{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,30]],"date-time":"2026-09-30T00:28:34Z","timestamp":1790728114693,"version":"4.1.0"},"reference-count":32,"publisher":"MDPI AG","issue":"10","license":[{"start":{"date-parts":[[2025,5,12]],"date-time":"2025-05-12T00:00:00Z","timestamp":1747008000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"Post-doctoral Research Project in Shaanxi Province","award":["2023BSHEDZZ266"],"award-info":[{"award-number":["2023BSHEDZZ266"]}]},{"name":"Post-doctoral Research Project in Shaanxi Province","award":["2024JC-YBQN-0031"],"award-info":[{"award-number":["2024JC-YBQN-0031"]}]},{"name":"Natural Science Basic Research Program (Youth) of Shaanxi Province","award":["2023BSHEDZZ266"],"award-info":[{"award-number":["2023BSHEDZZ266"]}]},{"name":"Natural Science Basic Research Program (Youth) of Shaanxi Province","award":["2024JC-YBQN-0031"],"award-info":[{"award-number":["2024JC-YBQN-0031"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>The integral welded panel represents a highly promising aircraft structural component, owing to its lightweight design and reduced connector requirements. However, the complexity of its welded structure results in the formation of cross-welded joints. This study systematically investigated the mechanical properties of the cross-welded joints through tensile tests across different welded regions, which were complemented by fracture morphology examination via scanning electron microscopy (SEM). The residual stress distribution was characterized using X-ray diffraction, while electron backscatter diffraction (EBSD) analysis was used to elucidate the relationship between residual stress and microstructure. Key findings revealed that the cross-welded zone exhibited lower yield strength and ductility than the single-welded zone, and the advancing heat-affected zone demonstrated superior tensile properties relative to the retreating side. Residual stress analysis showed that the cross-welded joint lacked the \u201cdouble peak\u201d profile characteristic and displayed lower maximum residual stress than the single-welded joint. EBSD analysis indicated significant grain elongation in the cross-welded zone due to mechanical forces during the welding process, resulting in higher dislocation density and deformation, corresponding with elevated residual stress levels.<\/jats:p>","DOI":"10.3390\/ma18102223","type":"journal-article","created":{"date-parts":[[2025,5,12]],"date-time":"2025-05-12T06:17:08Z","timestamp":1747030628000},"page":"2223","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":3,"title":["Study on Mechanical Properties and Microstructure of 2024 Aluminum Alloy Cross-Welded Joint by Friction Stir Welding"],"prefix":"10.3390","volume":"18","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-3502-8914","authenticated-orcid":false,"given":"Yanning","family":"Guo","sequence":"first","affiliation":[{"name":"School of Civil Engineering, Xi\u2019an University of Architecture and Technology, Xi\u2019an 710055, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Wenbo","family":"Sun","sequence":"additional","affiliation":[{"name":"School of Aeronautics, Northwestern Polytechnical University, Xi\u2019an 710072, China"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2025,5,12]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"107162","DOI":"10.1016\/j.ijfatigue.2022.107162","article-title":"The effects of welded clips on fatigue crack growth in AA6156 T6 panels","volume":"165","author":"Sedmak","year":"2022","journal-title":"Int. J. Fatigue"},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"1608","DOI":"10.1016\/j.tws.2009.05.003","article-title":"Buckling analysis for an integrally stiffened panel structure with a friction stir weld","volume":"47","author":"Yoon","year":"2009","journal-title":"Thin-Walled Struct."},{"key":"ref_3","doi-asserted-by":"crossref","first-page":"346","DOI":"10.1016\/j.engfailanal.2017.09.001","article-title":"The effect of residual stresses on fatigue crack propagation in welded stiffened panels","volume":"84","author":"Schmauder","year":"2018","journal-title":"Eng. Fail. Anal."},{"key":"ref_4","doi-asserted-by":"crossref","unstructured":"Sarfaraz, Z., Awan, Y.R., Saeed, H.A., Khan, R., Wieczorowski, M., and Din, N.A. (2025). Residual Stress in Friction Stir Welding of Dissimilar Aluminum Alloys: A Parametric Study. Materials, 18.","DOI":"10.3390\/ma18020316"},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"775","DOI":"10.1080\/10408436.2022.2138828","article-title":"A review of residual stress effects on fatigue properties of friction stir welds","volume":"48","author":"Zhang","year":"2023","journal-title":"Crit. Rev. Solid State Mater. Sci."},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"107989","DOI":"10.1016\/j.ijfatigue.2023.107989","article-title":"Estimation of residual stress relaxation in low alloy steel with different hardness during fatigue by in situ X-ray measurement","volume":"178","author":"Hayama","year":"2024","journal-title":"Int. J. Fatigue"},{"key":"ref_7","doi-asserted-by":"crossref","unstructured":"Gangwar, K., and Ramulu, M. (2024). Residual Stress Measurement Using X-ray Diffraction in Friction Stir-Welded Dissimilar Titanium Alloys. Materials, 17.","DOI":"10.3390\/ma17071482"},{"key":"ref_8","doi-asserted-by":"crossref","first-page":"178","DOI":"10.1177\/0954410012468537","article-title":"Buckling\/post-buckling strength of friction stir welded aircraft stiffened panels","volume":"228","author":"Murphy","year":"2014","journal-title":"Proc. Inst. Mech. Eng. Part G J. Aerosp. Eng."},{"key":"ref_9","doi-asserted-by":"crossref","first-page":"339","DOI":"10.1016\/j.tws.2007.02.007","article-title":"The characterization of friction stir welding process effects on stiffened panel buckling performance","volume":"45","author":"Murphy","year":"2007","journal-title":"Thin-Walled Struct."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"232","DOI":"10.1016\/j.jmapro.2023.09.047","article-title":"Optimizing welding sequence of TIG cross-joint of Invar steel using residual stresses and deformations","volume":"105","author":"Su","year":"2023","journal-title":"J. Manuf. Process."},{"key":"ref_11","doi-asserted-by":"crossref","first-page":"168532","DOI":"10.1016\/j.nima.2023.168532","article-title":"Residual stress measurement system of the general purpose powder diffractometer at CSNS","volume":"1055","author":"Hao","year":"2023","journal-title":"Nucl. Instrum. Methods Phys. Res. Sect. A Accel. Spectrometers Detect. Assoc. Equip."},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"107729","DOI":"10.1016\/j.ijfatigue.2023.107729","article-title":"Residual stress relaxation by bending fatigue in induction-hardened gear studied by neutron Bragg edge transmission imaging and X-ray diffraction","volume":"174","author":"Su","year":"2023","journal-title":"Int. J. Fatigue"},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"107827","DOI":"10.1016\/j.ijmecsci.2022.107827","article-title":"Heat generation, plastic deformation and residual stresses in friction stir welding of aluminium alloy","volume":"238","author":"Salih","year":"2023","journal-title":"Int. J. Mech. Sci."},{"key":"ref_14","doi-asserted-by":"crossref","first-page":"365","DOI":"10.1016\/j.cirpj.2022.11.021","article-title":"Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys","volume":"41","author":"Sabry","year":"2023","journal-title":"CIRP J. Manuf. Sci. Technol."},{"key":"ref_15","doi-asserted-by":"crossref","first-page":"102708","DOI":"10.1016\/j.marstruc.2020.102708","article-title":"The effect of weld residual stress on fracture toughness at the intersection of two welding lines of offshore tubular structure","volume":"71","author":"Lee","year":"2020","journal-title":"Mar. Struct."},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"103027","DOI":"10.1016\/j.tafmec.2021.103027","article-title":"Fatigue and fracture behaviour of Friction Stir Welded AA-2024-T351 joints","volume":"114","author":"Vuherer","year":"2021","journal-title":"Theor. Appl. Fract. Mech."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"105556","DOI":"10.1016\/j.ijfatigue.2020.105556","article-title":"Microstructure, mechanical properties and fatigue crack growth behavior of friction stir welded joint of 6061-T6 aluminum alloy","volume":"135","author":"Zhang","year":"2020","journal-title":"Int. J. Fatigue"},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"109058","DOI":"10.1016\/j.engfailanal.2024.109058","article-title":"Notch fatigue behaviour of friction stir welded AA6061-T651 aluminium alloy joints: Role of microstructure, and residual stresses","volume":"167","author":"Srivastava","year":"2025","journal-title":"Eng. Fail. Anal."},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"3679","DOI":"10.1016\/j.jmrt.2025.02.007","article-title":"Effect of joining material direction on material flow, microstructure and mechanical properties of dissimilar AA2024\/7075 joints fabricated by friction stir welding","volume":"35","author":"Xing","year":"2025","journal-title":"J. Mater. Res. Technol."},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"108","DOI":"10.1016\/j.cirpj.2024.09.006","article-title":"Asymmetric study on the microstructure and mechanical properties of friction stir welded joints: Finite element simulation and experiment","volume":"55","author":"Xue","year":"2024","journal-title":"CIRP J. Manuf. Sci. Technol."},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"104911","DOI":"10.1016\/j.engfailanal.2020.104911","article-title":"Study on residual stress distribution of 2024-T3 and 7075-T6 aluminum dissimilar friction stir welded joints","volume":"118","author":"Guo","year":"2020","journal-title":"Eng. Fail. Anal."},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"105102","DOI":"10.1016\/j.mtcomm.2022.105102","article-title":"Effect of welding position and direction on the interfacial microstructure and mechanical properties of double-pass friction stir lap welded A6061\/Q235 joints","volume":"34","author":"Zhu","year":"2023","journal-title":"Mater. Today Commun."},{"key":"ref_23","doi-asserted-by":"crossref","first-page":"240","DOI":"10.1016\/j.matdes.2016.01.047","article-title":"Interfacial microstructure and properties of aluminum\u2013magnesium AZ31B multi-pass friction stir processed composite plate","volume":"94","author":"Zhao","year":"2016","journal-title":"Mater. Des."},{"key":"ref_24","doi-asserted-by":"crossref","first-page":"6023","DOI":"10.1016\/j.jmrt.2023.02.222","article-title":"The microstructure and mechanical properties of single-pass and double-pass lap joint of Al 5754H-11 and Mg AZ31-O alloys by friction stir welding","volume":"23","author":"Ghiasvand","year":"2023","journal-title":"J. Mater. Res. Technol."},{"key":"ref_25","doi-asserted-by":"crossref","first-page":"155052","DOI":"10.1016\/j.jallcom.2020.155052","article-title":"Improvement of microstructure and mechanical properties of C44300 tin brass subjected to double-pass rapid cooling friction stir welding","volume":"834","author":"Xu","year":"2020","journal-title":"J. Alloys Compd."},{"key":"ref_26","doi-asserted-by":"crossref","first-page":"398","DOI":"10.1016\/j.msea.2018.04.017","article-title":"Tensile properties of AZ61 magnesium alloy produced by multi-pass friction stir processing: Effect of sample orientation","volume":"725","author":"Luo","year":"2018","journal-title":"Mater. Sci. Eng. A"},{"key":"ref_27","doi-asserted-by":"crossref","first-page":"102132","DOI":"10.1016\/j.mtcomm.2021.102132","article-title":"Effect of welding parameters on the microstructures and mechanical properties of double-pass aluminum\/magnesium dissimilar metal friction stir lap welding joint","volume":"26","author":"Zhao","year":"2021","journal-title":"Mater. Today Commun."},{"key":"ref_28","unstructured":"(2022). Standard Test Methods for Tension Testing of Metallic Materials. Standard No. ASTM E8."},{"key":"ref_29","doi-asserted-by":"crossref","unstructured":"Guo, Y.N., and Li, P.Y. (2024). Effect of Residual Stress and Microstructure on the Fatigue Crack Growth Behavior of Aluminum Friction Stir Welded Joints. Materials, 17.","DOI":"10.3390\/ma17020385"},{"key":"ref_30","doi-asserted-by":"crossref","first-page":"142423","DOI":"10.1016\/j.msea.2021.142423","article-title":"Low cycle fatigue properties of friction stir welded dissimilar 2024-to-7075 aluminum alloy joints","volume":"832","author":"Niu","year":"2022","journal-title":"Mater. Sci. Eng. A"},{"key":"ref_31","doi-asserted-by":"crossref","first-page":"112","DOI":"10.1016\/j.matchar.2015.06.039","article-title":"Microstructure and anisotropic mechanical behavior of friction stir welded AA2024 alloy sheets","volume":"107","author":"Zhang","year":"2015","journal-title":"Mater. Charact."},{"key":"ref_32","doi-asserted-by":"crossref","first-page":"102372","DOI":"10.1016\/j.tafmec.2019.102372","article-title":"Dynamic fracture properties of 2024-T3 and 7075-T6 aluminum friction stir welded joints with different welding parameters","volume":"104","author":"Guo","year":"2019","journal-title":"Theor. Appl. Fract. Mech."}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/18\/10\/2223\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,9]],"date-time":"2025-10-09T17:31:01Z","timestamp":1760031061000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/18\/10\/2223"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2025,5,12]]},"references-count":32,"journal-issue":{"issue":"10","published-online":{"date-parts":[[2025,5]]}},"alternative-id":["ma18102223"],"URL":"https:\/\/doi.org\/10.3390\/ma18102223","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2025,5,12]]}}}