Fatigue property of Gap-Filling Friction Stir Welded Joints in Aluminum Alloy Profiles for Rail Vehicles

ZHANG Xinmeng; WANG Shijun; WANG Dachen; YANG Jian; CHEN Yuxin; ZHANG Linru; ZHANG Chao; WANG Beibei; XUE Peng

doi:10.7512/j.issn.1001-2303.2026.06.08

Welding Technology | Views : 0 下载量: 80 CSCD: 0

PDF
Export
Share
Collection
Album

Fatigue property of Gap-Filling Friction Stir Welded Joints in Aluminum Alloy Profiles for Rail Vehicles
Vol. 56, Issue 6, Pages: 64-69(2026)
Received：30 April 2026，

Revised：2026-06-05，

Published：20 June 2026
DOI： 10.7512/j.issn.1001-2303.2026.06.08
稿件说明：

移动端阅览

张欣盟，王世君，王大臣，等.铝合金型材间隙填料搅拌摩擦焊接头疲劳性能研究［J］.电焊机，2026，56（6）：64-69. DOI： 10.7512/j.issn.1001-2303.2026.06.08.

ZHANG Xinmeng, WANG Shijun, WANG Dachen, et al.Fatigue property of Gap-Filling Friction Stir Welded Joints in Aluminum Alloy Profiles for Rail Vehicles[J].Electric Welding Machine, 2026, 56(6): 64-69. DOI： 10.7512/j.issn.1001-2303.2026.06.08.

摘要

针对轨道车辆6005A-T6铝合金型材搅拌摩擦焊（FSW）过程中装配间隙导致的接头成形与服役性能问题，该研究以1 mm间隙型材FSW接头为对象，分别采用6005A铝合金填片（同质）和ER5087铝合金异质填丝（直径1 mm）两种方式填充间隙，在优化工艺参数（转速800 r/min、200 mm/min下制备FSW接头，对比研究两种填料对接头疲劳性能及断裂行为的影响。结果表明，6005A铝合金同质填片和ER5087异质填丝均实现较好接头成形和有效熔合。S-N曲线结果表明，同质填片接头在10

周次下的疲劳强度约40 MPa，而异质填丝接头提升至约70 MPa。两种接头的疲劳断裂主要发生在热影响区，而非焊核区，且裂纹未沿“S”线扩展，表明在优化参数下外加填料未成为主导疲劳失效的主要因素。断口分析显示，裂纹多从试样表面边角或焊缝“鱼鳞纹”下方萌生，裂纹扩展区以解理特征为主，瞬时断裂区呈韧窝形貌。研究结果可为轨道车辆铝合金型材间隙填充FSW工艺优化及服役可靠性评价提供参考。

Abstract

To address the joint formation and service performance issues caused by assembly gaps during friction stir welding (FSW) of 6005A-T6 aluminum alloy extruded profiles for rail vehicles

FSW joints with a 1 mm gap were fabricated using two gap-filling methods: 6005A aluminum alloy homogeneous filler strip (1 mm thick) and ER5087 aluminum alloy heterogeneous filler wire (1 mm in diameter). The joints were produced under optimized welding parameters (rotational speed of 800 rpm and travel speed of 200 mm/min)

and the effects of the two filler methods on high-cycle fatigue performance and fracture behavior were comparatively investigated. The S-N curve results indicate that the fatigue strength at 10⁷ cycles of the homogeneous filler-strip joint is approximately 40 MPa

while that of the heterogeneous filler-wire joint increases to approximately 70 MPa

representing a significant improvement in fatigue performance. Fatigue fracture in both types of joints predominantly occurs in the heat-affected zone (HAZ) and parent material (PM)

rather than in the stir zone (SZ). No crack propagation along the "S-line" or hook defects is observed

indicating that under the optimized parameters

the introduced filler materials are not the dominant factor controlling fatigue failure. Fractographic analysis reveals that fatigue cracks generally initiate from the specimen surface corners or beneath the welding ripples

the crack propagation region exhibits predominantly cleavage characteristics

and the final fracture region displays dimple morphology. These results provide experimental references for the selection of gap-filling FSW process schemes for aluminum alloy profiles in rail vehicle applications.

关键词

Keywords

references

Wang B B ， Chen F F ， Liu F ， et al . Enhanced mechanical properties of friction stir welded 5083Al-H19 joints with additional water cooling ［J］. Journal of Materials Science & Technology ， 2017 ， 33 （ 9 ）： 1009 - 1014 .

Liu F C ， Feng A H ， Pei X ， et al . Friction stir based welding，processing，extrusion and additive manufacturing ［J］. Progress in Materials Science ， 2024 ， 146 ： 101330 .

Huang X ， Reynolds A P . Effects of the friction stir welding process variants on residual stress ［J］. Science and Technology of Welding and Joining ， 2018 ， 23 （ 4 ）： 279 - 286 .

Zhao T ， Sato Y S ， Kokawa H ， et al . Predicting Tensile Properties of Friction-Stir-Welded 6063 Aluminum with Experimentally Measured Welding Heat Input ［J］. Acta Metallurgica Sinica （English Letters）， 2020 ， 33 （ 9 ）： 1235 - 1242 .

Aziz S B ， Dewan M W ， Huggett D J ， et al . A fully coupled thermomechanical model of friction stir welding （FSW） and numerical studies on process parameters of lightweight aluminum alloy joints ［J］. Acta Metallurgica Sinica （English Letters）， 2018 ， 31 （ 1 ）： 1 - 18 .

张欣盟，何广忠，王贝贝，等 . 6082-T6铝合金填料搅拌摩擦焊工艺［J］. 电焊机， 2020 ， 50 （ 12 ）： 54 - 58 .

ZHANG X M ， HE G Z ， WANG B B ， et al . PInvestigation of friction stir welded 6082-T6 Al alloy with fillers ［J］. Electric Welding Machine ， 2020 ， 50 （ 12 ）： 54 - 58 .

Wanjara P ， Monsarrat B ， Larose S . Gap tolerance allowance and robotic operational window for friction stir butt welding of AA6061 ［J］. Journal of Materials Processing Technology ， 2013 ， 213 ： 631 - 640 .

Inada K ， Fujii H ， Ji Y S ， et al . Effect of gap on FSW joint formation and development of friction powder processing ［J］. Science and Technology of Welding and Joining ， 2010 ， 15 ： 131 - 136 .

Ji S ， Meng X ， Xing J ， et al . Vertical compensation friction stir welding of 6061-T6 aluminum alloy ［J］. High Temperature Materials And Processes ， 2016 ， 35 ： 843 - 851 .

Sun G ， Wang C ， Wei X ， et al . Study on small fatigue crack initiation and growth for friction stir welded joints ［J］. Materials Science and Engineering：A ， 2019 ， 739 ： 71 - 85 .

Guo S ， Shah L ， Ranjan R ， et al . Effect of quality control parameter variations on the fatigue performance of aluminum friction stir welded joints ［J］. International Journal of Fatigue ， 2019 ， 118 ： 150 - 161 .

沈可心，李权，张思聪，等 . 2195-T8铝锂合金及其搅拌摩擦焊接头的低周疲劳行为（英文）［J］. 中国有色金属学报（英文版）： 1 - 24 . ［ 2026-05-01 ］. https：//link.cnki.net/urlid/43.1239.TG.20260331.1119.002 https://link.cnki.net/urlid/43.1239.TG.20260331.1119.002 .

Jolu T L ， Morgeneyer T F ， Gourgues-Lorenzon A F . Effect of joint line remnant on fatigue lifetime of friction stir welded Al-Cu-Li alloy ［J］. Science and Technology of welding and joining ， 2010 ， 15 （ 8 ）： 694 - 698 .

赵亚东，沈长斌，刘书华，等 . 6082铝合金搅拌摩擦焊焊缝的电化学腐蚀行为［J］. 焊接学报， 2008 （ 10 ）： 105 - 107 .

ZHAO Y D ， SHEN C B ， LIU S H ， et al . Electrochemical corrosion behavior of friction stir welding weld of 6082 aluminum alloy ［J］. Transactions of The China Welding Institution ， 2008 （ 10 ）： 105 - 107 .

卢峰华，钮旭晶，候振国，等 . 6082-T6厚板铝合金搅拌摩擦焊焊接接头应力腐蚀的敏感性［J］. 焊接技术， 2020 ， 49 （ 06 ）： 31 - 34 .

LU F H ， NIU X J ， HOU Z G ， et al . Sensitivity to stress corrosion of friction stir welded joint of 6082-t6 thick plate aluminum alloy ［J］. Welding Technology ， 2020 ， 49 （ 06 ）： 31 - 34 .

Zhang Z ， Xiao B L ， Ma Z Y . Effect of segregation of secondary phase particles and “S” line on tensile fracture behavior of friction stir-welded 2024Al-T351 joints ［J］. Metallurgical and materials transactions A ， 2013 ， 44 （ 9 ）： 4081 - 4097 .

Zhou C ， Yang X ， Luan G . Effect of root flaws on the fatigue property of friction stir welds in 2024-T3 aluminum alloys ［J］. Materials Science and Engineering：A ， 2006 ， 418 （ 1-2 ）： 155 - 160 .

Yoon T J ， Kang C Y . Observations on metallurgical phenomena and formation of onion ring nugget during friction stir lap welding of dissimilar aluminum by a new 3D technique ［J］. Materials Letters ， 2015 ， 142 ： 253 - 257 .

Alert me when the article has been cited

提交

Influence of Different Offsets on the Mechanical and Fatigue Properties of Friction Stir Weld Lap Joints

Effect of Post-Weld Cold Rolling on Microstructure and Properties of Al-Cu Dissimilar FSW Joints

Effect of Pre-weld Polishing on Properties of High-Speed Friction Stir Welded 6005A-T6 Aluminum Alloy Profile Joints

Research Status of High-Strength Steel Metal-Cored Wires

Study on Mechanical Properties of Dissimilar Metal Joints Between Haynes 230 and Inconel 617 Brazed with Amorphous BNi2 Filler Metal