Abstract
Friction Stir Welding (FSW) is expected as one of the industrial solutions to fabricate high-performance dissimilar metal welds consisting of materials to which conventional fusion welding process(es) is (are) difficult to apply. However, the strength of FSWed T-lap joint, especially for the fatigue failures, has not been satisfactory so far, due to the formation of some undesirable defects in the joint, e.g., tunnel, kissing bond, zigzag line, bonding line, oxide line defects, etc., those may directly degrade the mechanical properties of the joint. In this work, a trial was made to minimize the defect size in the dissimilar metal FSWed T-lap joint between AA7075 and AA5083, by employing a double stir welding method. The fatigue strength of the joint was also explored, paying attention to the fatigue crack nucleation sites and the morphologies. Some fracture mechanics strategies are proposed to improve the fatigue strength associating with enough rupture ductility.
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