Role of Friction Stir Channel Geometry on the Fatigue Behaviour of AA5083-H111 at 120°C and 200°C

Abstract

Friction StirChannelling (FSC) is an innovative solid-state manufacturing technology able toproduce, in a single step, continuous integral channels in monolithic platesthat can be used to produce conformal cooling systems as well as heatexchanging devices. FSC is based on the same principles of Friction StirWelding (FSW) process and the features of the channels produced by FSC can becontrolled by the processing parameters and tool geometry. Bending fatiguetests have been performed using friction stir channelling specimens of 5083‑H111aluminium alloy with different channel geometries. Fatigue tests have beencarried out at 120°C and 200°C in a servo-hydraulic testing machine coupledwith a furnace, in order to understand the role of channel geometry on thefatigue behaviour at elevated temperature. Results were compared with thoseobtained at room temperature. The specimens were tested until fracture or up to 3x106 cycles. For the channel geometries tested, the fatiguestrength of friction stir channelling specimens is dependent on the testingtemperature, decreasing with the temperature increased. At all temperaturesstudied, for both channel geometries, fatigue-crack always initiated into theinterior of the specimen, namely on the boundary between the channel nugget andthe thermo‑mechanically affected zone. It was observed that crack initiationhas been occurred earlier at elevated temperature than at room temperature.