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<p>This study investigates the fatigue behavior of AA2219 aluminum alloy butt joints produced by tungsten inert gas (TIG) welding, focusing on weld reinforcement geometry and residual stresses. An analytical method was developed to calculate theoretical stress concentration factors (SCFs) in test specimens with misaligned face and root reinforcement axes. Analysis revealed SCFs of approximately 2.3, with initial tensile residual stresses of about 35&#xa0;MPa in critical areas. A computational algorithm determined actual loading cycle characteristics by accounting for residual stresses and elastic–plastic stress fields. Results showed that the actual SCF decreased by approximately 7% at higher applied stress ranges, with this reduction diminishing at lower loads. Fatigue tests on three specimens validated a calculation-experimental methodology that efficiently predicts S–N curves using minimal test data. By establishing an empirical relationship between the stress concentration sensitivity coefficient and the actual cycle SCF, we successfully extrapolated fatigue limits at 2 × 10<sup>6</sup> cycles with minimal deviation from experimental values. This methodology can significantly reduce testing while maintaining accurate fatigue life predictions for aluminum welded structures.</p>

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Fatigue behavior assessment of AA2219 TIG butt joints considering weld reinforcement geometry and residual stresses measurements

  • 期刊论文

  • 发表日期：

    2026年1月23日

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  • Sviatoslav Motrunich,
  • Andriy Moltasov,
  • Viktor Savitskiy,
  • Jacob Kleiman,
  • Volodymyr Kot,
  • Iliya Klochkov

摘要

This study investigates the fatigue behavior of AA2219 aluminum alloy butt joints produced by tungsten inert gas (TIG) welding, focusing on weld reinforcement geometry and residual stresses. An analytical method was developed to calculate theoretical stress concentration factors (SCFs) in test specimens with misaligned face and root reinforcement axes. Analysis revealed SCFs of approximately 2.3, with initial tensile residual stresses of about 35 MPa in critical areas. A computational algorithm determined actual loading cycle characteristics by accounting for residual stresses and elastic–plastic stress fields. Results showed that the actual SCF decreased by approximately 7% at higher applied stress ranges, with this reduction diminishing at lower loads. Fatigue tests on three specimens validated a calculation-experimental methodology that efficiently predicts S–N curves using minimal test data. By establishing an empirical relationship between the stress concentration sensitivity coefficient and the actual cycle SCF, we successfully extrapolated fatigue limits at 2 × 106 cycles with minimal deviation from experimental values. This methodology can significantly reduce testing while maintaining accurate fatigue life predictions for aluminum welded structures.