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This research aims to predict the fatigue life of friction stir-welded dissimilar aluminum joints using various methods.

Fatigue life prediction of FSW lap joints 6061/2A12 dissimilar aluminum alloy

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This research aims to predict the fatigue life of friction stir-welded dissimilar aluminum joints using various methods.
Conducted constant-amplitude fatigue tests on different lap configurations.
Performed metallographic observations of weld cross-sections.
Utilized finite element models based on notch stress, fracture mechanics, and hot-spot stress methods for predictions.
Fatigue failures were found to originate from a hook defect on the advancing side.
The hook defect is linked to maximum stress and strain concentration.
All prediction methods yielded results within a scatter band of three factors compared to experimental data.

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Fatigue behavior is assessed in friction stir-welded aluminum joints, suggesting key factors influencing lifespan.

Dai et al. (2026) studied this question.

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