Skip to main content
SpringerLink
Log in

Fatigue Damage Evaluation of Friction Stir Spot Welded Cross-Tension Joints Under Repeated Two-Step Force Amplitudes

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

This paper investigates an approach to evaluate the fatigue damage of FSSW cross-tension specimens under two-step force amplitude conditions. In fatigue tests with repeated two-step force amplitude, the fatigue limit of the welded joint disappeared. However, the fatigue damage evaluation using the modified Miner’s rule erred too much on the side of safety, as the modified Miner’s rule tends to overestimate the damage by applied forces below the fatigue limit. Thus, it was determined that, within the testing conditions used in this study, the fatigue damage evaluation using Haibach’s method yielded an accurate evaluation. In the case where significant plastic deformation caused by the applied force occurred near the welded zone, the cumulative fatigue damage value based on Miner’s rule was often larger than unity. Therefore, it is important to consider a cumulative damage estimation that takes into account the effect of pre-strain from the high force amplitude.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. R.S. Mishra and Z.Y. Ma, Friction Stir Welding and Processing, Mater. Sci. Eng. R Rep., 2005, 50(1-2), p 1–78

    Article  Google Scholar 

  2. Z.Y. Ma, Friction Stir Processing Technology: A Review, Metall. Mater. Trans. A, 2008, 39(3), p 642–658

    Article  Google Scholar 

  3. W.-B. Lee and S.-B. Jung, The Joint Properties of Copper by Friction Stir Welding, Mater. Lett., 2004, 58(6), p 1041–1046

    Article  Google Scholar 

  4. Z. Feng, M.L. Santella, S.A. David, R.J. Steel, S.M. Packer, T. Pan, M. Kuo, and R.S. Bhatnagar, Friction Stir Spot Welding of Advanced High-Strength Steels—A Feasibility Study, SAE International, 2005-01-1248, 2005

  5. N. Pathak, K. Bandyopadhyay, M. Sarangi, and S.K. Panda, Microstructure and Mechanical Performance of Friction Stir Spot-Welded Aluminum-5754 Sheets, J. Mater. Eng. Perform., 2012, 22(1), p 131–144

    Article  Google Scholar 

  6. P. Su, A. Gerlich, T.H. North, and G.J. Bendzsak, Material Flow During Friction Stir Spot Welding, Sci. Technol. Weld. Join., 2006, 11(1), p 61–71

    Article  Google Scholar 

  7. S. Babu, V.S. Sankar, G.D. Janaki Ram, P.V. Venkitakrishnan, G. Madhusudhan Reddy, and K. Prasad Rao, Microstructures and Mechanical Properties of Friction Stir Spot Welded Aluminum Alloy AA2014, J. Mater. Eng. Perform., 2012, 22(1), p 71–84

    Article  Google Scholar 

  8. Y.F. Sun, H. Fujii, N. Takaki, and Y. Okitsu, Microstructure and Mechanical Properties of Mild Steel Joints Prepared by a Flat Friction Stir Spot Welding Technique, Mater. Des., 2012, 37, p 384–392

    Article  Google Scholar 

  9. D.-A. Wang and S.-C. Lee, Microstructures and Failure Mechanisms of Friction Stir Spot Welds of Aluminum 6061-T6 Sheets, J. Mater. Process. Technol., 2007, 186(1–3), p 291–297

    Article  Google Scholar 

  10. L. Fratini, G. Buffa, and R. Shivpuri, In-process Heat Treatments to Improve FS-Welded Butt Joints, Int. J. Adv. Manuf. Technol., 2009, 43(7-8), p 664–670

    Article  Google Scholar 

  11. R. Tanegashima, H. Akebono, M. Kato, and A. Sugeta, 3-Dimensional Observation of the Interior Fracture Mechanism and Establishment of Cumulative Fatigue Damage Evaluation on Spot Welded Joints Using 590 MPa-Class Steel, Int. J. Fatigue, 2013, 51, p 121–131

    Article  Google Scholar 

  12. R. Tanegashima, I. Ohara, H. Akebono, M. Kato, and A. Sugeta, Cumulative Fatigue Damage Evaluations on Spot-Welded Joints Using 590 MPa-Class Automobile Steel, Fatigue Fract. Eng. Mater. Struct., 2015. doi:10.1111/ffe.12258

    Google Scholar 

  13. D. Radaj, C.M. Sonsino, and W. Fricke, Structural Stress or Strain Approach for Spot-Welded and Similar Lap Joints, Fatigue Assessment of the Welded Joints by Local Approaches, 2nd ed., Woodhead Publishing Limited, Cambridge, 2006, p 366–372

    Book  Google Scholar 

  14. H.S. Park, T. Kimura, T. Murakami, Y. Nagano, K. Nakata, and M. Ushio, Microstructures and Mechanical Properties of Friction Stir Welds of 60% Cu-40% Zn Copper Alloy, Mater. Sci. Eng. A, 2004, 371(1-2), p 160–169

    Article  Google Scholar 

  15. H. Fujii, Y. Sun, and H. Kato, Microstructure and Mechanical Properties of Friction Stir Welded Pure Mo Joints, Scr. Mater., 2011, 64(7), p 657–660

    Article  Google Scholar 

  16. M.S. Khorrami, M. Kazeminezhad, and A.H. Kokabi, Mechanical Properties of Severely Plastic Deformed Aluminum Sheets Joined by Friction Stir Welding, Mater. Sci. Eng. A, 2012, 543, p 243–248

    Article  Google Scholar 

  17. M. Shiraly, M. Shamanian, M.R. Toroghinejad, and M. Ahmadi Jazani, Effect of Tool Rotation Rate on Microstructure and Mechanical Behavior of Friction Stir Spot-Welded Al/Cu Composite, J. Mater. Eng. Perform., 2014, 23(2), p 413–420

    Article  Google Scholar 

  18. R. Sołtysiak, Local Strain Analysis in Friction Stir Welded 2024-T3 Aluminium Joint Under Cyclic Loading, J. Polish Cimac, 2010, 5(3), p 187–192

    Google Scholar 

  19. D. Boroński, R. Sołtysiak, and Z. Lutowski, Analysis of Strain Distribution in Notch Zone in Aluminium FSW Joints for Irregular Fatigue Loading Conditions, Solid State Phenom., 2015, 224, p 27–32

    Article  Google Scholar 

  20. P. Lin, J. Pan, and T. Pan, Failure Modes and Fatigue Life Estimations of Spot Friction Welds in Lap-Shear Specimens of Aluminum 6111-T4 Sheets. Part 1: Welds Made by a Concave Tool, Int. J. Fatigue, 2008, 30(1), p 74–89

    Article  Google Scholar 

  21. V. Tran, J. Pan, and T. Pan, Fatigue Behavior of Aluminum 5754-O and 6111-T4 Spot Friction Welds in Lap-Shear Specimens, Int. J. Fatigue, 2008, 30(12), p 2175–2190

    Article  Google Scholar 

  22. C. Jonckheere, B. Meester, C. Cassiers, M. Delhaye, and A. Simar, Fracture and Mechanical Properties of Friction Stir Spot Welds in 6063-T6 Aluminum Alloy, Int. J. Adv. Manuf. Technol., 2011, 62(5-8), p 569–575

    Article  Google Scholar 

  23. Y.D. Chung, H. Fujii, R. Ueji, and N. Tsuji, Friction Stir Welding of High Carbon Steel with Excellent Toughness and Ductility, Scr. Mater., 2010, 63(2), p 223–226

    Article  Google Scholar 

  24. Y.S. Sato, H. Yamanoi, H. Kokawa, and T. Furuhara, Microstructural Evolution of Ultrahigh Carbon Steel During Friction Stir Welding, Scr. Mater., 2007, 57(6), p 557–560

    Article  Google Scholar 

  25. L. Cui, H. Fujii, N. Tsuji, and K. Nogi, Friction Stir Welding of A High Carbon Steel, Scr. Mater., 2007, 56(7), p 637–640

    Article  Google Scholar 

  26. Y. Uematsu, K. Tokaji, Y. Tozaki, and Y. Nakashimac, Fatigue Behaviour of Dissimilar Friction Stir Spot Weld Between A6061 and SPCC Welded by a Scrolled Groove Shoulder Tool, Procedia Eng., 2010, 2(1), p 193–201

    Article  Google Scholar 

  27. J.D. Costa, J.A.M. Ferreira, L.P. Borrego, and L.P. Abreu, Fatigue Behaviour of AA6082 Friction Stir Welds Under Variable Loadings, Int. J. Fatigue, 2012, 37, p 8–16

    Article  Google Scholar 

  28. J.D. Costa, J.A.M. Ferreira, and L.P. Borrego, Influence of Spectrum Loading on Fatigue Resistance of AA6082 Friction Stir Welds, Int. J. Struct. Integr., 2011, 2(2), p 122–134

    Article  Google Scholar 

  29. Standard Evaluation Method of Fatigue Reliability for Metallic Materials: Standard Regression Method of S-N Curves, The Society of Materials Science, Japan, JSMS-SD-6-04, 2004 (in Japanese)

  30. S. Joy-A-Ka, T. Hirano, H. Akebono, M. Kato, A. Sugeta, Fatigue Properties and Crack Growth Behavior of Friction Stir Spot Welded 300 MPa-Class Automobile Steel Sheets, Proceedings of the 9th International Conference on Fracture & Strength of Solids, Jun 9-13, Korea, 2013

  31. S. Joy-A-Ka, T. Hirano, H. Akebono, M. Kato, A. Sugeta, H. Fujii, and Y.F. Sun, 3-Dimensional Observation of the Interior Fatigue Fracture Mechanism on Friction Stir Spot Welded Using 300 MPa-Class Automobile Steel Sheets, Proceedings of the 1st International Joint Symposium on Joining and Welding, Nov 6-8, 2013, Woodhead publishing, Japan, 2013, p 435–442

  32. E. Haibach, The allowable stresses under variable amplitude loading, Proceeding of the Conference on Fatigue of Welded Structures, Jul 6-9, 1970, The Welding Institute, England, 1971, p 328–339

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Science and Engineering, Graduate School of Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima, 739-8527, Japan

    Sutep Joy-A-Ka, Yuki Ogawa, Hiroyuki Akebono, Masahiko Kato & Atsushi Sugeta

  2. Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka, 567-0047, Japan

    Yufeng Sun & Hidetoshi Fujii

Authors
  1. Sutep Joy-A-Ka
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuki Ogawa
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hiroyuki Akebono
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Masahiko Kato
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Atsushi Sugeta
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Yufeng Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Hidetoshi Fujii
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Sutep Joy-A-Ka or Atsushi Sugeta.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Joy-A-Ka, S., Ogawa, Y., Akebono, H. et al. Fatigue Damage Evaluation of Friction Stir Spot Welded Cross-Tension Joints Under Repeated Two-Step Force Amplitudes. J. of Materi Eng and Perform 24, 2494–2502 (2015). https://doi.org/10.1007/s11665-015-1534-x

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-015-1534-x

Keywords

Search

Navigation