Study on the Fatigue Performance of Aluminum Alloy Weld Joints under Various Loading Conditions

Due to their excellent strength-to-weight ratio, corrosion resistance and recyclability, aluminum alloys find wide utility in many engineering applications. However, as far as aircraft, bridges and offshore platforms are concerned, the susceptibility of the material to fatigue failure under cyclic loading is a major problem. 

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The fatigue strength of aluminum alloy weld joints is seriously affected by many factors, such as the kind of aluminum alloy used, the welding process (inert gas shield or molten electrode gas shielded arc welding) and weld geometry.

Moreover, the loading conditions greatly influence it. In this study, the fatigue strength of an aluminum alloy welded in different welding conditions was compared.

The purpose of this study is to clarify what factors significantly affect the fatigue life of aluminum alloy weld joints and recommend how they can be improved with reference to experience.

Materials and Methods

The study of durable goods on this material both aluminum alloy, AA6061-T6 as well as AA7075-T6. These alloys have high strength and reasonable toughness, often used for structures. The welding of the weld joint was processed by GMAW using ER5356 aluminum welding wire. The weld geometry was designed so that stress concentrations could be eliminated and even distributed evenly to the load.

Fatigue tests were determined to be performed under three different loading conditions, namely tension-tension, bending and push-pull. At a given stress level, fatigue life is defined as the number of cycles to failure. The fatigue data were analyzed using the S-N curve approach, which links life of fatigue with stress level


The fatigue performance analyses of welded aluminum alloy joints revealed that loading conditions greatly impacted endurance. Tension-tension loading prompted the shortest lifespans, followed by bending and push-pull stressors. This resulted from tension-tension inducing the most tensile stresses in the weld, known to primarily cause aluminum alloy fatigue failure.

The chosen aluminum alloy also considerably affected weld joint durability. AA7075-T6 alloy joints demonstrated enhanced endurance over AA6061-T6 alloy joints. This stemmed from AA7075-T6 possessing superior tensile strength and ductility compared to AA6061-T6. Interestingly, examinations found that welded 6065 joints constructed with filet welds rather than butt welds exhibited increased fatigue resistance, highlighting the significance of weld geometry.


The study uncovered significant conclusions about aluminum alloy compositions and welding methods. Namely, alloys with greater tensile resilience and malleability exhibited elongated endurance under cyclic stress. Moreover, soldering techniques inducing minimal localized strain concentrations within the union augmented the fatigue life. Finally, with judicious consideration of the applied loads faced by the construction, structures fashioned from these materials and joints endured stress fluctuations to a higher degree. The insights inform optimized designs and fabrication sequences to successfully deploy lightweight yet robust aluminum constructions.


This research delved into how aluminum alloy welded connections endure tiredness under diverse lots. Strikingly, the examination discovered that the various burdens applied, metal types joined, and welding plans manufactured had serious sway over how long the joints withstood repeated pressure before faltering. Connections fabricated with series 2000 aluminum alloys demonstrated more prominent weakness than those made with arrangement 6000, especially when confronted with changing enormous loads. Then again, joints with altogether estimated welds that carefully conveyed burden crossways the weld line demonstrated more prominent perseverance than those with littler, slanted welds. These revelations give crucial bits of knowledge that designers and fabricators can use to enhance plan and assembling strategies, bringing about more drawn out useful lifetimes even in grueling conditions.

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