Skip to main content

Fatigue In Friction Stir Welding

In Order to Read Online or Download Fatigue In Friction Stir Welding Full eBooks in PDF, EPUB, Tuebl and Mobi you need to create a Free account. Get any books you like and read everywhere you want. Fast Download Speed ~ Commercial & Ad Free. We cannot guarantee that every book is in the library!

Fatigue in Friction Stir Welding

Fatigue in Friction Stir Welding Book
Author : J. Brian Jordon,Robert Amaro,Paul Allison,Harish Rao
Publisher : Butterworth-Heinemann
Release : 2019-02-27
ISBN : 0128163054
Language : En, Es, Fr & De

GET BOOK

Book Description :

Fatigue in Friction Stir Welding provides knowledge on how to design and fabricate high performance, fatigue resistance FSW joints. It summarizes fatigue characterizations of key FSW configurations, including butt and lap-shear joints. The book's main focus is on fatigue of aluminum alloys, but discussions of magnesium, steel, and titanium alloys are also included. The FSW process-structure-fatigue performance relationships, including tool rotation, travel speeds, and pin tools are covered, along with sections on extreme fatigue conditions and environments, including multiaxial, variable amplitude, and corrosion effects on fatigue of the FSW. From a practical design perspective, appropriate fatigue design guidelines, including engineering and microstructure-sensitive modeling approaches are discussed. Finally, an appendix with numerous representative fatigue curves for design and reference purposes completes the work. Provides a comprehensive characterization of fatigue behavior for various FSW joints and alloy combinations, along with an in-depth presentation on crack initiation and growth mechanisms Presents the relationships between process parameters and fatigue behavior Discusses modeling strategies and design recommendations, along with experimental data for reference purposes

Fatigue of Friction Stir Welded Lap Joints with Sealants

Fatigue of Friction Stir Welded Lap Joints with Sealants Book
Author : Kenneth Thomas Nathaniel Doering
Publisher : Unknown
Release : 2009
ISBN : 0987650XXX
Language : En, Es, Fr & De

GET BOOK

Book Description :

"A lack of understanding of corrosion fatigue in friction stir welded aluminum joints prevents friction stir welding from being implemented in aerospace applications. Fatigue testing reveals a 60-75% reduction in the fatigue life of friction stir welded aluminum lap joints immersed in 3.5% NaCl solution (corrosion fatigue) compared with that of lap joints tested in ambient air. The loss in fatigue life is attributed to accelerated fatigue cracking due to hydrogen environment embrittlement. Two polymer sealant candidates are investigated: silicone rubber and nylon-11. Both sealant candidates can be applied prior to welding and seal the faying surface gaps in lap joints upon welding. The rubber sealant cures at room temperature after welding and can be welded with the same parameters as without the sealant. The 50% sample population corrosion fatigue life is increased by 22% with the use of the rubber sealant, but the effectiveness of the rubber sealant is limited by its cohesive mechanical properties, e.g. elongation to failure. In ambient fatigue, the nylon sealed welds exhibit twice the 50% sample population fatigue life of other welds. Finite element modeling predicts a reduction in the stresses in the weld due the stiffness contribution of the nylon sealant. The effectiveness of the nylon sealant is limited by its adhesive bond strength. When immersed in water, as in corrosion fatigue, the adhesive bond strength is reduced, the sealant bond fails within 500 fatigue cycles, and the mechanical benefits of the nylon sealant are negated. The corrosion fatigue life of nylon sealed welds is 26% less than that of welds without sealant because of the more severe hook defect associated with hotter welding conditions required to melt the nylon. Finite element modeling results indicate an increase in stress intensity factors of about 10% in welds with more severe hook defects--Abstract, leaf iii.

Advances in Friction Stir Welding and Processing

Advances in Friction Stir Welding and Processing Book
Author : M.-K. Besharati-Givi,P. Asadi
Publisher : Elsevier
Release : 2014-12-08
ISBN : 0857094556
Language : En, Es, Fr & De

GET BOOK

Book Description :

Friction-stir welding (FSW) is a solid-state joining process primarily used on aluminum, and is also widely used for joining dissimilar metals such as aluminum, magnesium, copper and ferrous alloys. Recently, a friction-stir processing (FSP) technique based on FSW has been used for microstructural modifications, the homogenized and refined microstructure along with the reduced porosity resulting in improved mechanical properties. Advances in friction-stir welding and processing deals with the processes involved in different metals and polymers, including their microstructural and mechanical properties, wear and corrosion behavior, heat flow, and simulation. The book is structured into ten chapters, covering applications of the technology; tool and welding design; material and heat flow; microstructural evolution; mechanical properties; corrosion behavior and wear properties. Later chapters cover mechanical alloying and FSP as a welding and casting repair technique; optimization and simulation of artificial neural networks; and FSW and FSP of polymers. Provides studies of the microstructural, mechanical, corrosion and wear properties of friction-stir welded and processed materials Considers heat generation, heat flow and material flow Covers simulation of FSW/FSP and use of artificial neural network in FSW/FSP

Fatigue Crack Growth in Integrally Stiffened Panels Joined Using Friction Stir Welding and Swept Friction Stir Spot Welding

Fatigue Crack Growth in Integrally Stiffened Panels Joined Using Friction Stir Welding and Swept Friction Stir Spot Welding Book
Author : Christian A. Widener,Dwight A. Burford,Bryan M. Tweedy
Publisher : Unknown
Release : 2008
ISBN : 0987650XXX
Language : En, Es, Fr & De

GET BOOK

Book Description :

Fatigue crack growth rates in AA2024-T3 sheet joined to AA7075-T6 stiffeners by friction stir welding have been compared with rates measured in panels joined with rivets and in unstiffened parent material panels. Friction stir panels were prepared with both continuous friction stir welding (FSW) and swept friction stir spot welding (FSSW). Fatigue cracks in edge crack panels with continuous FSW joints tended to grow into the parent material away from the stiffeners. This behavior was attributed to the reduced stress levels corresponding to the increased thickness of continuous FSW joints and the support of the attached stiffener. Fatigue cracks in edge crack panels were found to follow the joint line in panels made with discrete fasteners (both rivets and swept FSSW joints). The measured crack growth rates in riveted panels increased at an increasing rate as the crack approached the riveted joints. In contrast, crack growth rates in panels joined with FSSW decreased at a decreasing rate as the crack approached the swept spot joints. Test results indicate that the swept FSSW process produced favorable residual stresses that inhibited fatigue crack growth along the joint line.

Friction Stir Welding and Processing

Friction Stir Welding and Processing Book
Author : Rajiv Sharan Mishra,Partha Sarathi De,Nilesh Kumar
Publisher : Springer
Release : 2014-08-04
ISBN : 3319070436
Language : En, Es, Fr & De

GET BOOK

Book Description :

This book lays out the fundamentals of friction stir welding and processing and builds toward practical perspectives. The authors describe the links between the thermo-mechanical aspects and the microstructural evolution and use of these for the development of the friction stir process as a broader metallurgical tool for microstructural modification and manufacturing. The fundamentals behind the practical aspects of tool design, process parameter selection and weld related defects are discussed. Local microstructural refinement has enabled new concepts of superplastic forming and enhanced low temperature forming. The collection of friction stir based technologies is a versatile set of solid state manufacturing tools.

Mechanical Metallurgical and Fatigue Properties of Friction Stir Welded and Tungsten Inert Gas Welded Aa6061 T6 Aluminium Alloys

Mechanical  Metallurgical and Fatigue Properties of Friction Stir Welded and Tungsten Inert Gas Welded Aa6061 T6 Aluminium Alloys Book
Author : Akshansh Mishra
Publisher : Grin Publishing
Release : 2017-09-12
ISBN : 9783668521643
Language : En, Es, Fr & De

GET BOOK

Book Description :

Project Report from the year 2017 in the subject Engineering - Mechanical Engineering, grade: 8.9, SRM University, language: English, abstract: This paper deals with the mechanical, microstructural and fatigue analysis of welded joints. In the study, 6061-T6 aluminium alloy plates in 4mm thickness, that are particularly used for aerospace and in automotive industries, were welded using Tungsten Inert Gas (TIG) welding and Friction Stir Welding (FSW) methods as similar joints with one side pass and parameters of varying tool rotation, weld speed and 2.3 degree tool tilt angle. The weld zones cross sections were analysed with light optical microscopy (LOM). During recent years several investigations have been made of fatigue properties of friction stir welded joints. The great majority of available data from the fatigue analysis of friction stir welded joints are concerned with uniaxial loading conditions for a simple geometry. In uniaxial loading nominal stress is normally used as reference stress and it is easy to determine. However, fatigue failure is a highly localized phenomenon in engineering components and determining the nominal stress is not always possible due to the complexity of structures and presence of stress concentrators such as notches and cracks in which many approaches based on local parameters.

Methods to Increase the Fatigue Life of Friction Stir Lap Welds in No load Transfer Coupons Using a Retractable Pin Tool

Methods to Increase the Fatigue Life of Friction Stir Lap Welds in No load Transfer Coupons Using a Retractable Pin Tool Book
Author : Farzad Baratzadeh,Christian A. Widener,Hamid M. Lankarani,Dwight A. Burford
Publisher : Unknown
Release : 2012
ISBN : 0987650XXX
Language : En, Es, Fr & De

GET BOOK

Book Description :

The purpose of this study was to obtain a better understanding of crack initiation at friction stir weld exit holes in no-load transfer coupons as a first-order approximation of the potential performance of friction stir welding (FSW) joints employed for aircraft fuselage applications. In order to meet this goal, the effects of weld exit location on fatigue life in discontinuous friction stir lap-welded panels were documented. Sheets of aluminum alloys 7075-T6 and 2024-T3 were chosen for the FSW lap welds. Constant amplitude fatigue tests were carried out in order to determine the effect of various welding scenarios on fatigue crack initiation. A number of weld exit strategies were investigated, as well as another FSW tool design called a retractable pin tool (RPT). This tool was shown to eliminate the exit hole and reduce the stress concentration around the weld exit location. Prior to this work, none of the attempted exit strategies was found to delay or eliminate the initiation of fatigue cracks at the exit holes of discontinuous FSW lap welds. Only by using the RPT, which is able to eliminate the exit hole completely, was it possible to produce fatigue life results in coupons with a tool extraction zone that were comparable to those in baseline coupons containing no extraction zone.

Friction Stir Welding and Processing VIII

Friction Stir Welding and Processing VIII Book
Author : Rajiv Mishra,Murray Mahoney,Yutaka Sato,Yuri Hovanski
Publisher : Springer
Release : 2016-12-01
ISBN : 3319481738
Language : En, Es, Fr & De

GET BOOK

Book Description :

This collection focuses on all aspects of science and technology related to friction stir welding and processing.

Friction Stir Welding

Friction Stir Welding Book
Author : Daniela Lohwasser,Zhan Chen
Publisher : Elsevier
Release : 2009-12-18
ISBN : 1845697715
Language : En, Es, Fr & De

GET BOOK

Book Description :

Friction stir welding (FSW) is a highly important and recently developed joining technology that produces a solid phase bond. It uses a rotating tool to generate frictional heat that causes material of the components to be welded to soften without reaching the melting point and allows the tool to move along the weld line. Plasticized material is transferred from the leading edge to trailing edge of the tool probe, leaving a solid phase bond between the two parts. Friction stir welding: from basics to applications reviews the fundamentals of the process and how it is used in industrial applications. Part one discusses general issues with chapters on topics such as basic process overview, material deformation and joint formation in friction stir welding, inspection and quality control and friction stir welding equipment requirements and machinery descriptions as well as industrial applications of friction stir welding. A chapter giving an outlook on the future of friction stir welding is included in Part one. Part two reviews the variables in friction stir welding including residual stresses in friction stir welding, effects and defects of friction stir welds, modelling thermal properties in friction stir welding and metallurgy and weld performance. With its distinguished editors and international team of contributors, Friction stir welding: from basics to applications is a standard reference for mechanical, welding and materials engineers in the aerospace, automotive, railway, shipbuilding, nuclear and other metal fabrication industries, particularly those that use aluminium alloys. Provides essential information on topics such as basic process overview, materials deformation and joint formation in friction stir welding Inspection and quality control and friction stir welding equipment requirements are discussed as well as industrial applications of friction stir welding Reviews the variables involved in friction stir welding including residual stresses, effects and defects of friction stir welds, modelling thermal properties, metallurgy and weld performance

AMST 05 Advanced Manufacturing Systems and Technology

AMST 05 Advanced Manufacturing Systems and Technology Book
Author : Elso Kuljanic
Publisher : Springer Science & Business Media
Release : 2007-03-23
ISBN : 3211380531
Language : En, Es, Fr & De

GET BOOK

Book Description :

Manufacturing a product is not difficult, the difficulty consists in manufacturing a product of high quality, at a low cost and rapidly. Drastic technological advances are changing global markets very rapidly. In such conditions the ability to compete successfully must be based on innovative ideas and new products which has to be of high quality yet low in price. One way to achieve these objecti ves would be through massive investments in research of computer based technology and by applying the approaches presented in this book. The First International Conference on Advanced Manufacturing Systems and Technology AMST87 was held in Opatija (Croatia) in October 1987. The Second International Conference on Advanced Manufacturing Systems and Technology AMSV90 was held in Trento (Italy) in lune 1990. The Third, Fourth, Fifth and Sixth Conferences on Advanced Manufacturing Systems and Technology were all held in Udine (Italy) as follows: AMST93 in April 1993, AMST96 in September 1996, AMST99 in June 1999 and AMST02 in June 2002.

Friction Stir Welding and Processing VII

Friction Stir Welding and Processing VII Book
Author : Rajiv Mishra,Murray Mahoney,Yutaka Sato,Yuri Hovanski,Ravi Verma
Publisher : Springer
Release : 2016-12-01
ISBN : 3319481088
Language : En, Es, Fr & De

GET BOOK

Book Description :

This collection focuses on all aspects of science and technology related to friction stir welding and processing.

Friction Stir Welding of High Strength 7XXX Aluminum Alloys

Friction Stir Welding of High Strength 7XXX Aluminum Alloys Book
Author : Rajiv S. Mishra,Mageshwari Komarasamy
Publisher : Butterworth-Heinemann
Release : 2016-06-08
ISBN : 0128094605
Language : En, Es, Fr & De

GET BOOK

Book Description :

Friction Stir Welding of High Strength 7XXX Aluminum Alloys is the latest edition in the Friction Stir series and summarizes the research and application of friction stir welding to high strength 7XXX series alloys, exploring the past and current developments in the field. Friction stir welding has demonstrated significant benefits in terms of its potential to reduce cost and increase manufacturing efficiency of industrial products in transportation, particularly the aerospace sector. The 7XXX series aluminum alloys are the premium aluminum alloys used in aerospace. These alloys are typically not weldable by fusion techniques and considerable effort has been expended to develop friction stir welding parameters. Research in this area has shown significant benefit in terms of joint efficiency and fatigue performance as a result of friction stir welding. The book summarizes those results and includes discussion of the potential future directions for further optimization. Offers comprehensive coverage of friction stir welding of 7XXX series alloys Discusses the physical metallurgy of the alloys Includes physical metallurgy based guidelines for obtaining high joint efficiency Summarizes the research and application of friction stir welding to high strength 7XXX series alloys, exploring the past and current developments in the field

Mechanical Metallurgical and Fatigue Properties of Friction Stir Welded and Tungsten Inert Gas Welded AA6061 T6 Aluminium Alloys

Mechanical  Metallurgical and Fatigue Properties of Friction Stir Welded and Tungsten Inert Gas Welded AA6061 T6 Aluminium Alloys Book
Author : Akshansh Mishra,A Razal Rose,Saravanan .M,Anand Singh
Publisher : GRIN Verlag
Release : 2017-09-11
ISBN : 3668521638
Language : En, Es, Fr & De

GET BOOK

Book Description :

Project Report from the year 2017 in the subject Engineering - Mechanical Engineering, grade: 8.9, SRM University, language: English, abstract: This paper deals with the mechanical, microstructural and fatigue analysis of welded joints. In the study, 6061-T6 aluminium alloy plates in 4mm thickness, that are particularly used for aerospace and in automotive industries, were welded using Tungsten Inert Gas (TIG) welding and Friction Stir Welding (FSW) methods as similar joints with one side pass and parameters of varying tool rotation, weld speed and 2.3 degree tool tilt angle. The weld zones cross sections were analysed with light optical microscopy (LOM). During recent years several investigations have been made of fatigue properties of friction stir welded joints. The great majority of available data from the fatigue analysis of friction stir welded joints are concerned with uniaxial loading conditions for a simple geometry. In uniaxial loading nominal stress is normally used as reference stress and it is easy to determine. However, fatigue failure is a highly localized phenomenon in engineering components and determining the nominal stress is not always possible due to the complexity of structures and presence of stress concentrators such as notches and cracks in which many approaches based on local parameters.

Residual Stresses in Friction Stir Welding

Residual Stresses in Friction Stir Welding Book
Author : Nilesh Kumar,Rajiv S. Mishra,John A. Baumann
Publisher : Butterworth-Heinemann
Release : 2013-11-20
ISBN : 012800732X
Language : En, Es, Fr & De

GET BOOK

Book Description :

This book describes the fundamentals of residual stresses in friction stir welding and reviews the data reported for various materials. Residual stresses produced during manufacturing processes lead to distortion of structures. It is critical to understand and mitigate residual stresses. From the onset of friction stir welding, claims have been made about the lower magnitude of residual stresses. The lower residual stresses are partly due to lower peak temperature and shorter time at temperature during friction stir welding. A review of residual stresses that result from the friction stir process and strategies to mitigate it have been presented. Friction stir welding can be combined with additional in-situ and ex-situ manufacturing steps to lower the final residual stresses. Modeling of residual stresses highlights the relationship between clamping constraint and development of distortion. For many applications, management of residual stresses can be critical for qualification of component/structure. Reviews magnitude of residual stresses in various metals and alloys Discusses mitigation strategies for residual stresses during friction stir welding Covers fundamental origin of residual stresses and distortion

Temperature and Stress Effect Modeling in Fatigue of H13 Tool Steel at Elevated Temperatures with Applications in Friction Stir Welding

Temperature and Stress Effect Modeling in Fatigue of H13 Tool Steel at Elevated Temperatures with Applications in Friction Stir Welding Book
Author : Brad Jones
Publisher : Unknown
Release : 2015
ISBN : 0987650XXX
Language : En, Es, Fr & De

GET BOOK

Book Description :

Tooling reliability is critical to welding success in friction stir welding, but tooling fatigue is not well understood because it occurs in conditions that are often unique to friction stir welding. A fatigue study was conducted on a commonly used tooling material, H13 tool steel, using constant stress loading at temperatures between 300°C and 600°C, and the results are presented. A model is proposed accounting for temperature and stress effects on fatigue life, utilizing a two-region Arrhenius temperature model. A transition in temperature effect on fatigue life is identified. Implications of the temperature effect for friction stir welding suggest that tooling fatigue life dramatically decreases above 500°C and accelerated testing should be conducted below 500°C.

Advanced Joining Processes

Advanced Joining Processes Book
Author : Lucas F. M. da Silva,Mohamad S. El-Zein,Paulo Martins
Publisher : Elsevier
Release : 2020-10-31
ISBN : 0128208872
Language : En, Es, Fr & De

GET BOOK

Book Description :

Advanced Joining Processes: Welding, Plastic Deformation, and Adhesion brings together a range of advanced thermal, mechanical, and chemical methods of joining, offering an up-to-date resource for those looking to understand and utilize the very latest techniques. Efficient joining techniques are critical to a range of innovative applications, with technology in constant development. The first section of the book provides in-depth information on advanced welding techniques, including friction stir, explosive, ultrasonic, laser, electron beam, and computational weld analysis and fatigue of structures. The second section highlights key developments in joining by plastic deformation, adhesive bonding, and hybrid joining. The coverage of each technique is supported by practical guidance, detailed analysis, and finite element simulations. This is an essential reference for researchers and advanced students in joining, welding, adhesion, materials processing, mechanical engineering, plastics engineering, manufacturing, civil engineering, and automotive/aerospace engineering, as well as engineers, scientists, and R&D professionals, using joining, welding, and adhesion methods, across a range of industries. Presents the latest research findings and developments across welding, joining by plastic deformation, and adhesion Includes state-of-the-art methods, such as laser, ultrasonic and electron beam welding, hybrid joining, and the use of electromagnetic pulses Offers practical guidance, detailed analysis, and finite element simulations, for all techniques covered

Solid State Welding Friction and Friction Stir Welding Processes

Solid State Welding  Friction and Friction Stir Welding Processes Book
Author : Esther Titilayo Akinlabi,Rasheedat Modupe Mahamood
Publisher : Springer Nature
Release : 2020-01-06
ISBN : 3030370151
Language : En, Es, Fr & De

GET BOOK

Book Description :

This book presents critical information on the principles and operation of friction welding, friction stir welding, and friction stir processing enhanced with many robust illustrations. It explains the application of these technologies and the current research efforts in the field. The authors explain in detail the advantages offered by these welding processes, in particular their ability to join dissimilar materials not possible to weld in the past. Written for graduate students, researchers, and industrial professionals, the book reinforces concepts presented with case studies on the experimental analysis of welding the dissimilar materials of copper and aluminum, and on friction stir processing.

An Investigation Into Methods to Increase the Fatigue Life of Friction Stir Lap Welds

An Investigation Into Methods to Increase the Fatigue Life of Friction Stir Lap Welds Book
Author : Farzad Baratzadeh
Publisher : Unknown
Release : 2010
ISBN : 0987650XXX
Language : En, Es, Fr & De

GET BOOK

Book Description :

Recent advancements in friction stir welding (FSW) technology have potential for applications in aerospace structures. Friction stir spot welds have been found to be much stronger than rivets in the same material thickness, while maintaining the discontinuous crack growth path preferred by aircraft designers. In this study, the test coupons have been investigated in fatigue with the weld aligned with the loading direction. The purpose of this study was to better understand crack initiation at friction stir weld exit holes in no-load transfer coupons representative of aircraft fuselage applications. The goal was to document the effects of weld exit location on fatigue life in discontinuous friction stir welded panels and to determine possible solutions in order to reduce the stress concentration around the exit hole location, thereby increasing the panel's fatigue life. Aluminum alloys 7075-T6 and 2024-T3, which are commonly used in conventional airframe construction, were chosen for the FSW lap welds in this thesis. The methodology of this research was to weld the coupons with discontinuous friction stir lap welding using different exit hole configurations. The weld parameters such as rotation speed, travel speed, lead angle and load force had already been evaluated prior to this investigation in an earlier study during the first year of this project by Josh Merry. Once all of the coupons were welded, the next step was to fatigue test them with constant amplitude in order to determine the number of fatigue cycles and then compare all the different coupon results with the baseline coupon result that were determined in the previous study. This project investigated a number of weld exit strategies with conventional one-piece weld tools. This study also included welds produced with a two-piece weld tool called Retractable Pin Tool (RPT) in which the length of the tool probe can be adjusted during welding. The RPT weld tool was used to eliminate the exit hole of the weld in order to reduce or eliminate viii the stress concentration around the weld exit. The ultimate goal of this research was to achieve equivalent or better fatigue life in discontinuous FSW joints as compared to riveted coupons.

Friction Stir Welding and Processing X

Friction Stir Welding and Processing X Book
Author : Yuri Hovanski,Rajiv Mishra,Yutaka Sato,Piyush Upadhyay,David Yan
Publisher : Springer
Release : 2019-02-11
ISBN : 3030057526
Language : En, Es, Fr & De

GET BOOK

Book Description :

This book is a compilation of the recent progress on friction stir technologies including high-temperature applications, industrial applications, dissimilar alloy/materials, lightweight alloys, simulation, control, characterization, and derivative technologies. The volume offers a current look at friction stir welding technology from application to characterization and from modeling to R&D. Contributions document advances in application, controls, and simulation of the friction stir process to aid researchers in seeing the current state-of-the-art.

Fatigue and Static Properties of Built up Friction Stir Welded Ti 6Al 4V I Beams

Fatigue and Static Properties of Built up Friction Stir Welded Ti 6Al 4V I Beams Book
Author : Rahul Sharma,Damon R. Fick,Bharat K. Jasthi,Michael K. West
Publisher : Unknown
Release : 2018
ISBN : 0987650XXX
Language : En, Es, Fr & De

GET BOOK

Book Description :

Modern aircraft systems use high-strength alloys, such as Ti-6Al-4V (Ti-6-4), for their components. The advantage of using Ti-6-4 is its high corrosion resistance and low weight to strength ratio when compared with other metals. The downside of using titanium is its high cost and lead time associated with procurement in addition to the material wastage that occurs with machining different cross-sectional geometries. Built-up titanium beams fabricated using friction stir welding (FSW) and readily available titanium plates may be a viable alternative that reduces these expenses. This study investigates the fatigue and static strengths of built-up titanium I-beams using FSW and 7-mm-thick Ti-6-4 plate material and compares the results with strengths of representative coupon specimens. Coupons in the transverse and longitudinal directions of the FSW were evaluated for both polished and as-welded FSW surfaces. The results of the investigation showed that the static flexural strength of the built-up I-beam reached 57 % of the yield strength of the Ti-6-4 plate material. The fatigue strengths of the two I-beams tested reached 87 and 63 % of comparable coupon-level specimens with as-welded and polished finishes, respectively. Failures in these beams initiated at discontinuities in the welded fillet region, which suggests that strength and fatigue performance of built-up titanium I-beams can be improved through more consistent FSW methods for Ti-6-4 plate materials.