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<p>The structural integrity of welded joints is critical to the safety and long-term durability of aluminum alloy components in automotive and aerospace applications, where fatigue failure frequently initiates at localized stress concentrations. This study investigates the fatigue performance of representative welding configurations in 6061 aluminum alloy. The fracture mechanisms and underlying microstructural evolution, particularly dislocation behavior, in the welded joints were characterized to elucidate the failure origins. Additionally, this study proposes a high-precision fatigue life prediction method for welded components, leveraging finite element numerical simulations, empirical fatigue performance data of 6061 aluminum alloy base material, and key correction parameters from the Forschungskuratorium Maschinenbau guideline. The method establishes fatigue life predictions based on stress characteristics at critical locations—specifically, those corresponding to characteristic points on the fatigue <i>S-N</i> curve. While validated for aluminum alloy welded joints, the approach is broadly applicable to engineering components, offering a novel and robust framework for fatigue performance assessment.</p>

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Component Welding Structure and High Cycle Fatigue Failure Analysis: Based on 6061 Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Mengxiao Zhang,
  • Yan Jia,
  • Xiaobo Hua,
  • Juan Li,
  • Hongwu Song,
  • Huan Liu,
  • Yong Xu,
  • Shihong Zhang,
  • Ming Cheng,
  • Yan Chen,
  • Yaodong Liu

摘要

The structural integrity of welded joints is critical to the safety and long-term durability of aluminum alloy components in automotive and aerospace applications, where fatigue failure frequently initiates at localized stress concentrations. This study investigates the fatigue performance of representative welding configurations in 6061 aluminum alloy. The fracture mechanisms and underlying microstructural evolution, particularly dislocation behavior, in the welded joints were characterized to elucidate the failure origins. Additionally, this study proposes a high-precision fatigue life prediction method for welded components, leveraging finite element numerical simulations, empirical fatigue performance data of 6061 aluminum alloy base material, and key correction parameters from the Forschungskuratorium Maschinenbau guideline. The method establishes fatigue life predictions based on stress characteristics at critical locations—specifically, those corresponding to characteristic points on the fatigue S-N curve. While validated for aluminum alloy welded joints, the approach is broadly applicable to engineering components, offering a novel and robust framework for fatigue performance assessment.