Fatigue Life of 7005 Aluminum Alloy Cruciform Joint Considering Welding Residual Stress
Abstract
:1. Introduction
2. Framework and Experiments
2.1. Framework Description
2.2. Formulas of Crack Initiation and Propagation Life
2.3. The Boundary between the Crack Initiation and Propagation
2.4. Stress Concentration Model of the Crack Initiation and Propagation Stages
2.4.1. Stress in the Vicinity of Weld Toe under the Tensile Load
2.4.2. Stress Intensity Factor of Crack Propagation Stage under the Tensile Load
2.5. Stress Intensity Factor Considering Welding Residual Stress
2.5.1. Welding Finite Element Model of Cruciform Koint
2.6. Fitting of the Manson–Coffin and the Walker Equations
3. Results and Discussion
3.1. The Effect of Stress Concentration on the Cruciform Joint
3.2. Welding Residual Stress on Crack Plane and Its Stress Intensity Factor
3.3. The Boundary of Crack Initiation and Propagation for the Cruciform Joint
3.4. Crack Initiation and Propagation Life
4. Conclusions
- The boundary between the initiation and propagation stage is not a constant, but a variable value, which will increase when the external load rises. This phenomenon indicates that the microcrack propagation rate during the crack initiation stage is more sensitive to the applied external load than that at the crack propagation.
- In the context of the cruciform joint welded toe, the functional relationship between the residual stress intensity factor calculated by residual stress and the crack length is quite complex, whose functional curve during the period of crack propagation can be divided into three segments. In segment I, because of the rather small crack in the welding toe, although there is a large residual stress in the cruciform joint, stress intensity factor is still at a low level. In segment II, the crack size further increases, and sufficient residual stress is retained in the structure, thereby leading to the maximum of stress intensity factor. Finally, in segment III, whose phenomenon is that the crack size increases continuously, despite an increase in the crack size, the stress intensity factor drops to a low level again because of the release of the residual stress.
- The residual stress caused by welding process of the cruciform joint reduces the fatigue life at the crack initiation and propagation stages, respectively. However, the residual stress has a more significant impact on the crack initiation. The crack initiation stage only accounts for less than 7% of the total fatigue life based on selected metal material and welded joint. From the perspective of engineering practicability, the life of the crack initiation stage can be ignored without unacceptable deviations.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Si | Fe | Cu | Mn | Mg | Zn | Ti | Cr | Al |
---|---|---|---|---|---|---|---|---|
0.07 | 0.15 | 0.15 | 0.35 | 1.2 | 4.4 | 0.05 | 0.18 | Bal. |
0.25 | 0.4 | 0.1 | 0.3 | 0.12 | 0.1 | 0.14 | 0.13 | Bal. |
Yield Strength/MPa | Thermal Conductivity/W·m−1·K−1 | Specific Heat Capacity/mJ·t−1·K−1 | Elastic Modulus/MPa | Thermal Expansion Coefficient/K−1 | Density/t·m−3 | Poisson’s Ratio |
---|---|---|---|---|---|---|
295 | 129 | 9.0 × 108 | 6.7 × 104 | 2.38×10−5 | 209 | 0.33 |
167 | 119 | 9.0 × 108 | 6.7 × 104 | 2.23×10−5 | 2.75 × 10−9 | 0.33 |
Test Piece Number | ||
---|---|---|
1# | 0.2 | 25,427 |
2# | 0.3 | 1563 |
3# | 0.4 | 368 |
4# | 0.5 | 264 |
5# | 0.6 | 162 |
6# | 0.8 | 113 |
7# | 1 | 53 |
Parameters | |||||||
---|---|---|---|---|---|---|---|
fitted value | 0.2298 | 388.6 | −0.1083 | −0.7063 | 3.766 × 10−13 | 0.561 | 3.111 |
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Ma, J.; Wang, P.; Fang, H. Fatigue Life of 7005 Aluminum Alloy Cruciform Joint Considering Welding Residual Stress. Materials 2021, 14, 1253. https://doi.org/10.3390/ma14051253
Ma J, Wang P, Fang H. Fatigue Life of 7005 Aluminum Alloy Cruciform Joint Considering Welding Residual Stress. Materials. 2021; 14(5):1253. https://doi.org/10.3390/ma14051253
Chicago/Turabian StyleMa, Jianxiao, Ping Wang, and Hongyuan Fang. 2021. "Fatigue Life of 7005 Aluminum Alloy Cruciform Joint Considering Welding Residual Stress" Materials 14, no. 5: 1253. https://doi.org/10.3390/ma14051253