Structural Integrity of AA7075-T651 UWFSW Joints

This investigation is focused on the comparison of selected low-cycle fatigue properties of AA7075-T651 friction stir welded and underwater friction stir welded joints together with the evaluation of their lifetime prediction by the Manson-Coffin-Basquin formula. Additionally, the analysis of the fractured surface was involved to describe the character of joints decohesion. The analysis of the obtained hysteresis loops revealed that FSW joint exhibits cyclic hardening, with a stable maximum stress and a decreasing minimum stress, leading to an increased contribution of compressive stresses and a lower mean stress during stabilized fatigue. In comparison, the UWFSW joint also shows cyclic hardening but with a greater contribution of tensile stresses, a higher mean stress, and a reduced participation of plastic deformation. The Manson-Coffin-Basquin equation effectively predicts the fatigue life of AA7075-T651 alloy joints, with UWFSW joints showing significantly lower standard deviation (0.0035 vs. 0.0135) and narrower dispersion bands (1.61 vs. 1.93) compared to conventional FSW joints.