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In this paper, the fatigue behaviour of pre-corroded 2024-T3 joints is investigated, as a first step toward assessing this problem. Unnotched specimens of 4 mm thick 2024-T3 base material and FSW joints were pre-corroded by alternate immersion in 3.5% NaCl solution, in accordance with ASTM G44 standards, for 100, 250 and 1000 hours. Subsequently pristine and pre-corroded coupons were tested under constant amplitude loading and lab environment at load ratio F mi  n /F max  of R = 0.1. The decrease of fatigue life due to corrosion damage was similar in welded and unwelded specimens. It is further shown that it is possible to estimate the fatigue life with a simple fracture mechanics model based on the parent material data and the maximum sizes of the corrosion damaged areas.

Fatigue Life of Friction Stir Welded Joints in the Presence of Corrosion Damage: Experiments and Calculations