Effect of kissing bond on fatigue behavior of friction stir welds on Al 5083 alloy

Fatigue properties of FS welds with a kissing bond (bonded welds) were studied by comparing the test results of bonded welds with those of sound welds. The fatigue life of bonded welds is 21∼43 times shorter than that of sound welds under the stress ratio R = 0.1, and the fatigue characteristic values of each welds have decreased from 100.24 MPa for sound welds to 65.57 MPa for bonded welds at 2 × 106 cycles. At the macroscopic level there is no evidence of failure by shear. The fatigue fracture revealed cracks initiated from the root tip of kissing bond. C 2006 Springer Science + Business Media, Inc.