A FEM-DBEM investigation of the influence of process parameters on crack growth in aluminum friction stir welded butt joints

This paper deals with a numerical investigation on the influence of FSW process parameters on fatigue crack growth in AA2024-T3 butt joints. The computational approach is based on the sequential usage of Finite Element Method (FEM) and Dual Boundary Element Method (DBEM). The distribution of the process induced residual stresses has been mapped by means of the contour method. The residual stress field has then been superimposed in a DBEM environment to the stress field induced by a remote fatigue traction load. A two-parameter crack growth law has been used for the crack propagation rate assessment. The simulation results corresponding to different combinations of process parameters are presented. The influence of process parameters on the residual stress distribution has also been highlighted.