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Cast aluminium (Al) alloys are widely used for structural components because of their advantages such as cost saving and flexibility in fabrication compared with wrought alloys. However as-cast materials generally reveal a coarse microstructure and contain many casting defects arisen from shrinkage and release of dissolved gases during solidification. Such casting defects act frequently as the crack initiation site and reduce the fatigue strength and fatigue life in cast Al alloys. From a viewpoint of fatigue reliability, therefore, controlling casting defect is extremely important, but it is very difficult to completely eliminate casting defects during casting process even though the advances in casting technology can reduce the defect size.

Effect of Friction Stir Processing on the Fatigue Behaviour of Cast Aluminium Alloy