Author(s)

M. M. El Rayes, E. A. El-Danaf, M. S. Soliman

Abstract

FSW is a solid state welding process which is widely used with high strength Aluminum Alloys (AA) such as AA-7xxx series. This alloy series is typically used in various structural applications such as truck wheels and bodies, heavy duty structures and aerospace. Durability of these structures is perhaps the most significant attribute they can possess manifesting the importance of fatigue life assessment. In this work, FSW was applied on AA-7010 using tool rotational speed of 850 rpm at a welding speed of 56 mm/min. The tool axial load was maintained constant within the whole welding runs. The resulting weldments were divided into two groups namely; as-welded and shot-peened conditions. Tensile and axial fatigue testing with stress-ratio (R=0.1) were used to evaluate and compare tensile properties and S-N curves of the welded and welded + peened conditions. The weldments were also characterized using optical microscopy, fractography, mechanical and fatigue testing as well as microhardness profiles across the weldment.

Keywords

friction stir welding, aluminum alloy, fatigue, fractography