Deficiencies in friction stir welding (FSW) numerical modelling are identified. Applicability of flow stress data derived from hot compression, hot torsion, and split Hopkinson bar testing methods is assessed. A new method of measuring flow stresses in the stir zone of a friction stir welding tool is developed. This test utilizes a non-consumable flat-faced cylindrical tool of different geometries that induces a vertical and rotational load on the material of interest. A constant vertical load and rpm value is used for each test yielding the resulting motor torque and temperature generation to define the material response. Experimental samples are cross-sectioned, polished, and etched to reveal the material flow behavior below the tool. A viscosity-based model is used to quantify the shear stress and rim shear rate present in the shear layer below the tool. This test is referred to as the high-pressure shear (HPS) experiment. A parameter window is developed for two alloys of interest, AA6061-T6 and AA2219-T87 and results are reported. The HPS experiments yields flow stress estimates that are pressure and strain rate dependent. Different tool geometries are explored to understand the impact of the "dead zone"at the center axis of the tool. When compared to hot compression and hot torsion the HPS flow stress datasets trend 20-86 % lower across the two materials tested.

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The mechanically compressive flow stress sensitivities of various polymers are investigated at high strain rates above 103 s-1. Temperatures near the glass transition temperature are investigated and the polymer stress-strain responses have been studied from ambient temperature to 100°C. Previous work has reported peaks in flow stress as a function of strain rate [Al-Maliky/Parry 1994, Al-Maliky 1997]. The analyses showed rapid increases of flow stress followed by a sudden drop at elevated strain rates, which is unlike the well known linear relationship documented at the low strain rates. The mechanics and stipulation of what bring about this phenomenon, or the types of polymers influenced are still unclear. Two fluoropolymers, polytetrafluoroethylene (PTFE) and polychlorotrifluoroethylene (PCTFE), and two vinyl polymers, polyvinylchloride (PVC) and polymethylmethacrylate (PMMA), are chosen for this study. PTFE, PCTFE and PVC are semi-crystalline polymers with different percentage of crystallinity contents, whereas PMMA is an amorphous polymer. The glass transition temperature, Tg, is the characteristic of the amorphous content in polymers, which has been suggested to influence the flow stress peaks [Swallowe/Lee 2003]. Tg of the semi-crystalline polymers are within the test temperature range. High strain rate compression tests have been carried out using the split Hopkinson pressure bar (SHPB). This is a well-established method for determining the stress, strain, and strain rate of materials. The strain rate range of interest is 103 s-1 to 105 s-1 where the strain rate sensitivity has previously been identified [Al-Maliky/Parry 1994, Al-Maliky 1997, Walley/Field 1994]. Two thermal analyses techniques are used to quantify the dependency of the viscoelastic behaviour in relation to time and temperature. Differential scanning calorimetry (DSC) measures the enthalpy of the polymers to show how the materials are affected by heat, and Dynamic mechanical analysis (DMA) is used to characterise the time-temperature dependence of the elastic storage and loss moduli of the polymers A total of 42 PCTFE, 44 PTFE, 45 PVC and 55 PMMA specimens were tested using the SHPB system, with the strain rate varying between 1600 s-1 and 6100 s-1. Initial results for PMMA have been reported [Forrester/Swallowe 2009]. The rate of strain where specimens begin to show crazing is identified. The value of yield stress increases with the increase of strain rate and the decrease in temperature. Large strain hardening can be seen in all three semi-crystalline polymers at higher strain rates. The temperature rise during plastic flow of compression is calculated by the stress-strain rate curves. In this thesis, the emphasis is on the relation of yield/flow stress to strain rate as the polymers deform under high strain compression. The mechanism behind the cause of high strain rate deformation responses for amorphous to semi-crystalline polymers in ductile state is discussed, with a view to understanding the sensitivity of yield/flow stresses as a function of strain rate. Also, the modelling of the polymers has been carried in order to alleviate doubts about the validity of the real experimental results that may arise due to the nature of the decomposition of the polymers. It has been shown that the strain energy density pulses through the sample in response to the compression wave in various circular intensities.

<p>The work material in metal working operations always showssome kind of anisotropy. In order to simplify the theoreticalanalysis, especially considering bulk deformation processes,anisotropy is usually neglected and the material is assumed tobe isotropic. On the other hand, the analysis that consideredthe influence of anisotropy seldom incorporates the influenceof friction. For predicting the material flow during plasticdeformation and for predicting the final material properties ofthe product, adequate descriptions of both flow stress curvesand coefficients of friction have to be developed.</p><p>In the present work a number of experimental methods fordetermining the anisotropy have been utilized and compared:Yield loci, strain ratios (R-values) and establishing flowstress-curves in different directions. The results show thatthe yield loci measurements are weak in predicting anisotropywhen the material strain hardening is different in differentdirections. It is concluded that also the strain ration(R-value) measurements are unreliable for describinganisotropy. The most trustable and useful results were foundfrom multi-direction determinations of the flow stresses.</p><p>Three typical cases of ring upsetting conditions wereanalyzed by theory (3D-FEM) and experiments:</p><p>    An anisotropic ring, oriented 900 to the axis ofrotational symmetrical anisotropy. The friction coefficientwas the same in all directions</p><p>    An isotropic ring. The friction coefficient was differentin different directions</p><p>    An anisotropic ring oriented 00 to the axis of rotationalsymmetrical anisotropy. The friction coefficient was the samein all directions</p><p>The cases 1) and 2) reveal that the influence of anisotropyon the ring deformation is quite similar to that obtained bychanging the frictional condition. The case 3) exposes that ifthe material flow caused by anisotropy is incorrectly referredto friction, the possible error of the friction coefficient canbe as high as 80% for a pronounced anisotropic material. Amodified two-specimen method (MTSM) has been establishedaccording to an inverse method. Experiments were carried ascylinder upsetting. Here both ordinary cylinders were used aswell as so-called Rastegaev specimen. Also plane straincompression tests were utilized. The results show that MTSM isable to evaluate the validity of a selected mathematical modelwhen both the friction coefficient and the flow stress areunknown for a certain process. MTSM can also be used toestimate the friction coefficient and flow stress provided thatthe selected mathematical model is adequate.</p><p><b>Key words:</b>Anisotropy, friction coefficient, flowstress, modified two-specimen method and FE-analysis</p>

The understanding of the strengthening mechanisms is crucialboth in the development of new materials with improvedmechanical properties and in the development of better materialmodels in the simulation of industrial processes. The aim ofthis work has been to study different strengthening mechanismsfrom a fundamental point of view that enables the developmentof a general model for the flow stress. Two differentmechanisms namely, solid solution strengthening and grain sizestrengthening have been examined in detail. Analytical modelsproposed in the literature have been critically evaluated withrespect to experimental data from the literature. Two differentexperimental surface techniques, atomic force microscopy (AFM)and electron backscattered diffraction (EBSD) were used tocharacterize the evolving deformation structure at grainboundaries, in an ultra low-carbon (ULC) steel. A numericalmodel was also developed to describe experimental featuresobserved locally at grain boundaries. For the case of solid solution strengthening, it is shownthat existing models for solid solution strengthening cannotexplain the observed experimental features in a satisfactoryway. In the case of grain size strengthening it is shown that asimple model seems to give a relatively good description of theexperimental data. Further, the strain hardening in materialsshowing a homogenous yielding, is controlled by grainboundaries at relatively small strains. The experimentalresults from AFM and EBSD, indicate more inhomogenousdeformation behaviour, when the grain size is larger. Bothtechniques, AFM and EBSD, correlate well with each other andcan be used to describe the deformation behaviour both on alocal and global scale. The results from the numerical modelshowed a good qualitative agreement with experimentalresults. Another part of this project was directed towards thedevelopment of continuum models that include relevantmicrostructural features. One of the results was the inclusionof the pearlite lamellae spacing in a micromechanically basedFEM-model for the flow stress of ferriticperlitic steels.Moreover a good agreement was achieved between experimentalresults from AFM and FEM calculations using a non-local crystalplasticity theory that incorporates strain gradients in thehardening moduli. The main philosophy behind this research has been to combinean evaluation of existing strengthening models, with newexperiments focused on studying the fundamental behaviour ofthe evolving dislocation structure. This combination can thenbe used to draw general conclusions on modelling thestrengthening mechanisms in metals. <b>Keywords:</b>strengthening mechanisms, flow stress, solidsolution strengthening, grain size strengthening,micromechanical modelling, AFM, EBSD

<p>The understanding of the strengthening mechanisms is crucialboth in the development of new materials with improvedmechanical properties and in the development of better materialmodels in the simulation of industrial processes. The aim ofthis work has been to study different strengthening mechanismsfrom a fundamental point of view that enables the developmentof a general model for the flow stress. Two differentmechanisms namely, solid solution strengthening and grain sizestrengthening have been examined in detail. Analytical modelsproposed in the literature have been critically evaluated withrespect to experimental data from the literature. Two differentexperimental surface techniques, atomic force microscopy (AFM)and electron backscattered diffraction (EBSD) were used tocharacterize the evolving deformation structure at grainboundaries, in an ultra low-carbon (ULC) steel. A numericalmodel was also developed to describe experimental featuresobserved locally at grain boundaries.</p><p>For the case of solid solution strengthening, it is shownthat existing models for solid solution strengthening cannotexplain the observed experimental features in a satisfactoryway. In the case of grain size strengthening it is shown that asimple model seems to give a relatively good description of theexperimental data. Further, the strain hardening in materialsshowing a homogenous yielding, is controlled by grainboundaries at relatively small strains. The experimentalresults from AFM and EBSD, indicate more inhomogenousdeformation behaviour, when the grain size is larger. Bothtechniques, AFM and EBSD, correlate well with each other andcan be used to describe the deformation behaviour both on alocal and global scale. The results from the numerical modelshowed a good qualitative agreement with experimentalresults.</p><p>Another part of this project was directed towards thedevelopment of continuum models that include relevantmicrostructural features. One of the results was the inclusionof the pearlite lamellae spacing in a micromechanically basedFEM-model for the flow stress of ferriticperlitic steels.Moreover a good agreement was achieved between experimentalresults from AFM and FEM calculations using a non-local crystalplasticity theory that incorporates strain gradients in thehardening moduli.</p><p>The main philosophy behind this research has been to combinean evaluation of existing strengthening models, with newexperiments focused on studying the fundamental behaviour ofthe evolving dislocation structure. This combination can thenbe used to draw general conclusions on modelling thestrengthening mechanisms in metals.</p><p><b>Keywords:</b>strengthening mechanisms, flow stress, solidsolution strengthening, grain size strengthening,micromechanical modelling, AFM, EBSD</p>

The work material in metal working operations always showssome kind of anisotropy. In order to simplify the theoreticalanalysis, especially considering bulk deformation processes,anisotropy is usually neglected and the material is assumed tobe isotropic. On the other hand, the analysis that consideredthe influence of anisotropy seldom incorporates the influenceof friction. For predicting the material flow during plasticdeformation and for predicting the final material properties ofthe product, adequate descriptions of both flow stress curvesand coefficients of friction have to be developed. In the present work a number of experimental methods fordetermining the anisotropy have been utilized and compared:Yield loci, strain ratios (R-values) and establishing flowstress-curves in different directions. The results show thatthe yield loci measurements are weak in predicting anisotropywhen the material strain hardening is different in differentdirections. It is concluded that also the strain ration(R-value) measurements are unreliable for describinganisotropy. The most trustable and useful results were foundfrom multi-direction determinations of the flow stresses. Three typical cases of ring upsetting conditions wereanalyzed by theory (3D-FEM) and experiments:     An anisotropic ring, oriented 900 to the axis ofrotational symmetrical anisotropy. The friction coefficientwas the same in all directions     An isotropic ring. The friction coefficient was differentin different directions     An anisotropic ring oriented 00 to the axis of rotationalsymmetrical anisotropy. The friction coefficient was the samein all directions The cases 1) and 2) reveal that the influence of anisotropyon the ring deformation is quite similar to that obtained bychanging the frictional condition. The case 3) exposes that ifthe material flow caused by anisotropy is incorrectly referredto friction, the possible error of the friction coefficient canbe as high as 80% for a pronounced anisotropic material. Amodified two-specimen method (MTSM) has been establishedaccording to an inverse method. Experiments were carried ascylinder upsetting. Here both ordinary cylinders were used aswell as so-called Rastegaev specimen. Also plane straincompression tests were utilized. The results show that MTSM isable to evaluate the validity of a selected mathematical modelwhen both the friction coefficient and the flow stress areunknown for a certain process. MTSM can also be used toestimate the friction coefficient and flow stress provided thatthe selected mathematical model is adequate. <b>Key words:</b>Anisotropy, friction coefficient, flowstress, modified two-specimen method and FE-analysis / NR 20140805

Thesis (Ph. D.)--Virginia Commonwealth University, 2009. / Prepared for: Dept. of Health and Human Performance. Title from resource description page. Includes bibliographical references.