S-N curves for fatigue life estimation of friction stir welded 19501 aluminum alloy T-joint

In this study, the mechanical properties and fatigue life of 19501 aluminum alloy friction stir welded T-joint is investigated. Tensile properties of friction stir welded joint show that there is a marginal reduction of about 5% in strength and ductility as compared to unwelded 19501 aluminum alloy. Fatigue test results of T-joint specimen at two stress ratios of 0 and -1 show that there is a reduction of 15% in fatigue strength due to change of stress ratio from -1 to 0. Also, higher variation is seen in fatigue strength in low cycle zone than the high cycle zone. Effect of mean stress on fatigue life is discussed on the basis of different mean stress effect models. Morrow's mean stress effect model is found to be better than other models. Micrographs from the fracture surfaces of retreating side, mid weld zone, and advancing side of the T-joint indicates that fracture surfaces are cleavage fracture. Different sizes of inter-metallic bonding are seen in the micrographs, which indicate that fracture is initiated due to breaking of the brittle inter-metallic bonding.