000637332 001__ 637332 000637332 005__ 20250902212647.0 000637332 0247_ $$2doi$$a10.1016/j.ijfatigue.2025.109223 000637332 0247_ $$2ISSN$$a0142-1123 000637332 0247_ $$2ISSN$$a1879-3452 000637332 0247_ $$2datacite_doi$$a10.3204/PUBDB-2025-03824 000637332 037__ $$aPUBDB-2025-03824 000637332 041__ $$aEnglish 000637332 082__ $$a600 000637332 1001_ $$0P:(DE-H253)PIP1096790$$aBernardi, Matteo$$b0$$eCorresponding author 000637332 245__ $$aThree-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 000637332 260__ $$aOxford$$bElsevier$$c2026 000637332 3367_ $$2DRIVER$$aarticle 000637332 3367_ $$2DataCite$$aOutput Types/Journal article 000637332 3367_ $$0PUB:(DE-HGF)16$$2PUB:(DE-HGF)$$aJournal Article$$bjournal$$mjournal$$s1756815847_1372736 000637332 3367_ $$2BibTeX$$aARTICLE 000637332 3367_ $$2ORCID$$aJOURNAL_ARTICLE 000637332 3367_ $$00$$2EndNote$$aJournal Article 000637332 520__ $$aRefill Friction Stir Spot Welding (refill FSSW) shows strong potential to replace riveting in the aerospace industry. However, the complex deformation and thermal effects associated with this process lead to residual stresses that may influence the fatigue life of the joint. This study reveals for the first time the non-uniform residual stresses across the thickness of a refill FSSW aluminium joint using synchrotron X-ray radiation in combination with a conical slit cell. Clear differences can be observed in the stresses between the region subjected to plasticisation and that affected solely by heat input. A fatigue testing campaign on the aluminium joints demonstrated their high reproducibility and robustness. X-ray micro-computed tomography enabled the three-dimensional visualisation of fatigue crack nucleation and propagation morphology, the latter correlated with the tensile residual stresses in the weld area. The results can contribute to the development of more accurate fatigue life prediction models and improve the overall reliability of refill FSSW aluminium joints in engineering applications. 000637332 536__ $$0G:(DE-HGF)POF4-6G3$$a6G3 - PETRA III (DESY) (POF4-6G3)$$cPOF4-6G3$$fPOF IV$$x0 000637332 588__ $$aDataset connected to CrossRef, Journals: bib-pubdb1.desy.de 000637332 693__ $$0EXP:(DE-H253)P-P07-20150101$$1EXP:(DE-H253)PETRAIII-20150101$$6EXP:(DE-H253)P-P07-20150101$$aPETRA III$$fPETRA Beamline P07$$x0 000637332 7001_ $$0P:(DE-HGF)0$$aCanelo-Yubero, David$$b1$$eCorresponding author 000637332 7001_ $$0P:(DE-H253)PIP1104798$$aChen, Ting$$b2 000637332 7001_ $$0P:(DE-H253)PIP1105066$$aSuhuddin, Uceu F. 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