Esta tese tem por objetivo a aplicação do processamento por atrito linear na liga de titânio Ti-6Al-4V. Derivado da solda por atrito linear, é um processo recente desenvolvido na década de 90 para união de alumínio. Sua aplicação em outros tipos de materiais como aços e ligas de alto desempenho, em especial o titânio, tem interessado a industria. A metodologia utilizada nesta tese para avaliar o processamento por atrito linear, consistiu na execução de ensaios mecânicos de tração em condições mistas em chapas da liga de titânio Ti-6Al-4V. A máquina utilizada para o processamento das chapas foi um centro de usinagem CNC convencional, adaptado com dispositivos especiais. Além dos ensaios de tração em condições mistas, foram executadas medições de microdurezas nas regiões atingidas pelo processo, avaliação das microestruturas resultantes e medições de tensão residual para uma caracterização mais ampla do processo. As microestruturas na região processada são caracterizadas por uma estrutura totalmente transformada. As temperaturas de pico na região processada excederam a temperatura -transus durante o processamento e a transformação da fase + ocorreu durante a fase de resfriamento. A transformação da fase para resultou na formação de agulhas de fase nos contornos e pelo interior dos grãos da fase . Pequenas regiões com estrutura equiaxial de grãos ( globular) foram observados na zona de processamento. A abordagem dos resultados quantitativos foi feita de forma estatística, visando identificar os parâmetros de maior interação com os resultados observados. Foi identificado nesta tese que a rotação da ferramenta apresentou a maior influência nos resultados de tensão residual, microdureza e tensão de escoamento. Uma importante contribuição à modelagem da tensão de escoamento para materiais anisotrópicos é proposta, baseado em um critério de escoamento ortotrópico. Equações complementares baseadas nos testes mistos de tração e cisalhamento são propostas para modificar o modelo ortotrópico. O intuito deste modelo é indicar em que condições o material tem seu regime de escoamento atingido, podendo servir de base para simulações práticas de peças em condições similares. / This thesis aims at the application of friction stir processing (FSP) in Ti-6Al-4V titanium alloy. Derived from friction stir welding (FSW), it is a recent process developed in the 90s for aluminum joining. Its application to other types of materials such as steel and high performance alloys, in particular titanium, has interested industry. The methodology applied in this thesis to evaluate FSP, consisted in the execution of tensile test at mixed conditions to Ti-6Al-4V sheets 4. The machine used for processing the sheet was a conventional CNC milling machine, assembled with special fixture devices. In addition to tensile tests, measurements have been performed to the regions affected by the process such as evaluation of microhardness, microstructure and residual stress condition. The microstructures at the processed region are characterized by a transformed structure. The peak temperatures, in the processed region, exceeded the -transus temperature during the processing and transformation of the phase + occurred during the cooling phase. This transformation resulted in the formation of boundary and intergranular phase (Widmanstätten) at the grains. Small regions of equiaxed grain structure (globular ) were observed in the processed zone. The approach to the quantitative results was made in statistical form aiming to identify the parameters interaction with the observed results. It was identified in this thesis that the tool spinning rotation showed the highest influence on the results of residual stress, hardness and yield strength. An important contribution to the modeling of anisotropic materials yield stress is proposed based on an orthotropic yield criterion. Additional equations based on the mixed tests for tensile and shear are proposed to modify the orthotropic model. The purpose of this model is to indicate the conditions under which the material has reached its yield regime, and may be a basis for practical simulations in similar conditions.

Esta tese tem por objetivo a aplicação do processamento por atrito linear na liga de titânio Ti-6Al-4V. Derivado da solda por atrito linear, é um processo recente desenvolvido na década de 90 para união de alumínio. Sua aplicação em outros tipos de materiais como aços e ligas de alto desempenho, em especial o titânio, tem interessado a industria. A metodologia utilizada nesta tese para avaliar o processamento por atrito linear, consistiu na execução de ensaios mecânicos de tração em condições mistas em chapas da liga de titânio Ti-6Al-4V. A máquina utilizada para o processamento das chapas foi um centro de usinagem CNC convencional, adaptado com dispositivos especiais. Além dos ensaios de tração em condições mistas, foram executadas medições de microdurezas nas regiões atingidas pelo processo, avaliação das microestruturas resultantes e medições de tensão residual para uma caracterização mais ampla do processo. As microestruturas na região processada são caracterizadas por uma estrutura totalmente transformada. As temperaturas de pico na região processada excederam a temperatura -transus durante o processamento e a transformação da fase + ocorreu durante a fase de resfriamento. A transformação da fase para resultou na formação de agulhas de fase nos contornos e pelo interior dos grãos da fase . Pequenas regiões com estrutura equiaxial de grãos ( globular) foram observados na zona de processamento. A abordagem dos resultados quantitativos foi feita de forma estatística, visando identificar os parâmetros de maior interação com os resultados observados. Foi identificado nesta tese que a rotação da ferramenta apresentou a maior influência nos resultados de tensão residual, microdureza e tensão de escoamento. Uma importante contribuição à modelagem da tensão de escoamento para materiais anisotrópicos é proposta, baseado em um critério de escoamento ortotrópico. Equações complementares baseadas nos testes mistos de tração e cisalhamento são propostas para modificar o modelo ortotrópico. O intuito deste modelo é indicar em que condições o material tem seu regime de escoamento atingido, podendo servir de base para simulações práticas de peças em condições similares. / This thesis aims at the application of friction stir processing (FSP) in Ti-6Al-4V titanium alloy. Derived from friction stir welding (FSW), it is a recent process developed in the 90s for aluminum joining. Its application to other types of materials such as steel and high performance alloys, in particular titanium, has interested industry. The methodology applied in this thesis to evaluate FSP, consisted in the execution of tensile test at mixed conditions to Ti-6Al-4V sheets 4. The machine used for processing the sheet was a conventional CNC milling machine, assembled with special fixture devices. In addition to tensile tests, measurements have been performed to the regions affected by the process such as evaluation of microhardness, microstructure and residual stress condition. The microstructures at the processed region are characterized by a transformed structure. The peak temperatures, in the processed region, exceeded the -transus temperature during the processing and transformation of the phase + occurred during the cooling phase. This transformation resulted in the formation of boundary and intergranular phase (Widmanstätten) at the grains. Small regions of equiaxed grain structure (globular ) were observed in the processed zone. The approach to the quantitative results was made in statistical form aiming to identify the parameters interaction with the observed results. It was identified in this thesis that the tool spinning rotation showed the highest influence on the results of residual stress, hardness and yield strength. An important contribution to the modeling of anisotropic materials yield stress is proposed based on an orthotropic yield criterion. Additional equations based on the mixed tests for tensile and shear are proposed to modify the orthotropic model. The purpose of this model is to indicate the conditions under which the material has reached its yield regime, and may be a basis for practical simulations in similar conditions.

Friction stir spot welding (FSSW) is a solid-state welding process which is especially useful for joining precipitation-hardened aluminium alloys that undergo adverse property changes during fusion welding. It also has potential as an effective method for solid-state joining of dissimilar alloys. In FSSW, heat generation and plastic flow are strongly linked, and the scale of the process in time and space is such that it is difficult to separate and control the influence of all the relevant input parameters. The use of modelling is well-established in the field of welding research, and this thesis presents an analysis of the thermal and mechanical aspects of FSSW, principally using the finite element (FE) technique. Firstly, a thermal FE model is shown, which is subsequently validated by reference to experimental temperature data in both aluminium-to-aluminium and aluminium-to-steel welds. Correlations between high-quality welds and temperature fields are established, and predictions are made for peak temperatures reached under novel welding conditions. Deformation and heating are strongly linked in FSSW, but existing modelling tools are poorly suited to modelling flow processes in the conditions extant in FSSW. This thesis discusses the development and optimisation of two novel techniques to overcome the limitations of current approaches. The first of these uses greatly simplified constitutive behaviour to convert the problem into one defined purely by kinematics. In doing so, the boundary conditions reduce to a small number of assumptions about the contact conditions between weld material and tool, and the model calculation time is very rapid. This model is used to investigate changes in the slip condition at the tool to workpiece interface without an explicit statement of the friction law. Marker experiments are presented which use dissimilar composition but similar strength alloys to visualise flow patterns. The layering behaviour and surface patterns observed in the model agree well with observations from these experiments. The second approach extends the FE method to include deformation behaviour without the need for a fully-coupled approach, guided by the kinematic model. This is achieved using an innovative sequential small-strain analysis method in which thermal and deformation analyses alternate, with each running at a very different timescale. This technique avoids the requirement to either remesh the model domain at high strains or to use an explicit integration scheme, both of which impose penalties in calculation time and model complexity. The method is used to relate the purely thermal analysis developed in the work on thermal modelling to welding parameters such as tool speed. The model enables predictions of the spatial and temporal evolution of heat generation to be made directly from the constitutive behaviour of the alloy and the assumed velocity profile at the tool-workpiece interface. Predictions of the resulting temperature history are matched to experimental data and novel conditions are simulated, and these predictions correlate accurately with experimental results. Hence, the model is used to predict welding outcomes for situations for which no experimental data exists, and process charts are produced to describe optimum welding parameters. The methods and results presented in this thesis have significant implications for modelling friction stir spot welding, from optimising process conditions, to integration with microstructural models (to predict softening in the heat-affected zone, or the formation of intermetallics at the interface in dissimilar welds). The technique developed for sequential small strain finite element analysis could also be investigated for use in other kinematically constrained solid-state friction joining processes.

Le soudage FSW (Friction Stir Welding) est un procédé de soudage en phase solide pressenti pour des applications de transport en générale aérospatial et naval. Malgré le nombre considérable d’études qui ont été réalisées depuis son avènement en 1991, le contrôle du procédé n’est pas encore effectif.Ce travail a consisté en une partie expérimentale visant à la génération, par un outil trigone, de joints soudés dont la microstructure a été corrélée à l’écoulement de matière pendant le procédé. La connaissance de cet écoulement de matière a permis dans la deuxième partie d’enrichir le modèle thermofluide développé en périodique pour prédire la microstructure des joints de soudure FSW, notamment les "onion rings". Finalement, l’occurrence des "onion rings" a été corrélée à la vitesse de déformation maximale atteinte par les particules de la zone soudée, prédite par le modèle. Par ailleurs, un travail d’affinement du champ de vitesse en voisinage du pion est réalisé en modélisant l’outil trigone. Ce qui permet en plus de l’interaction (entrainement) outil/matière par frottement, d’intégrer une interaction par obstacle. Cette approche devrait permettre, en perspectives de ce travail, une meilleur description thermomécanique locale et par voie de conséquence microstructurale. / Friction Stir Welding is a solid state joining process developed for transport applications as aerospace and naval. Since its introduction, a large number of investigations have been carried out but the process is not fully controlled. This work including experimental section in which welds have been generated by trigonal tool. The microstructure of these welds has been correlated with the material flow during the process. By understanding the material flow, the transient thermofluid model developed in the second section has been significantly enriched. This modeled has been developed for predicting the microstructure of the weld, especially, the "onion rings". Finally, the occurrence of "onion rings" has been correlated with the maximal strain rate reached by any particle in the weld seam, simulated by the model. However, the velocity has been refined at the vicinity of the tool through the trigonal pin modelling. This was helpful to move the material not only by friction but also by obstacle at the interaction tool/material. The above approach should enable, in this work layout, a better local thermomechanical description and consequently microstructural.

<div>Aluminum 6061 is extensively used in industry and welding and additive manufacturing (AM) of Al6061 offer flexibility in manufacturing. Solid-state welding and AM processes can overcome the shortcomings of fusion-based processes, such as porosity and hot cracking. In this thesis, friction stir welding and friction stir additive manufacturing, which are both based on the concepts of friction stir processing (solid-state), were studied. The welding parameters for a sound weld during friction stir welding of Al6061-T6 alloy were determined based on the experimental and numerical analysis. Formation of tunnel defects and cavity defects was also studied. A Coupled Eulerian-Lagrangian (CEL) finite element model was established to analyze the process, where the workpiece was modeled as an Eulerian body, and the tool as Lagrangian. The model was validated by conducting experiments and correlating the force measured by a three-axis dynamometer. The experimentally validated simulation model was used to find an optimum parameter set for the sound weld case.</div><div>To demonstrate the friction stir additive manufacturing process, a 40 mm × 8 mm × 8 mm (L×B×H) material was fabricated by adding five 1.6 mm thick plates. A similar coupled Eulerian-Lagrangian based finite element model was used to predict the effects of sound process parameters, such as the tool’s rotational speed and the translational speed. The temperature predicted by the model was used to predict the microhardness distribution in the sample and to further elucidate the hardness change in the weld zone, which showed a good agreement with the experimental results. The microstructure of the samples was analyzed, and the mechanical properties of the additive manufactured samples were characterized and compared with those of other AM techniques via tensile tests and tensile shear tests.</div>

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Al 7050-T7451 alloy with good combinations of strength, stress corrosion cracking resistance and toughness, is used broadly in the aerospace/aviation industry for fatigue-critical airframe structural components. However, it is also considered as a highly anisotropic alloy as the crack growth behavior along the short transverse direction is very different from the one in the long transverse direction, due to the inhomogeneous microstructure with the elongated grains distributed in the work material used in the sheet/plate applications. Further processes on these materials are needed to improve its mechanical and material properties and broaden its applications. The material with ultra-fine or nano grains exhibits improved wear and corrosion resistance, higher hardness and better fatigue life, compared to the one with coarse grains. In recent times, the development of novel processing technologies has gained great attention in the research community to enhance the properties of the materials employed in the aerospace, biomedical, precision instrument, automotive, nuclear/power industries. These novel processing technologies modify the microstructure of this alloy and improve the properties. The aim of this dissertation is to investigate the effects of cryogenic processes, including friction stir processing (FSP), machining and burnishing, on Al 7050-T7451 alloy to solve the inhomogeneity issue and improve its surface integrity. FSP is applied to modify the microstructure of Al 7050-T7451 alloy for achieving more homogeneous structure with near ultra-fine grains (UFG) which were less than 2 µm, particularly in cryogenic FSP with liquid nitrogen as the coolant. Approximately 10% increase could be observed from the hardness measurement from the samples processed by cryogenic FSP, in contrast to dry FSP. Also, the texture change from Al (200) to Al (111) could be achieved in all the samples processed by dry and cryogenic FSP. Cryogenic machining and burnishing processes were also applied to enhance the surface integrity of the manufactured components with near-UFG structure. The highest cutting temperature was reduced by up to 44.7% due to the rapid cooling effect of liquid nitrogen in cryogenic machining, compared with dry machining. Nano grains were produced in the refined layers induced by cryogenic burnishing. And, up to 35.4% hardness increase was obtained within the layer depth of 200 µm in the cryogenically-burnished surface. A numerical finite element method (FEM) model was developed for predicting the process performance in burnishing. Less than 10% difference between the experimental and predicted burnishing forces was achieved in the simulation of cryogenic burnishing, and reasonable predictions were also achieved for temperatures, severe plastic deformation (SPD) layers.

Friction stir processing (FSP) has been developed based on the basic principles of friction stir welding (FSW), a solid-state joining process originally developed for aluminum alloys. What is attractive about FSP is that it can be incorporated in the overall manufacturing cycle as a post-processing step during the machining operation to provide localized modification and control of microstructures in near-surface layers of metallic components. FSP has emerged as an important post-processing technique, and has been identified as a process that may have a high impact, and perhaps is a disruptive manufacturing process. In this study, FSP has been applied to Al cast alloy A206, which is a high strength, widely used cast alloy in the manufacturing industry. Motivations behind this work are to (1) investigate the feasibility of FSP on manipulating the cast microstructure and strengthening the material, and (2) to explore the viability of FSP to produce a localized particle reinforced zone in cast A206 aluminum components. The thesis will show that we have optimized FSP for processing of Al alloys to locally manipulate the cast microstructure, eliminate casting defects, and attain grain refinement and second phase homogenization. We have established the mechanism leading to the microstructure evolution and have evaluated the resultant mechanical properties, i.e. hardness, tensile property and fatigue properties. We have also synthesized a localized composite material in the A206 work piece with three different reinforcement materials via FSP. These results will be presented and discussed.