PSI - Issue 61

Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2023) 000 – 000 Available online at www.sciencedirect.com ScienceDirect

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Procedia Structural Integrity 61 (2024) 188–194

3rd International Workshop on Plasticity, Damage and Fracture of Engineering Materials (IWPDF 2023) Fatigue crack growth behavior in SS304-Al5083 dissimilar friction stir welded joints Jignesh Nakrani a,b,c , Wenyi Yan b , Amber Shrivastava a, *

a Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai 400076, India b Department of Mechanical and Aerospace Engineering, Monash University, Clayton, VIC 3800, Australia c IITB-Monash Research Academy, Indian Institute of Technology Bombay, Mumbai 400076, India

© 2024 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of IWPDF 2023 Chairman Abstract Aluminum-stainless steel joints are desirable for weight reduction in applications such as aerospace and automotive. Such joints are unavoidably exposed to cyclic loading, thus requiring a study of fatigue crack propagation in joints. A Friction stir welding (FSW) exhibited potential for fabrication of dissimilar joints. This work aims to explore the fatigue crack propagation behavior of SS304-Al5083 dissimilar weld prepared using friction stir welding. The SS304 and Al5083 sheets (250 mm × 80 mm × 3 mm) are friction stir welded, using a tool made of tungsten carbide featuring 16.5 mm shoulder diameter and cylindrical pin with 2.7 mm height 4 mm diameter. Tensile tests and fatigue crack growth rate (FCGR) assessments are conducted on both the base materials and the welded joints. Notably, the yield strength of the FSW joints align closely with that of Al5083. Two initial notch cases, notch at interface and at 3 mm offset from the interface towards Al5083, are considered for the welded joints. In the FSW joint, higher fatigue crack growth rate along Al-SS interface crack is observed to that of both individual base materials. For offset notch, crack growth rate is lower compared to the Al5083. Fractography of FCGR specimens revealed a brittle failure of the interface crack in welded joints which leads to a higher crack growth rate. © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of IWPDF 2023 Keywords: Dissimilar weld; SS304; Al5083; Fatigue crack growth behavior

* Corresponding author. Tel.: +91-22-2576-9358; fax: +91-22-2572-6875 E-mail address: ashrivastava.me@iitb.ac.in

2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of IWPDF 2023

2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of IWPDF 2023 Chairman 10.1016/j.prostr.2024.06.025