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Fatigue Behavior of Friction Stir Linear Welded Dissimilar Aluminum-to-Magnesium Alloys

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Friction Stir Welding and Processing VIII

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Abstract

In this paper, we present the results of fatigue testing and analysis of friction stir linear welded dissimilar aluminum-to-magnesium alloys in lap-shear configuration. The overlap linear welds were created by joining AA6022 aluminum alloy to AM60 magnesium alloy. In general, the test data exhibited significant scatter in the fatigue life results and the corresponding failure modes. In fact, observations from fractography analysis revealed two distinct modes of failure. In the first mode of failure observed, fracture occurred when the dominant fatigue crack propagated into either the magnesium or aluminum sheet in a kinked crack formation. Interestingly, frettinglike debris was observed at the initiation sites for this failure mode. In the second mode of failure observed, fracture occurred by interfacial weld separation. In this mode, fractography analysis suggests that the fatigue cracks initiated at weld defects and then propagated through the intermetallic phase.

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Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, The University of Alabama, AL, 35487, USA

    H. M. Rao & J. B. Jordon

  2. R&D Division, Automotive Products Research Laboratory, Hitachi America Ltd., Farmington Hills, MI, 48335, USA

    W. Yuan

  3. Ford Research and Innovation Center, Ford Motor Company, Dearborn, MI, 48124, USA

    B. Ghaffari & X. Su

  4. General Motors Research and Development Center, Warren, MI, 48090, USA

    A. K. Khosrovaneh

  5. Chrysler Group LLC, MI, 48326, USA

    Y. L. Lee

Authors
  1. H. M. Rao
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  2. J. B. Jordon
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  3. W. Yuan
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  4. B. Ghaffari
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  5. X. Su
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  6. A. K. Khosrovaneh
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  7. Y. L. Lee
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Editor information

Editors and Affiliations

  1. Department of Materials Science and Engineering, University of North Texas, USA

    Rajiv S. Mishra (Professor of Materials Science and Engineering) (Professor of Materials Science and Engineering)

  2. Structural Metals Department, Rockwell Scientific, USA

    Murray W. Mahoney (Prior, Manager/Senior Scientist, B.S., physical metallurgy, M.S., physical metallurgy) (Prior, Manager/Senior Scientist, B.S., physical metallurgy, M.S., physical metallurgy)

  3. University of California Berkeley, USA

    Murray W. Mahoney (Prior, Manager/Senior Scientist, B.S., physical metallurgy, M.S., physical metallurgy) (Prior, Manager/Senior Scientist, B.S., physical metallurgy, M.S., physical metallurgy)

  4. University of California Los Angeles, USA

    Murray W. Mahoney (Prior, Manager/Senior Scientist, B.S., physical metallurgy, M.S., physical metallurgy) (Prior, Manager/Senior Scientist, B.S., physical metallurgy, M.S., physical metallurgy)

  5. Department of Materials Processing, Tohoku University, Japan

    Yutaka Sato (Associate Professor) (Associate Professor)

  6. Pacific Northwest National Laboratory, USA

    Yuri Hovanski (Senior Research Engineer) (Senior Research Engineer)

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© 2015 TMS (The Minerals, Metals & Materials Society)

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Rao, H.M. et al. (2015). Fatigue Behavior of Friction Stir Linear Welded Dissimilar Aluminum-to-Magnesium Alloys. In: Mishra, R.S., Mahoney, M.W., Sato, Y., Hovanski, Y. (eds) Friction Stir Welding and Processing VIII. Springer, Cham. https://doi.org/10.1007/978-3-319-48173-9_16

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