The effects of weld temperature, travel speed, and backing plate thermal diffusivity on themechanical properties of a weld have been studied. A face centered cubic experiment of designwas completed in which the response variables were yield strength, minimum hardness in the HAZ, and charpy impact toughness. Three models were created from the data gathered usinga stepwise regression in order to see the effects of each parameter. For the yield strength andminimum hardness it was found that only travel speed and backing plate thermal diffusivities werestatistically significant to the properties. The charpy impact toughness saw that all three parameterswere statistically significant to its value. In all three models the travel speed had the greatest affecton the material properties.

Friction Stir Welding (FSW) is an emerging joining technology in which basic process understanding is still inadequate. Knowledge of FSW parameter relationships is needed to better understand the process and implement proper machine control. This study utilized a 3-factor, 3-level factorial design of experiments to investigate relationships between key process inputs and measured output parameters. All experiments utilized 7075-T7 aluminum and a threaded pin tool with a 25.4 mm shoulder diameter, 4.76 mm pin length, and 7.9 mm pin diameter. Spindle speed, feed rate, and tool depth were varied throughout 54 welds while X, Y, and Z forces, X torque, three tool temperatures, and motor power were measured. Empirical models were developed to relate outputs to inputs. The relationships between inputs and outputs are nonlinear and require, at a minimum, a quadratic equation to reasonably model them. These models were further analyzed to explore possible control schemes. Tool depth was found to be the most fundamental means of controlling weld forces and tool temperatures. This research describes the input/output relationships enumerated above for FSW as well as a discussion of possible control schemes.

Interrogating metals with ultrasonic waves can be used to evaluate their microstructural and mechanical properties. These techniques analyze ultrasonic wave features in order to make inferences on the medium of interest. Current research is being conducted to determine higher order elastic properties and characterize material degradation of 7075-T651 aluminum with ultrasonics. This thesis topic will use acoustoelasticity, the stress dependency of acoustic velocity, to accomplish these goals. Acoustoelasticity is a manifestation of the inherent nonlinearity in the interatomic binding energy, which appears mathematically as higher order elastic terms in the stress strain constitutive relation. The acoustoelasticity will be determined for longitudinal and shear waves propagating through a sample under uni-axial stress. Experimentally, specific techniques and tooling will be designed to insure accurate measurements of acoustic wave velocity as a function of stress. Using acoustoelasticity the third order elastic constants of 7075-T651 aluminum will be determined. Further, Al samples will be fatigue damaged and acoustoelasticity and third order elastic constants will be mapped versus damage. Literature will be used to verify measured values of acoustoelasticity as well as provide theoretical models for acoustoelastic dependence on damage.