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On the Application of Laser Shock Peening as a Manufacturing and Repair Process to Improve the Fatigue Performance of Refill Friction Stir Spot-Welded AA2024-T3 Joints

Nikolai Kashaev

Nikolai Kashaev

Institute of Material and Process Design, Helmholtz-Zentrum HereonGeesthacht, Germany
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Kashaev, Nikolai
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Tim Mohr

Tim Mohr

Institute of Material and Process Design, Helmholtz-Zentrum HereonGeesthacht, Germany
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Mohr, Tim
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Sören Keller

Sören Keller

Institute of Material and Process Design, Helmholtz-Zentrum HereonGeesthacht, Germany
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Keller, Sören
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Uceu Fuad Hasan Suhuddin

Uceu Fuad Hasan Suhuddin

Institute of Material and Process Design, Helmholtz-Zentrum HereonGeesthacht, Germany
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Hasan Suhuddin, Uceu Fuad
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Benjamin Klusemann

Benjamin Klusemann

  • Institute of Material and Process Design, Helmholtz-Zentrum HereonGeesthacht, Germany
  • Institute for Production Technology and Systems, Leuphana University of LüneburgLüneburg, Germany
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Klusemann, Benjamin
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Falk Dorn

Falk Dorn

Institute of Material and Process Design, Helmholtz-Zentrum HereonGeesthacht, Germany
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Dorn, Falk
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Volker Ventzke

Volker Ventzke

Institute of Material and Process Design, Helmholtz-Zentrum HereonGeesthacht, Germany
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Ventzke, Volker
  
07 lug 2025
On the Application of Laser Shock Peening as a Manufacturing and Repair Process to Improve the Fatigue Performance of Refill Friction Stir Spot-Welded AA2024-T3 Joints's Cover Image
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Categoria dell'articolo: Research Article
Pubblicato online: 07 lug 2025
DOI: https://doi.org/10.2478/fas-2024-0003
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© 2025 Nikolai Kashaev et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

Figure 1.

a) Geometry of the welded overlap joint and b) schematic representation of the refill FSSW joint: BM – base material, SZ – stir zone, HAZ – heat-affected zone, TMAZ – thermomechanical-affected zone.
a) Geometry of the welded overlap joint and b) schematic representation of the refill FSSW joint: BM – base material, SZ – stir zone, HAZ – heat-affected zone, TMAZ – thermomechanical-affected zone.

Figure 2.

a) Schematic illustration of the application of the LSP treatment to the base material specimens and to the welded specimen with refill FSSW joint in the case of b) LSP treatment on one side and c) LSP treatment on both sides. The starting point of each LSP sequence was in the lower right-hand corner. The direction of the LSP sequence is parallel to the y-direction. The step-position of each LSP sequence is in the negative direction of the x-axis. All dimensions are in mm.
a) Schematic illustration of the application of the LSP treatment to the base material specimens and to the welded specimen with refill FSSW joint in the case of b) LSP treatment on one side and c) LSP treatment on both sides. The starting point of each LSP sequence was in the lower right-hand corner. The direction of the LSP sequence is parallel to the y-direction. The step-position of each LSP sequence is in the negative direction of the x-axis. All dimensions are in mm.

Figure 3.

a) Sketch of specimen with positions for three drilled holes used for the residual stress analysis, b) weld side of specimen in as-welded condition with position of drilled hole, c) back side of specimen in as-welded condition with position for drilled hole, d) weld side of specimen welded and LSP-treated with position for drilled hole, e) back side of specimen welded and LSP-treated with position for drilled hole. Depth-resolved residual stress profiles obtained for f) BM and LSP-treated AA2024 sheet and g) AA2024 lap-joint in as-welded as well as welded and LSP-treated condition.
a) Sketch of specimen with positions for three drilled holes used for the residual stress analysis, b) weld side of specimen in as-welded condition with position of drilled hole, c) back side of specimen in as-welded condition with position for drilled hole, d) weld side of specimen welded and LSP-treated with position for drilled hole, e) back side of specimen welded and LSP-treated with position for drilled hole. Depth-resolved residual stress profiles obtained for f) BM and LSP-treated AA2024 sheet and g) AA2024 lap-joint in as-welded as well as welded and LSP-treated condition.

Figure 4.

Fatigue test results for as-welded and welded and LSP-treated.
Fatigue test results for as-welded and welded and LSP-treated.

Figure 5.

Fatigue test results for pre-damaged specimens.
Fatigue test results for pre-damaged specimens.

Figure 6.

a) Schematic representation of the cross section of the overlap joint with the weld and positions 1 and 2 indicating the two crack origins in the cross section (marked with the red box). b) Cross-section of the as-welded specimen tested at 3.5 kN and subjected to 6.5 × 103 cycles with cracks starting at positions 1 and 2, and c) the magnification of the crack at position 1. d) Cross-section of the as-welded specimen tested at 3.5 kN and subjected to 1.4 × 104 cycles with cracks starting at positions 1 and 2, and e) the magnification of the crack at position 2 located near the interface between the upper and lower parts and f) the magnification of the position 2 near the outer surface of the lower part (crack tip). g) Cross section of the welded and LSP-treated specimen on both sides tested at 3.5 kN and subjected to 1.0 × 107 cycles with cracks starting at positions 1 and 2, and h) the magnification of the crack at position 2.
a) Schematic representation of the cross section of the overlap joint with the weld and positions 1 and 2 indicating the two crack origins in the cross section (marked with the red box). b) Cross-section of the as-welded specimen tested at 3.5 kN and subjected to 6.5 × 103 cycles with cracks starting at positions 1 and 2, and c) the magnification of the crack at position 1. d) Cross-section of the as-welded specimen tested at 3.5 kN and subjected to 1.4 × 104 cycles with cracks starting at positions 1 and 2, and e) the magnification of the crack at position 2 located near the interface between the upper and lower parts and f) the magnification of the position 2 near the outer surface of the lower part (crack tip). g) Cross section of the welded and LSP-treated specimen on both sides tested at 3.5 kN and subjected to 1.0 × 107 cycles with cracks starting at positions 1 and 2, and h) the magnification of the crack at position 2.

Figure 7.

Categorization of the mechanisms responsible for the failure of specimens in the fatigue test. a) Fatigue fracture failure “crack through the sheet” and b) fatigue fracture failure “shearing the weld”.
Categorization of the mechanisms responsible for the failure of specimens in the fatigue test. a) Fatigue fracture failure “crack through the sheet” and b) fatigue fracture failure “shearing the weld”.

Figure 8.

Fracture surfaces of a)-d) as-welded specimen tested at 1.5 kN and subjected to 1.41 × 106 loading cycles and e)-h) welded and LSP-treated specimen on both sides tested at 4.0 kN and subjected to 1.60 × 106 loading cycles.
Fracture surfaces of a)-d) as-welded specimen tested at 1.5 kN and subjected to 1.41 × 106 loading cycles and e)-h) welded and LSP-treated specimen on both sides tested at 4.0 kN and subjected to 1.60 × 106 loading cycles.
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