Unusual fatigue behavior of friction-stir welded Al-Mg-Si alloy

Vysotskiy, Igor and Malopheyev, Sergey and Rahimi, Salaheddin and Mironov, Sergey and Kaibyshev, Rustam (2019) Unusual fatigue behavior of friction-stir welded Al-Mg-Si alloy. Materials Science and Engineering: A, 760 (7). pp. 277-286. ISSN 0921-5093 (https://doi.org/10.1016/j.msea.2019.06.005)

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In this work, high-cycle fatigue behavior of friction-stir welded AA6061-T6 was studied. An emphasis has been made on the inter-relationship between microstructure, residual stress and fatigue resistance. The welds were produced under optimized conditions, including a combination of relatively high welding temperature and rapid cooling rate, and subsequently undergone a standard post-weld aging heat treatment. The optimized welds exhibited excellent fatigue performance that was comparable (or even superior) to that of the base material. This result was attributed to a considerable grain refinement in the stir zone, subtle material softening in the heat-affected zone as well as to significant residual stress generated during the optimized FSW.