding has demonstrated significant benefits in terms of its potential to reduce cost and increase manufacturing efficiency of industrial products in transportation, particularly the aerospace sector. The 7XXX series aluminum alloys are the premium aluminum alloys used in aerospace. These alloys are typically not weldable by fusion techniques and considerable effort has been expended to develop friction stir welding parameters. Research in this area has shown significant benefit in terms of joint efficiency and fatigue performance as a result of friction stir welding. The book summarizes those results and includes discussion of the potential future directions for further optimization. - Offers comprehensive coverage of friction stir welding of 7XXX series alloys - Discusses the physical metallurgy of the alloys - Includes physical metallurgy based guidelines for obtaining high joint efficiency - Summarizes the research and application of friction stir welding to high strength 7XXX series alloys, exploring the past and current developments in the field

This collection focuses on all aspects of science and technology related to friction stir welding and processing.

These recommendations present general methods for the assessment of fatigue damage in welded components, which may affect the limit states of a structure, such as ultimate limit state and serviceability limited state. Fatigue resistance data is given for welded components made of wrought or extruded products of ferritic/pearlitic or banitic structural steels up to fy = 700 Mpa and of aluminium alloys commonly used for welded structures.

Recent advancements in friction stir welding (FSW) technology have potential for applications in aerospace structures. Friction stir spot welds have been found to be much stronger than rivets in the same material thickness, while maintaining the discontinuous crack growth path preferred by aircraft designers. In this study, the test coupons have been investigated in fatigue with the weld aligned with the loading direction. The purpose of this study was to better understand crack initiation at friction stir weld exit holes in no-load transfer coupons representative of aircraft fuselage applications. The goal was to document the effects of weld exit location on fatigue life in discontinuous friction stir welded panels and to determine possible solutions in order to reduce the stress concentration around the exit hole location, thereby increasing the panel's fatigue life. Aluminum alloys 7075-T6 and 2024-T3, which are commonly used in conventional airframe construction, were chosen for the FSW lap welds in this thesis. The methodology of this research was to weld the coupons with discontinuous friction stir lap welding using different exit hole configurations. The weld parameters such as rotation speed, travel speed, lead angle and load force had already been evaluated prior to this investigation in an earlier study during the first year of this project by Josh Merry. Once all of the coupons were welded, the next step was to fatigue test them with constant amplitude in order to determine the number of fatigue cycles and then compare all the different coupon results with the baseline coupon result that were determined in the previous study. This project investigated a number of weld exit strategies with conventional one-piece weld tools. This study also included welds produced with a two-piece weld tool called Retractable Pin Tool (RPT) in which the length of the tool probe can be adjusted during welding. The RPT weld tool was used to eliminate the exit hole of the weld in order to reduce or eliminate viii the stress concentration around the weld exit. The ultimate goal of this research was to achieve equivalent or better fatigue life in discontinuous FSW joints as compared to riveted coupons.

Friction stir welding (FSW) is a highly important and recently developed joining technology that produces a solid phase bond. It uses a rotating tool to generate frictional heat that causes material of the components to be welded to soften without reaching the melting point and allows the tool to move along the weld line. Plasticized material is transferred from the leading edge to trailing edge of the tool probe, leaving a solid phase bond between the two parts. Friction stir welding: from basics to applications reviews the fundamentals of the process and how it is used in industrial applications.Part one discusses general issues with chapters on topics such as basic process overview, material deformation and joint formation in friction stir welding, inspection and quality control and friction stir welding equipment requirements and machinery descriptions as well as industrial applications of friction stir welding. A chapter giving an outlook on the future of friction stir welding is included in Part one. Part two reviews the variables in friction stir welding including residual stresses in friction stir welding, effects and defects of friction stir welds, modelling thermal properties in friction stir welding and metallurgy and weld performance.With its distinguished editors and international team of contributors, Friction stir welding: from basics to applications is a standard reference for mechanical, welding and materials engineers in the aerospace, automotive, railway, shipbuilding, nuclear and other metal fabrication industries, particularly those that use aluminium alloys. - Provides essential information on topics such as basic process overview, materials deformation and joint formation in friction stir welding - Inspection and quality control and friction stir welding equipment requirements are discussed as well as industrial applications of friction stir welding - Reviews the variables involved in friction stir welding including residual stresses, effects and defects of friction stir welds, modelling thermal properties, metallurgy and weld performance

This collection focuses on all aspects of science and technology related to friction stir welding and processing.