Fracture Behavior of AA7075-AA6061 and AA7075-Cu Friction-Stir Welded Joints Containing Blunt V-Notches under Opening-Mode Loading

The purpose of this study is to predict the load-bearing capacity (LBC) of fracture specimens containing V-notched friction-stir welded (FSWed) joints of AA7075-Cu and AA7075-AA6061 materials and subjected to mode I loading conditions. Due to the resulting elastic-plastic behavior and the corresponding development of significant plastic deformations, the fracture analysis of the FSWed alloys requires elastic-plastic fracture criteria, which are complex and time-consuming. Thus, in this study, the equivalent material concept (EMC) is applied, equating the actual AA7075-AA6061 and AA7075-Cu materials to equivalent virtual brittle materials. Then, two brittle fracture criteria, the maximum tangential stress (MTS) and mean stress (MS), are utilized to estimate the LBC of the V-notched FSWed parts. The comparison between the experimental results and the theoretical predictions reveals that both fracture criteria, in combination with EMC, can accurately predict the LBC in the analyzed components.