Les robots industriels sont très utilisés aujourd’hui dans de nombreuses applications industrielles pour leur polyvalence et leur facilité programmation. Cependant, malgré leurs performances, ces robots ne sont pas adaptés à certains procédés de fabrication où des forces uniformes et élevées ainsi qu'une précision de positionnement appropriée sont requises. Le présent travail est axé sur la robotisation de l'une des opérations à forte charge, le soudage par friction-malaxage (FSW). Cette méthode d’assemblage s’utilise pour assembler des pièces en phase solide. Pour cette raison, une force de poussée très élevée est nécessaire pour ramollir le matériau pendant cette opération. En raison des forces élevées, la position de l'outil dévie de la trajectoire désirée. Dans ces travaux de thèse, la possibilité d'utiliser un dispositif d’assistance associé à un robot manipulateur est étudiée afin d’améliorer sa capacité de charge et sa rigidité. Dans une première partie, une modélisation géométrique, cinématique et dynamique ainsi que de déformation d’un robot industriel Kuka KR500-2MT est développée en localisant la flexibilité au niveau des articulations. La deuxième partie consiste à améliorer les performances de la robotisation du procédé FSW par différentes méthodes qui sont la modification du système de compensation de gravité, l’ajout d’une masse additionnelle sur l’outil, l’ajout d’une structure parallèle et l’utilisation de deux robots en mode coopératif. Les deux dernières solutions consistent à exercer des forces directement sur l’outillage. De cette façon, le mouvement de l'outil est principalement piloté par le robot industriel, tandis que le dispositif d’assistance (soit la structure parallèle ou le deuxième robot utilisé dans le système coopératif) assure la génération de forces de poussées très élevées. Des algorithmes d’optimisation ont été utilisés afin de minimiser les déviations de l’outil et donc réduire les défauts de soudage. Finalement, une étude de l’espace de travail est menée en utilisant le logiciel Catia. La connaissance de l'espace de travail pour les solutions proposées nous permet d’estimer les applications de soudage possibles ainsi que leur comparaison.. / Nowadays industrial robots are used in many manufacturing applications because of their versatility and easy applicability. Notwithstanding their performance these robots are not suitable for some manufacturing processes where uniform and high forces together with suitable precision of position are required. The present research is focused on the robotization of one of the high-thrust operations, the friction stir welding (FSW). This method for connecting two parts works while the connected materials are in the solid phase. For this reason a very high axial force is needed to soften the material during the welding process. Due to these high forces the position of the tool of a serial robot deviates from the desired trajectory. In this PhD work, the possibility of using a parallel structure device is investigated to improve the load capacity and stiffness of a heavy loadmanipulator robot. In a first part, the geometric, kinematic and dynamic modeling and the flexibility of an industrial robot, Kuka KR500-2MT are developed by locating flexibility at the joints. The second part is to improve the performance of the FSW process using an industrial robot. So different methods are examined: the modification of the gravity compensation system, the addition of an additional mass on the tool, the addition of a parallel structure and the use of a cooperative system. The last two solutions exert forces directly on the process tool. In this way the movement of the tool is mainly generated by the industrial serial robot, while the assistive device (either the parallel structure or the second robot used in the cooperatif system) ensures the generation of very high axial forces. Optimization algorithms are developed to minimize deviations and thus reduce welding defects. Finally, a study of the workspace is studied using Catia software. Knowledge of the system workspace with the proposed solutions allows to estimate the possible welding applications that can be achieved using these systems.

A crescente escassez de recursos energéticos renováveis bem como o aumento contínuo dos seus custos, tem requerido uma redução drástica no consumo de energia utilizada para o transporte de cargas e passageiros nas últimas décadas. Uma alternativa é a redução de peso com a utilização de ligas leves em substituição às ligas convencionais utilizadas no setor de transporte. Nesse conceito o uso de ligas de magnésio é justificado pela sua baixa densidade. Dentre as ligas de magnésio, a matriz ASTM série ZK é a que apresenta maior resistência mecânica e a adição de elementos de terras raras (RE) elevam a resistência à corrosão, a temperatura de trabalho e o limite de escoamento, devido à formação de filmes de óxidos finos e densos, além de intermetálicos de alto ponto de fusão e de maior dureza. A formação de intermetálicos do tipo MgZn de baixo ponto de fusão, torna as ligas de matriz do tipo ZK susceptíveis à formação de trinca à quente durante a soldagem, inviabilizando o uso de processos de soldagem convencionais. Uma alternativa é a solda por fricção e mistura mecânica (SFMM) realizada abaixo da temperatura de fusão. Neste trabalho, foram produzidas ligas ZK60, ZK60-1,5RE (liga ZK60 com adição de 1,5% em peso de mischmetal) por fundição convencional e ZK60-1,5RE tixofundidas com batimento mecânico no estado semissólido. Todas foram laminadas a quente em um laminador simétrico e soldadas por fricção e mistura mecânica. Os métodos de fundição e resfriamento apresentaram materiais isentos de defeitos e com homogeneidade química, além do batimento mecânico proporcionar uma microestrutura com grãos globulares homogêneos. A adição de Mischmetal deu origem a uma microestrutura com granulometria aproximadamente 22% menor. Quando comparado com o método de fundição, a liga fundida com batimento no estado semissólido apresentou uma diminuição no tamanho médio de grão de aproximadamente 26%. A laminação deu origem a uma microestrutura parcialmente recristalizada, com tamanho médio de grãos entre 3 e 4 μm. A rede de intermetálicos foi quebrada, porém, manteve-se contínua para as ligas com adição de Mm. Quanto à resistência mecânica, a liga ZK60 foi superior, devido à menor quantidade e redes intermitentes de intermetálicos, uma vez que tanto para as ligas fundidas quanto para as laminadas, as trincas foram originadas nas regiões de aglomeração de intermetálicos. As ligas com adição de Mm apresentaram melhor estabilidade térmica durante a soldagem e melhor acabamento superficial, sendo possível a soldagem com rotação de 1200 rpm e velocidade de avanço de 400 mm/min enquanto a liga ZK60 só foi possível a soldagem com 200 mm/min. As análises das tensões residuais apresentaram valores e perfis semelhantes e seguem o fluxo de material, bem como a textura dos cordões de solda. Os mapas de microdureza na secção transversal do cordão de solda revelaram maior dureza nas zonas de mistura, e valores ainda maiores e mais homogêneos para liga ZK60, pode-se afirmar que os intermetálicos do tipo MgZn tem maior dureza que os do tipo MgZnRE. / The growing scarcity of renewable energy resources, as well as the continued rise in costs has required in recent decades a dramatic reduction in energy used for transportation freight and passenger, which is increasing daily all over the world. An alternative is to weight reduction with the use of light alloys, this concept the use of magnesium alloys is justified by their low density, about 1/3 lower than that of aluminum. Among the magnesium alloy, the matrix is ZK type that has greater mechanical strength and the addition of rare earth elements (RE) to increase corrosion resistance, working temperature and yield strength due to the formation of thin films and density oxides, and intermetallic of the high melting point and higher hardness. The formation of intermetallic of the MgZn type, which has a low melting point, makes alloys with matrix of the ZK type susceptible to formation of hot crack during the welding, making impossible the use of conventional welding processes, an alternative is the friction stir welding (FSW) that the union is made below the melting point. This work shows the studies the addition of 1.5% wt. of mischmetal (Mm) in the ZK60 alloy and effects of the casting process with mechanical mixing in the semi-solid state. Were produced the alloys: ZK60, ZK60-1.5RE with conventional casting and ZK60-1.5RE Tixo with mechanical mixing in the semi-solid state, all were hot-rolled in a symmetrical laminator and welded with friction stir welding (FSW) process. The methods of casting and cooling gave resulted in materials free of defects and chemical homogeneity, and the mechanical mixing provides homogeneous microstructure with globular grains. The alloy with mischmetal addition had an average grain size of about 22% lower than ZK60 alloy, when compared to the casting method the ZK60- 1.5RE Tixo alloy had an average grain size of about 26% lower than ZK60-1.5RE alloy. The rolling process gave rise to a partially recrystallized microstructure with average grain size of between 3.3 and 4.23 μm, the intermetallic network were broken, however, kept continuous for alloys with Mm addition. As for mechanical strength was higher for ZK60 alloy, due smaller amount and intermittent network of the intermetallic. The alloys with Mm addition had better thermal stability during welding and showed better surface quality, being possible to do a welding with rotation of 1200 rpm and advancing speed of 400 mm/min while the ZK60 alloy only was possible the welding with advancing speed of 200 mm/min. The analyzes of residual stresses had similar values and profiles and follow the flow of material as well as the texture of the weld beads. The micro hardness maps in the cross section of the weld bead showed a higher hardness in the mixing zones, and higher and more homogeneous values for ZK60 alloy, and can thus affirm that the intermetallic MgZn type has higher hardness than the MgZnRE type.

Le soudage par friction malaxage, ou FSW, est un procédé de soudage à l'« état solide » permettant d'éviter certains problèmes rencontrés en soudage par fusion comme la fissuration à chaud ou la création de soufflures. La soudure est réalisée par l'action d'un outil à l'interface de deux pièces à souder. Celui-ci a pour rôle de malaxer et d'échauffer par frottement la matière. Le cordon est réalisé de proche en proche. Les efforts générés à l'interface outil/matière doivent être repris par la machine et le montage de soudage. Ils sont donc un facteur important pour le choix des moyens de soudage. Ce travail de thèse consiste à mettre en place une démarche pour qualifier les moyens de production FSW, en identifiant la partie du domaine de soudabilité opératoire accessible par le moyen envisagé. Ce travail comporte trois phases. La première est l'identification des paramètres caractéristiques du procédé FSW. Cela aboutit à l'écriture de spécifications du cahier des charges pour le choix ou la conception d'un moyen de production. Une fois ces paramètres identifiés, la deuxième étape de la démarche est la caractérisation expérimentale des domaines de soudabilités opératoires (DSO). Les actions mécaniques appliquées sur l'outil ont été associées à chaque combinaison des paramètres opératoires de ces domaines. Cette étude expérimentale a mis en évidence l'influence des paramètres de conduite sur le torseur des efforts outil/matière. Ces derniers peuvent être réduits en agissant sur ces mêmes paramètres opératoires. Enfin, la dernière phase de la démarche est la validation du moyen de production FSW choisi, grâce à l'ensemble des données expérimentales recueillies. Ce moyen de production est modélisé dans le but de tester les capacités de la machine, de la broche et du porte-pièces pour réaliser l'opération de soudage. La démarche de qualification a été mise en œuvre à la réalisation de soudures FSW par un robot polyarticulé (6 axes). Cette structure « peu rigide » et de « faible » capacité en effort est très sensible aux actions mécaniques générées par le FSW. Le choix des paramètres opératoires de soudage s'appuie sur les DSO déterminés expérimentalement pour les phases de plongée et de soudage, bornées par les limites de la machine. Il est nécessaire, pour ce type de structure, de qualifier son aptitude à réaliser l'opération de soudage FSW, car ses capacités dépendent fortement de la position de l'outil dans l'espace de travail.

A crescente escassez de recursos energéticos renováveis bem como o aumento contínuo dos seus custos, tem requerido uma redução drástica no consumo de energia utilizada para o transporte de cargas e passageiros nas últimas décadas. Uma alternativa é a redução de peso com a utilização de ligas leves em substituição às ligas convencionais utilizadas no setor de transporte. Nesse conceito o uso de ligas de magnésio é justificado pela sua baixa densidade. Dentre as ligas de magnésio, a matriz ASTM série ZK é a que apresenta maior resistência mecânica e a adição de elementos de terras raras (RE) elevam a resistência à corrosão, a temperatura de trabalho e o limite de escoamento, devido à formação de filmes de óxidos finos e densos, além de intermetálicos de alto ponto de fusão e de maior dureza. A formação de intermetálicos do tipo MgZn de baixo ponto de fusão, torna as ligas de matriz do tipo ZK susceptíveis à formação de trinca à quente durante a soldagem, inviabilizando o uso de processos de soldagem convencionais. Uma alternativa é a solda por fricção e mistura mecânica (SFMM) realizada abaixo da temperatura de fusão. Neste trabalho, foram produzidas ligas ZK60, ZK60-1,5RE (liga ZK60 com adição de 1,5% em peso de mischmetal) por fundição convencional e ZK60-1,5RE tixofundidas com batimento mecânico no estado semissólido. Todas foram laminadas a quente em um laminador simétrico e soldadas por fricção e mistura mecânica. Os métodos de fundição e resfriamento apresentaram materiais isentos de defeitos e com homogeneidade química, além do batimento mecânico proporcionar uma microestrutura com grãos globulares homogêneos. A adição de Mischmetal deu origem a uma microestrutura com granulometria aproximadamente 22% menor. Quando comparado com o método de fundição, a liga fundida com batimento no estado semissólido apresentou uma diminuição no tamanho médio de grão de aproximadamente 26%. A laminação deu origem a uma microestrutura parcialmente recristalizada, com tamanho médio de grãos entre 3 e 4 μm. A rede de intermetálicos foi quebrada, porém, manteve-se contínua para as ligas com adição de Mm. Quanto à resistência mecânica, a liga ZK60 foi superior, devido à menor quantidade e redes intermitentes de intermetálicos, uma vez que tanto para as ligas fundidas quanto para as laminadas, as trincas foram originadas nas regiões de aglomeração de intermetálicos. As ligas com adição de Mm apresentaram melhor estabilidade térmica durante a soldagem e melhor acabamento superficial, sendo possível a soldagem com rotação de 1200 rpm e velocidade de avanço de 400 mm/min enquanto a liga ZK60 só foi possível a soldagem com 200 mm/min. As análises das tensões residuais apresentaram valores e perfis semelhantes e seguem o fluxo de material, bem como a textura dos cordões de solda. Os mapas de microdureza na secção transversal do cordão de solda revelaram maior dureza nas zonas de mistura, e valores ainda maiores e mais homogêneos para liga ZK60, pode-se afirmar que os intermetálicos do tipo MgZn tem maior dureza que os do tipo MgZnRE. / The growing scarcity of renewable energy resources, as well as the continued rise in costs has required in recent decades a dramatic reduction in energy used for transportation freight and passenger, which is increasing daily all over the world. An alternative is to weight reduction with the use of light alloys, this concept the use of magnesium alloys is justified by their low density, about 1/3 lower than that of aluminum. Among the magnesium alloy, the matrix is ZK type that has greater mechanical strength and the addition of rare earth elements (RE) to increase corrosion resistance, working temperature and yield strength due to the formation of thin films and density oxides, and intermetallic of the high melting point and higher hardness. The formation of intermetallic of the MgZn type, which has a low melting point, makes alloys with matrix of the ZK type susceptible to formation of hot crack during the welding, making impossible the use of conventional welding processes, an alternative is the friction stir welding (FSW) that the union is made below the melting point. This work shows the studies the addition of 1.5% wt. of mischmetal (Mm) in the ZK60 alloy and effects of the casting process with mechanical mixing in the semi-solid state. Were produced the alloys: ZK60, ZK60-1.5RE with conventional casting and ZK60-1.5RE Tixo with mechanical mixing in the semi-solid state, all were hot-rolled in a symmetrical laminator and welded with friction stir welding (FSW) process. The methods of casting and cooling gave resulted in materials free of defects and chemical homogeneity, and the mechanical mixing provides homogeneous microstructure with globular grains. The alloy with mischmetal addition had an average grain size of about 22% lower than ZK60 alloy, when compared to the casting method the ZK60- 1.5RE Tixo alloy had an average grain size of about 26% lower than ZK60-1.5RE alloy. The rolling process gave rise to a partially recrystallized microstructure with average grain size of between 3.3 and 4.23 μm, the intermetallic network were broken, however, kept continuous for alloys with Mm addition. As for mechanical strength was higher for ZK60 alloy, due smaller amount and intermittent network of the intermetallic. The alloys with Mm addition had better thermal stability during welding and showed better surface quality, being possible to do a welding with rotation of 1200 rpm and advancing speed of 400 mm/min while the ZK60 alloy only was possible the welding with advancing speed of 200 mm/min. The analyzes of residual stresses had similar values and profiles and follow the flow of material as well as the texture of the weld beads. The micro hardness maps in the cross section of the weld bead showed a higher hardness in the mixing zones, and higher and more homogeneous values for ZK60 alloy, and can thus affirm that the intermetallic MgZn type has higher hardness than the MgZnRE type.

De nos jours, la gestion des flux de matière autour de la zone decontact représente un des principaux verrous scientifiques pourl'amélioration des simulations des procédés d'usinage comme, parexemple, le procédé FSW. Les méthodes basées sur la mécanique desmilieux continus sont couramment utilisées dans ces simulations maiselles rencontrent de nombreuses difficultés dans les zones decontact. Une explication "physique" à ces difficultés estl'utilisation des équations issues de la mécanique des milieuxcontinus pour décrire des phénomènes discontinus. À ce point, laméthode des éléments discrets s'est révélée être une alternative auxapproches continues pour traiter le problème causé par cesdiscontinuités. Cette méthode est en revanche très gourmande en termede temps de calcul.Une solution à long terme passe par un couplage entre méthodescontinues et discrètes qui requiert une zone de recouvrement où lesdeux approches coexistent. Cette zone est classiquement placée dansune région continue et cela oblige à développer la méthode deséléments discrets pour qu'elle puisse opérer dans ce type derégion. Le travail de thèse présente une méthode pour simuler laconduction de la chaleur et le comportement mécanique des milieuxcontinus élasto-plastiques. Cette méthode peut travailler dans la zonecontinue de recouvrement et, en plus, elle peut être facilementcouplée avec les méthodes discontinues classiques.Le couplage entre l'aspect thermique et l'aspect mécanique estégalement étudié et comparé aux résultats expérimentaux issus de labibliographie. / Currently, almost all material manufacturing processes are simulatedusing methods based on continuum approaches. These methods, thoughwidely studied, face difficulties with contact problems that areusually found in processes such as FSW. One "physical" explanationto this issue is given by the fact that these methods use equationsbased on continuum mechanics to describe discontinuous problems. Insome cases, the Discrete Element Method is used to overcome theseproblems. However, it is known to be a very time-consuming method.Thus, a long term solution consists of coupling both continuum anddiscontinuous approaches. This solution requires an overlapping zonewhere the two methods work together. This overlapping zone isclassically placed on a continuous region. Consequently, the DiscreteElement Method must be improved to be reliable in such a region. Thepresent work describes a DEM approach to simulate elasto-plasticmechanical behaviour and heat conduction through a continuousmaterial. This method can be used both to carry out calculations onthe continuous overlapping zone as well as to be coupled withclassical Discrete Element Method in order to deal with discontinuousproblems.Finally, coupling between thermal and mechanical aspects is studiedand compared to experimental results found in the bibliography.

Ces travaux de thèse portent sur le soudage par friction-malaxage hétérogène entre le titane (Ti grade II) et l'aluminium (Al1050). La recherche est axée sur la configuration de l'assemblage par recouvrement afin de limiter les contraintes pendant le procédé. La méthode de plans d'expérience de Taguchi a permis de déterminer l'influence des paramètres pour une jonction sans défaut. La vitesse de rotation de l'outil a été identifiée comme le paramètre influençant le plus la génération de défauts. Les combinaisons de paramètres sont liées à un coefficient d'apport de chaleur. La différence de conductivité thermique entre les deux matériaux conduit à un gradient thermique dans l'épaisseur jusqu'à 80°C. Aucune optimisation de la résistance mécanique des jonctions n'a été révélée par les tests de traction et de flexion trois points.Des analyses microstructurales ont été réalisées sur la jonction soudée afin de mieux comprendre les propriétés mécaniques. Un seul composé intermétallique TiAl3 se forme dans le volume de titane et assure la continuité chimique de l'interface. D'autres analyses par EBSD (MEB) et par la méthode ASTAR™ (MET) pour les plus petites échelles ont complété les observations. Le processus génère une déformation plastique sévère de l'aluminium qui induit une réduction de la taille des grains avec un gradient suivant l'épaisseur.Toutes les observations ont fournis des moyens pour comprendre le phénomène de soudage par friction-malaxage conduisant à une évolution microstructurale pour réaliser un meilleur lien entre la microstructure finale et les propriétés macroscopiques du cordon de soudure. / These PhD works are about heterogeneous friction stir welding between titanium (Ti grade II) and aluminum (AA1050). Research is focused on lap joining configuration in order to limit the process stress. Taguchi's design of experiments determined parameters influence for a defectless welded junction. The rotational speed of the tool has been identified as the parameter which influences the most the defects generation. Parameters combinations are linked to a heat input coefficient. The thermal conductivity difference between the two material leads to a thermal gradient in the thickness up to 80°C. No junction mechanical strength optimization has been revealed by tensile and bending tests.Microstructural analyses were performed on the welded junction in order to understand the mechanical properties. One single intermetallic compound TiAl3 nucleates in the titanium volume and ensures interface chemical continuity. Further analyses with EBSD (SEM) supplemented by ASTAR™ (TEM) method for the smaller scales have completed the observations. The process generates aluminum severe plastic deformation which induces a grain size reduction with a gradient following the configuration thicknessAll observations brought clues to understand friction stir welding phenomenon leading to microstructural evolution to realize a better link between resulting microstructure and macroscopic properties.

The aim of the thesis is the understanding of the thermal, mechanical and metallurgical phenomena occurring during friction stir welding of a 6005A aluminum alloy and the determination of the mechanical properties of the welded joints. The forces and the torque needed for welding as well as the thermal cycles were measured in the various zones of the joint. A first model predicts the influence of the welding parameters on the thermal cycles, and especially on the asymmetry of the temperature evolution with respect to the weld centerline. A second model links the local microstructural evolutions, and in particular the precipitation kinetics, to the thermomechanical cycles. A third model relates the local microstructures to the local mechanical properties, based on a novel physics-based strain hardening model. Finally, the link between the mechanical properties of the joint in service, the local mechanical properties and the microstructures is modeled using a multi-scale approach including a micro-mechanics damage constitutive model. The models are calibrated and validated through in-depth microstructure characterization and mechanical tests on the base material, on heat treated samples and on the friction stir welds.

Homophobia in men may be, in part, due to reaction formation rooted in unacceptable same-sex attraction. Previous studies have not confirmed a covert same-sex attraction in homophobic men, which is necessary for a reaction formation theory of homophobia. This study sought to reveal possible covert same-sex attraction in homophobic men. In this study, heterosexual and homosexual male erotic images were presented in a passive S1/S2 stimulus prediction design to 48 self-identified heterosexual participants, grouped by homophobia. Three event-related potential responses related to valenced emotional processing were examined: the medial frontal negativity (MFN), the late positive potential (LPP), and the positive frontal slow wave (FSW). While homophobic men have a larger FSW in response to erotics across the board, F(1,46) = 3.88, p = .055, no significant interactions between homophobia and image content were found. As such, homophobic men may have more interest in erotic images in general, but this study does not demonstrate that homophobic men find homosexual erotics appetitive.

Friction Stir Welding has seen a fast uptake in many industry segments. Mechanical properties superior to fusion welding, the ability to weld "unweldable" aluminium alloys and low distortion are often described as the main reasons for the fast industrial implementation of FSW. Most existing applications consist of long straight welding joints. Applications with complex weld geometries, however, are rarely produced by FSW. These geometries can induce thermal variations during the welding process, thus making it challenging to maintain a consistent weld quality. In-process adaptation of weld parameters to respond to geometrical variations and other environmental variants allow new design opportunities for FSW. Weld quality has been shown to be reliant on the welding temperature. However, the optimal methodology to control the temperature is still under development.The research work presented in this thesis focuses on some steps to take in order to reach the improvement of the FSW temperature controller, thus reach a better and consistent weld quality. In the present work different temperature methods were evaluated. Temperature measurements acquired by the tool-workpiece thermocouple (TWT) method were accurate and fast, and thereby enhanced suitable for the controller. Different environmental conditions influencing the material heat dissipation were imposed in order to verify the controller effect on the joint quality. In comparison with no controlled weld, the use of the controller enabled a fast optimization of welding parameters for the different conditions, leading to an improvement of the mechanical properties of the joint.For short weld lengths, such as stitch welds, the initial plunge and dwell stages occupy a large part of the total process time. In this work temperature control was applied during these stages. This approach makes the plunge and dwell stages more robust by preventing local material overheating, which could lead to a tool meltdown. The TWT method was demonstrated to allow a good process control during plunging and continuous welding. The approach proposed for control offers weld quality consistency and improvement. Also, it allows a reduction of the time required for the development of optimal parameters, providing a fast adaptation to disturbances during welding and, by decreasing the plunge time, provides a significant decrease on the process time for short welds.

Friction stir welding (FSW) is an advantageous solid-state joining process, suitable for many materials in the energy, aerospace, naval and automotive industries. Like all other welding processes, friction stir welding requires non-destructive evaluation (NDE). The time and resources to preform NDE is expensive. To reduce these costs, nontraditional NDE methods are being developed for FSW. Spectral based defect recognition uses the forces during the welding process to validate weld quality. Although spectral NDE methods have shown promise as an alternative NDE processes, many research welding speeds do not correspond to manufacturing speeds, nor do they explain the relationship between the spectral data and the process. The purpose of this work is to explore the possibility of acquiring additional information about the defect. Namely the defect’s type, location, and magnitude. In this study, welds with “wormhole” defects were produced at 2000, 2500 and 3000 mmpm in 5754 aluminum. The welding process forces and torque were measured and analyzed spectrally. The welded plates were then imaged with x-ray photography, a validated NDE method. It was found that low frequencies (0 – 4 Hz) in the y & z force signals correlate with defect presence in high speed FSW. In addition, the strong correlation between the spectral data and the presence of a defect allowed for defect magnitude predictions. Linear fits were applied to the defect measurements and the spectral data. Large error inhibits the wide use of this prediction method.