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<p>This study investigates the influence of friction stir welding (FSW) on the quasi-static fracture toughness of AA3003 aluminum alloy plates by comparing two fracture mechanics approaches: the essential work of fracture (EWF) method and the Begley–Landes J-integral method. The crack resistance of welded and non-welded double-edge notched tension (DENT) specimens was characterized using both techniques to assess their reliability and practical applicability for thin aluminum sheets. Tensile tests reveal a significant decrease in fracture toughness for FSW specimens, with the EWF method showing a 31.43% reduction in essential fracture energy (from 100.443 to 68.878 kJ/m<sup>2</sup>) and the Begley–Landes method indicating a 35.75% reduction in critical J-integral (from 116.570 to 74.913 kJ/m<sup>2</sup>) compared to non-welded specimens. Despite the Begley–Landes method yielding approximately 16% higher absolute values, both techniques demonstrate consistent trends in evaluating the detrimental effect of FSW on material toughness. The distinctiveness of this study lies in the systematic comparison of these two methodologies, establishing a strong correlation between J-integral values and essential fracture work (ratio <i>J</i><sub><i>Ic</i></sub>/<i>W</i><sub><i>e</i></sub> ≈ 1.16) and confirming their fundamental equivalence as measures of fracture resistance at crack initiation. Based on experimental efficiency and data interpretation simplicity, the EWF method is recommended for industrial quality control. At the same time, the Begley–Landes approach remains valuable for fundamental research requiring rigorous energy analysis. Results indicate that plastic deformation is more extensive in non-welded specimens, with microstructural changes induced by FSW – particularly dynamic recrystallization, which is responsible for reduced toughness in welded joints. These findings offer valuable insights for industrial applications requiring high structural integrity, provide practical guidelines for selecting methods for fracture toughness characterization, and contribute to a deeper understanding of aluminum joint performance under different welding conditions.</p>

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Evaluating the Fracture Toughness of FSW AA3003 Alloy: A Dual Approach with EWF and J-Integral

  • 期刊论文

  • 发表日期：

    2025年11月1日

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  • H. Mebarki,
  • H. Fekirini,
  • A. Moualid,
  • A. Regad,
  • M. Benguediab

摘要

This study investigates the influence of friction stir welding (FSW) on the quasi-static fracture toughness of AA3003 aluminum alloy plates by comparing two fracture mechanics approaches: the essential work of fracture (EWF) method and the Begley–Landes J-integral method. The crack resistance of welded and non-welded double-edge notched tension (DENT) specimens was characterized using both techniques to assess their reliability and practical applicability for thin aluminum sheets. Tensile tests reveal a significant decrease in fracture toughness for FSW specimens, with the EWF method showing a 31.43% reduction in essential fracture energy (from 100.443 to 68.878 kJ/m2) and the Begley–Landes method indicating a 35.75% reduction in critical J-integral (from 116.570 to 74.913 kJ/m2) compared to non-welded specimens. Despite the Begley–Landes method yielding approximately 16% higher absolute values, both techniques demonstrate consistent trends in evaluating the detrimental effect of FSW on material toughness. The distinctiveness of this study lies in the systematic comparison of these two methodologies, establishing a strong correlation between J-integral values and essential fracture work (ratio JIc/We ≈ 1.16) and confirming their fundamental equivalence as measures of fracture resistance at crack initiation. Based on experimental efficiency and data interpretation simplicity, the EWF method is recommended for industrial quality control. At the same time, the Begley–Landes approach remains valuable for fundamental research requiring rigorous energy analysis. Results indicate that plastic deformation is more extensive in non-welded specimens, with microstructural changes induced by FSW – particularly dynamic recrystallization, which is responsible for reduced toughness in welded joints. These findings offer valuable insights for industrial applications requiring high structural integrity, provide practical guidelines for selecting methods for fracture toughness characterization, and contribute to a deeper understanding of aluminum joint performance under different welding conditions.