Journal of Jilin University(Engineering and Technology Edition) ›› 2024, Vol. 54 ›› Issue (6): 1563-1569.doi: 10.13229/j.cnki.jdxbgxb.20220958

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Fatigue crack propagation behavior and life prediction of 2024-O aluminum alloy FSW joints

Lei WANG1,2(),Dong-xia LI2,Song ZHOU2,3,Li HUI3,Zhen-xin SHEN2   

  1. 1.College of Mechanical Engineering，Suzhou University of Science and Technology，Suzhou 215009，China
    2.School of Mechatronics Engineering，Shenyang Aerospace University，Shenyang 110136，China
    3.Key Laboratory of Fundamental Science for National Defense of Aeronautical Digital Manufacturing Process，Shenyang Aerospace University，Shenyang 110136，China
  • Received:2022-07-31 Online:2024-06-01 Published:2024-07-23

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Abstract:

The crack propagation behavior of 2024-O high-profile aluminum alloy friction stir welding prefabricated cracks in the weld nugget region， heat-affected region and perpendicular to the weld direction is analyzed through experiments and the method based on FRANC 3D and ABAQUS co-simulation， and the life prediction was carried out. The results show that the simulation results of crack propagation path and crack propagation rate in three regions are in good agreement with the experimental results. The crack propagation life of prefabricated cracks in three regions from low to high is weld core region， heat affected region， perpendicular to the weld. The relative error between the life prediction results of three kinds of samples and the test results by FRANC 3D is about 5%， which verifies the accuracy and feasibility of the co-simulation method to simulate the crack propagation behavior and life prediction of high-distribution aluminum alloy friction stir welding in different regions of welded joints.

Key words: mechanical design, 2024-O aluminum alloy, friction stir welding, FRANC 3D, crack propagation, life prediction

CLC Number: 

  • TG405

Fig.1

Crack propagation samples of prefabricated cracks in different regions"

Fig.2

Simulation flow chart of crack propagation"

Table 1

ABAQUS input material parameters for different regions of welded joints"

分区弹性模量E/MPa泊松比μ屈服强度σs/MPa
母材73 0000.3362.7
热机影响区73 0000.33113.6
热影响区73 0000.33101.3
焊核73 0000.33201.5

Fig.3

CT sample diagram of model partition"

Table 2

Fatigue crack propagation Paris basic parameters"

裂纹位置mC门槛值ΔKth/MPa
NZ2.978.58×10-1242.1
HAZ3.11.11×10-1135.4
PWZ3.955.98×10-1338.9

Fig.4

Multi-region crack propagation path of 2024-O aluminum alloy FSW"

Fig.5

FRANC 3D simulation of 2024-O aluminum alloy FSW multi-region crack propagation path"

Fig.6

Multi-region crack propagation rate curve of 2024-O aluminum alloy FSW"

Fig.7

a-N curve of multi-region crack propagation in 2024-O aluminum alloy FSW"

Fig.8

Multi-region crack propagation life of 2024-O aluminum alloy FSW"

Fig.9

Microscopic fracture morphologies of 2024-O aluminum alloy FSW multi-regional crack propagation at low speed"

Fig.10

Microscopic fracture morphologies of 2024-Oaluminum alloy FSW multi-region crack propagation at medium speed"

Fig.11

Microscopic fracture morphologies of 2024-O aluminum alloy FSW multi-region crack propagation at high speed"

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