Abstract
In this project, a front shock tower of a passenger vehicle is developed with various magnesium alloys and joining methods. To predict the fatigue life of the joints in the structure, fatigue tests of various joint specimens including friction stir linear welding, self-piecing rivet joint with and without adhesive, and friction stir spot welding were conducted. The magnesium alloys used for the specimens are AM60 (cast), AM30 (extrusion), and AZ31 (sheet). Various finite element modeling techniques were attempted for simulating the various joints. Fatigue life prediction method for the joints was performed using the stress-life curve approach. The finite element modeling technique and the fatigue prediction method will be verified with fatigue tests of the actual front shock tower structure subjected to variable amplitude loadings in near future.
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