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<p>This study investigates the fatigue behavior of AA6061-T6 to Cu dissimilar joints produced by High-Speed Friction Stir Butt Welding (HSFSBW). The influence of ultimate grain refinement, achieved through optimized parameters (2000&#xa0;rpm, 120&#xa0;mm/min), on fatigue life was analyzed. Tensile strength reached 177&#xa0;MPa (80% of Cu base material). A microstructure-sensitive fatigue modeling (MSF-FEM) framework, incorporating grain size and mechanical properties, predicted fatigue life. The MSF model accounts for crack incubation at microstructural discontinuities (voids, intermetallics), small crack growth, and long crack propagation. Experimentally, ultimate grain refinement significantly increased the number of failure cycles. The fracture surface results indicated a combination of ductile and brittle fractures, with small areas exhibiting only brittle fracture, which was more pronounced in the copper region compared to the AA6061-T6 region. The MSF-FEM results are validated by experimental data. HSFSBW effectively enhances fatigue performance via microstructural control, informing microstructure-property relationships. This approach provides a predictive capability for fatigue life in HSFSBW dissimilar joints.&#xa0;</p>

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Microstructure-sensitive fatigue modeling of High-Speed Friction Stir Butt Welding of dissimilar joints AA6061-T6 to copper

  • 期刊论文

  • 发表日期：

    2025年9月25日

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  • Esmaeil Mirmahdi,
  • Davood Afshari,
  • Masoud Mahmoodi

摘要

This study investigates the fatigue behavior of AA6061-T6 to Cu dissimilar joints produced by High-Speed Friction Stir Butt Welding (HSFSBW). The influence of ultimate grain refinement, achieved through optimized parameters (2000 rpm, 120 mm/min), on fatigue life was analyzed. Tensile strength reached 177 MPa (80% of Cu base material). A microstructure-sensitive fatigue modeling (MSF-FEM) framework, incorporating grain size and mechanical properties, predicted fatigue life. The MSF model accounts for crack incubation at microstructural discontinuities (voids, intermetallics), small crack growth, and long crack propagation. Experimentally, ultimate grain refinement significantly increased the number of failure cycles. The fracture surface results indicated a combination of ductile and brittle fractures, with small areas exhibiting only brittle fracture, which was more pronounced in the copper region compared to the AA6061-T6 region. The MSF-FEM results are validated by experimental data. HSFSBW effectively enhances fatigue performance via microstructural control, informing microstructure-property relationships. This approach provides a predictive capability for fatigue life in HSFSBW dissimilar joints.