PSI - Issue 60

ScienceDirect Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2023) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2023) 000–000 Available online at www.sciencedirect.com Procedia Structural Integrity 60 (2024) 13–19

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www.elsevier.com/locate/procedia

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 ICONS 2023 Organizers 10.1016/j.prostr.2024.05.027 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 ICONS 2023 Organizers 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 ICONS 2023 Organizers * Corresponding author. E-mail address: anoj.giri@vit.ac.in © 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 ICONS 2023 Organizers Abstract Aluminum Alloy is extensively used in aerospace and automotive industry due to its light weight and high strength properties. It is generally joined using Friction Stir Welding, which is a solid-state process. During this process residual stresses are developed in the welded region. It is a critical factor affecting the performance and lifespan of welded parts. Accurate measurement of residual stress is very important for ensuring the structural integrity of welded components. The conventional blind hole drilling method for residual stress estimation using the strain rosette, results error in the strain data capturing and compensating it is a challenging task. The omission of strain rosette is possible using the recently developed Digital Image Correlation in conjunction with Blind Hole Drilling. This paper focuses on the feasibility study of DIC in residual stress measurement. To accomplish this, Aluminum alloy AA6082 friction stir welded butt-joints are prepared. The residual stresses were measured at the top side of the weld joint using the DIC-BHD approach. At the weld top position, the transverse residual stress of -100 MPa approx. and the longitudinal residual stress of 118 MPa approx. were estimated. Abstract Aluminum Alloy is extensively used in aerospace and automotive industry due to its light weight and high strength properties. It is generally joined using Friction Stir Welding, which is a solid-state process. During this process residual stresses are developed in the welded region. It is a critical factor affecting the performance and lifespan of welded parts. Accurate measurement of residual stress is very important for ensuring the structural integrity of welded components. The conventional blind hole drilling method for residual stress estimation using the strain rosette, results error in the strain data capturing and compensating it is a challenging task. The omission of strain rosette is possible using the recently developed Digital Image Correlation in conjunction with Blind Hole Drilling. This paper focuses on the feasibility study of DIC in residual stress measurement. To accomplish this, Aluminum alloy AA6082 friction stir welded butt-joints are prepared. The residual stresses were measured at the top side of the weld joint using the DIC-BHD approach. At the weld top position, the transverse residual stress of -100 MPa approx. and the longitudinal residual stress of 118 MPa approx. were estimated. Keywords: AA6082; Blind Hole Drilling ; Digital Image Correlation ; FSW; Residual Stress Measurement 1. Introduction The worldwide demand for aluminum alloys is constantly increasing because of its wide range of applications over various industries. Due to high strength-to-weight ratio and good corrosion resistance property with good formability etc. Aluminum alloys are being used in aerospace, defense and other industries Rohilla et al. (2017). One of the commonly used Aluminum alloys is AA-6082 in the form of sheets or extruded parts Mroczka et al. (2009). Friction Third International Conference on Structural Integrity 2023 (ICONS 2023) A study on residual stress measurement by DIC approach in FSW welded AA6082 joints Aritro Chatterjee, Arpan Mandal, Anoj Giri* School of Mechanical Engineering, Vellore Institute of Technology, Vellore- 632014, India. Third International Conference on Structural Integrity 2023 (ICONS 2023) A study on residual stress measurement by DIC approach in FSW welded AA6082 joints Aritro Chatterjee, Arpan Mandal, Anoj Giri* School of Mechanical Engineering, Vellore Institute of Technology, Vellore- 632014, India. Keywords: AA6082; Blind Hole Drilling ; Digital Image Correlation ; FSW; Residual Stress Measurement 1. Introduction The worldwide demand for aluminum alloys is constantly increasing because of its wide range of applications over various industries. Due to high strength-to-weight ratio and good corrosion resistance property with good formability etc. Aluminum alloys are being used in aerospace, defense and other industries Rohilla et al. (2017). One of the commonly used Aluminum alloys is AA-6082 in the form of sheets or extruded parts Mroczka et al. (2009). Friction * Corresponding author. E-mail address: anoj.giri@vit.ac.in