Fatigue Strength of Friction Stir Welded Aluminum Alloy Joints

Strength of Al5083-O FSW joints was evaluated, in relation to FSW conditions. Static strength of the joints was found to be enough because base metal fracture occurred in the tensile tests of joints for some FSW conditions. However, the fatigue strength of those joints with fine static strength varied significantly. For example, in tensile strength of joints with the FSW condition with tool rotation: 800 rpm- welding speed: 100 mm/min (800-100), 800 rpm-200 mm/min (800-200) and 500 rpm- 100 mm/min (500-100), each condition of FSW joint efficiency were all hundred percent. In contrast, joint efficiency for fatigue strength varied from 75% for 500-100 to 31% for 800-200. Crack path in fatigue test was always initiated at the center of back surface of FSW weld zone, and propagated through stir zone. The variance of fatigue strength is believed to be attributed to the stirred condition at back surface.