Quasi-in-situ observation of fatigue crack growth behavior of friction stir welded 2024-T4 joint

Abstract This study presents a quasi- in situ observation of the fatigue crack growth behavior in a friction stir welded 2024-T4 joint. The microstructure and fatigue properties of the joint were investigated using electron backscatter diffraction (EBSD) technique, scanning electron microscopy (SEM), and fatigue crack growth tests. The fatigue crack growth behavior of the joint was examined by conducting fatigue crack growth tests with different notch locations. The results show that the sample with the notch in the stir zone (SZ) exhibited the highest resistance to fatigue crack growth, followed by the notched samples of the Advancing side (AS) and Retreating side (RS) weldments. Microstructural observations showed a homogeneous microstructure with a fine grain size in SZ and it was observed that this fine-grained structure significantly enhanced the material’s resistance to fatigue crack growth. The experimental results were further analyzed using the Paris model to provide a quantitative understanding of the crack growth behavior. The study underlines the impact of microstructural characteristics and notch location on the fatigue performance of the weldment. Overall, the quasi- in situ observations and experimental findings contribute to a comprehensive understanding of the fatigue crack growth behavior in friction stir welded 2024-T4 joints.