Journal Article

PUBDB-2025-03824

http://join2-wiki.gsi.de/foswiki/pub/Main/Artwork/join2_logo100x88.png Three-dimensional mapping of residual stresses and crack propagation in refill friction stir spot welded aluminium samples via synchrotron X-ray diffraction and X-ray micro-computed tomography

Bernardi, M. (Corresponding author)Extern* ; Canelo-Yubero, D. (Corresponding author) ; Chen, T.Extern* ; Suhuddin, U. F. H.Extern* ; Bergmann, L.Extern* ; Klusemann, B.Extern*

2026
Elsevier Oxford

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Please use a persistent id in citations: doi:10.1016/j.ijfatigue.2025.109223  doi:10.3204/PUBDB-2025-03824

Abstract: Refill Friction Stir Spot Welding (refill FSSW) shows strong potential to replace riveting in the aerospace industry. However, the complex deformation and thermal effects associated with this process lead to residual stresses that may influence the fatigue life of the joint. This study reveals for the first time the non-uniform residual stresses across the thickness of a refill FSSW aluminium joint using synchrotron X-ray radiation in combination with a conical slit cell. Clear differences can be observed in the stresses between the region subjected to plasticisation and that affected solely by heat input. A fatigue testing campaign on the aluminium joints demonstrated their high reproducibility and robustness. X-ray micro-computed tomography enabled the three-dimensional visualisation of fatigue crack nucleation and propagation morphology, the latter correlated with the tensile residual stresses in the weld area. The results can contribute to the development of more accurate fatigue life prediction models and improve the overall reliability of refill FSSW aluminium joints in engineering applications.

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Contributing Institute(s):

1. Helmholtz-Zentrum Hereon (Hereon)
2. DOOR-User (DOOR ; HAS-User)

Research Program(s):

1. 6G3 - PETRA III (DESY) (POF4-6G3) (POF4-6G3)

Experiment(s):

1. PETRA Beamline P07 (PETRA III)

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Database coverage:
; ; ; Clarivate Analytics Master Journal List ; Current Contents - Engineering, Computing and Technology ; Ebsco Academic Search ; Essential Science Indicators ; IF >= 5 ; JCR ; SCOPUS ; Science Citation Index Expanded ; Web of Science Core Collection

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