Research on shear buckling behaviour of friction stir welding 6061-T6 aluminium alloy H-section beams

IF 6.6 1区工程技术 Q1 ENGINEERING, CIVIL

Thin-Walled Structures Pub Date : 2025-09-04 DOI:10.1016/j.tws.2025.113922

Beibei Li , Yanjun Tong , Shuai Mo , Jingfeng Wang , Letian Hai , Yuanqing Wang

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引用次数: 0

Abstract

This study systematically investigated the shear buckling behaviour of the friction stir welding (FSW) 6061-T6 aluminium alloy H-section beams through experimental and numerical analysis methods. FSW is a solid-state joining process that exhibits superior retention of joint strength and markedly lower sensitivity to welding-induced defects in comparison to conventional fusion welding techniques. On the basis of experimental tests on six FSW 6061-T6 aluminium alloy H-section beams, the material properties, initial geometric imperfections, FSW-induced residual stresses, failure modes and load-deflection curves were reported. Finite element (FE) models were validated against experimental results to assess their predictive accuracy in failure modes and shear buckling resistances. A parametric analysis involving 708 FE models was subsequently conducted to expand the database. The results indicate that FE models incorporating FSW-induced strength reduction and residual stresses effectively enhanced the predictive accuracy and consistency of shear buckling resistances of specimens. The number/width of welds and residual stresses exhibited minimal influence on shear buckling performance, while the installation of rigid end posts could enhance the anchorage restraint on web tension field development, thereby improving the shear buckling capacity of beams. Initial geometric imperfections had a certain weakening effect on the ultimate bearing capacity of the beam, while the influence of their amplitude was limited. The experimental and FE results for FSW 6061-T6 aluminium alloy H-section beams were compared against current design requirements stipulated in Chinese, European, and American codes. The comparison results indicate that when the normalized width-to-thickness ratios of the web fell within the ranges of 0.5–1.0 and 0.6–1.2, the design resistance predictions of the Chinese and American codes were unsafe, and all predicted results were overall conservative by 24.0–34.5%, also with greater dispersion. Modifications were proposed based on Chinese and European codes, achieving a 6–18% improvement in prediction accuracy and reduced dispersion compared to current standards.

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6061-T6铝合金h型梁搅拌摩擦焊接剪切屈曲行为研究

通过试验和数值分析方法，系统研究了搅拌摩擦焊6061-T6铝合金h型钢梁的剪切屈曲行为。FSW是一种固态连接工艺，与传统的熔焊技术相比，它具有优越的接头强度保持能力和明显降低的焊接缺陷敏感性。在对6根FSW 6061-T6铝合金h型梁进行试验的基础上，报告了材料性能、初始几何缺陷、FSW残余应力、破坏模式和载荷-挠度曲线。通过实验验证了有限元模型在破坏模式和抗剪切屈曲方面的预测精度。随后进行了涉及708个有限元模型的参数分析，以扩大数据库。结果表明，考虑fsw强度折减和残余应力的有限元模型有效提高了试件抗剪切屈曲抗力预测的准确性和一致性。焊缝数量/宽度和残余应力对剪力屈曲性能的影响最小，而刚性端柱的安装可以增强对腹板张力场发展的锚固约束，从而提高梁的剪力屈曲能力。初始几何缺陷对梁的极限承载力有一定的削弱作用，但其幅值的影响有限。将FSW 6061-T6铝合金h型钢梁的试验和有限元结果与中国、欧洲和美国现行规范的设计要求进行了比较。对比结果表明，当归一化腹板宽厚比在0.5 ~ 1.0和0.6 ~ 1.2范围内时，中美两国规范的设计阻力预测不安全，预测结果总体保守24.0 ~ 34.5%，且离散性较大。基于中国和欧洲的规范提出了修改，与现行标准相比，预测精度提高了6-18%，并降低了离散度。

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来源期刊

Thin-Walled Structures 工程技术-工程：土木

CiteScore

9.60

自引率

20.30%

发文量

801

审稿时长

66 days

期刊介绍： Thin-walled structures comprises an important and growing proportion of engineering construction with areas of application becoming increasingly diverse, ranging from aircraft, bridges, ships and oil rigs to storage vessels, industrial buildings and warehouses. Many factors, including cost and weight economy, new materials and processes and the growth of powerful methods of analysis have contributed to this growth, and led to the need for a journal which concentrates specifically on structures in which problems arise due to the thinness of the walls. This field includes cold– formed sections, plate and shell structures, reinforced plastics structures and aluminium structures, and is of importance in many branches of engineering. The primary criterion for consideration of papers in Thin–Walled Structures is that they must be concerned with thin–walled structures or the basic problems inherent in thin–walled structures. Provided this criterion is satisfied no restriction is placed on the type of construction, material or field of application. Papers on theory, experiment, design, etc., are published and it is expected that many papers will contain aspects of all three.