Abstract
Friction Stir Welding (FSW) is a new type of solid-state connection which can reduce structural weight significantly. In this paper, fatigue tests and finite element analysis were employed to study fatigue properties and residual stresses of aerial aluminum alloy 2524-T3 FSW joint. The residual stresses in FSW joint were obtained by a nonlinear direct coupled-field finite element analysis. On the basis of finite element analysis results, the fatigue life of FSW joint was estimated. It is verified that the analytic and estimated results agree with that of experiment.
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