Multiple crack propagation in friction stir welded aluminium joints

This paper is concerned with the simulation of crack propagation in friction stir welded butt joints, in order to assess the influence of process induced microstructural alterations and residual stresses on the fatigue behaviour of the assembly. The approach employed is based on the coupled use of the finite element method and the dual boundary element method in order to take advantage of the main capabilities of the two methods. The distribution of the process induced residual stresses has been mapped by means of the contour method. Then, the computed residual stresses field has been superimposed, in a dual boundary element environment, to the stress field as a result of a remote fatigue traction load and the crack growth is simulated. A two-parameter crack growth law, based on the evaluation of two thresholds, for the material being analysed, is used for the crack propagation rate assessment. The stress intensity factors are evaluated using the J-integral technique. Computational results have been compared with experimental data, provided from constant amplitude crack propagation tests on welded samples, showing the subdivision of the overall fatigue life in the two periods of crack initiation and crack propagation