This thesis is devoted to the numerical and experimental investigation of residual stress and deformation in polycrystalline metallic alloys at different scales. The emphasis in the current study is placed on establishing the connection between the simulation of deformation by the Finite Element (FE) method and experimental characterisation by synchrotron X-Ray Diffraction (XRD). Of particular importance is the interpretation of modelling results and their validation by careful comparison with experimental data. The concept of eigenstrain was used extensively throughout the report to study the residual elastic strain distributions and their sources. A pseudo-thermal strain FE procedure was used systematically to simulate the residual stress states in samples and engineering components of different shape and dimensionality. The case of 1-D strain variation was considered using the example of a plastically bent bar. The direct and inverse problems of eigenstrain analysis were solved, and validated experimentally by the use of XRD and EDM slitting methods. A novel 2-D discrete inverse eigenstrain algorithm was proposed and implemented to reconstruct the residual stress distribution in a worn rail head. The link between the residual stress and deformation history was studied via thermo-mechanical modelling of the Linear Friction Welding (LFW) process. To advance the understanding of polycrystalline deformation behaviour across the scales, a crystal plasticity model was employed to simulate the elastic-plastic deformation behaviour of Ti-6Al-4V alloy. A post-processor was developed to extract the average elastic strains for orientation-specific grain groups and to compare them with XRD data. A “peak constructor” post-processor was developed that utilised the knowledge of both the elastic strain and dislocation density. In a further development step, a strain gradient crystal plasticity formulation was adopted to account for the local dislocation evolution. Intra-granular deformation analysis was carried out and micro-beam Laue experimental diffraction technique was used for validation. Thus, local lattice arrangement was studied at the microscopic, intragranular scale. Special attention was paid to the phenomenon of Laue spot “streaking”, indicative of the local lattice misorientation caused by dislocation activity during deformation. The results presented in this thesis contributed to the fundamental understanding of the residual stress and deformation in polycrystalline metallic alloys and lead to more than 20 publications in peer-reviewed journals and conference proceedings, which are listed in the Appendix.

The currently operating Generation II Advanced Gas-Cooled Reactors (AGR) in the nuclear power stations in the UK, mainly built in the 1960s and 1970s, are approaching their designed life. Besides the development of the new generation of reactors, the government is also seeking to extend the life of some AGRs. Creep and failure properties of Type 316H austenitic stainless steels used in some components of AGR at elevated temperature are under investigation in EDF Energy Ltd. However, the current empirical creep models used and examined in EDF Energy have deficiency and demonstrate poor agreement with the experimental data in the operational complex thermal/mechanical conditions. The overall objective of the present research is to improve our general understanding of the creep behaviour of Type 316H stainless steels under various conditions by undertaking theoretical studies and developing a physically based multiscale state variable model taking into account the evolution of different microstructural elements and a range of different internal mechanisms in order to make realistic life prediction. A detailed review shows that different microstructural elements are responsible for the internal deformation mechanisms for engineering alloys such as 316H stainless steels. These include the strengthening effects, associated with forest dislocation junctions, solute atoms and precipitates, and softening effects, associated with recovery of dislocation structure and coarsening of precipitates. All the mechanisms involve interactions between dislocations and different types of obstacles. Thus change in the microstructural state will lead to the change in materials' internal state and influence the mechanical/creep property. Based on these understandings, a multiscale self-consistent model for a polycrystalline material is established, consisting of continuum, crystal plasticity framework and dislocation link length model that allows the detailed dislocation distribution structure and its evolution during deformation to be incorporated. The model captures the interaction between individual slip planes (self- and latent hardening) and between individual grains and the surrounding matrix (plastic mismatch, leading to the residual stress). The state variables associated with all the microstructure elements are identified as the mean spacing between each type of obstacles. The evolution of these state variables are described in a number of physical processes, including the dislocation multiplication and climb-controlled network coarsening and the phase transformation (nucleation, growth and coarsening of different phases). The enhancements to the deformation kinetics at elevated temperature are also presented. Further, several simulations are carried out to validate the established model and further evaluate and interpret various available data measured for 316H stainless steels. Specimens are divided into two groups, respectively ex-service plus laboratory aged (EXLA) with a considerable population of precipitates and solution treated (ST) where precipitates are not present. For the EXLA specimens, the model is used to evaluate the microscopic lattice response, either parallel or perpendicular to the loading direction, subjected to uniaxial tensile and/or compressive loading at ambient temperature, and macroscopic Bauschinger effect, taking into account the effect of pre-loading and pre-crept history. For the ST specimens, the model is used to evaluate the phase transformation in the specimen head volume subjected to pure thermal ageing, and multiple secondary stages observed during uniaxial tensile creep in the specimen gauge volume at various temperatures and stresses. The results and analysis in this thesis improve the fundamental understanding of the relationship between the evolution of microstructure and the creep behaviour of the material. They are also beneficial to the assessment of materials' internal state and further investigation of deformation mechanism for a broader range of temperature and stress.

Predictive models of structures containing frictional joints presently suffer from poor descriptions of interface behaviour at the joints. This thesis aims to address this shortfall by furthering the physical understanding of parameters affecting interface behaviour such as friction and contact stiffness. Aspects of friction and contact stiffness relevant to the characterisation of fretting joints are investigated by a combined modelling and experimental approach. Friction and wear behaviour in gross-slip fretting are investigated by in-line and rotational fretting tests. New 3D topography parameters are found to be useful in the analysis of surfaces during fretting. Wear-scar shape is found to be dependent on material. A phenomenon whereby friction increases during the gross-slip phase of individual cycles is found to be due to wear-scar interaction primarily through the interference of local features distributed over the contact area. These features are similar in size to the applied fretting stroke. A simple model to explain the behaviour is put forward which shows that wear-scar shape determines the form of the friction variation. A finite-element (FE) model of the interaction of an elastic-plastic asperity junction is used to predict sliding friction coefficients. The modelling differs from previous work by: permitting greater asperity overlaps, enforcing an interface shear strength, and allowing material failure. The results are also used to predict friction coefficients for a stochastic rough surface. The magnitudes of the predicted friction coefficients are generally representative of experimental measurements. Results suggest that friction arises from both plasticity and tangential interface adhesion. Contact stiffness is studied for both fretting and non-fretting. A technique to isolate the true interface stiffness from results derived from load-deflection data is developed by comparing experimental and FE results. In the fretting wear case, comparison of tangential contact stiffness results in the literature with FE results reveals an interface whose compliance dominates the response to the extent that stiffness is proportional to contact area. In fretting tests such as this, wear debris is thought to be a factor contributing to high interface compliance. Non-fretting experiments performed here show that, at higher pressures, interface domination is reduced as the contact approaches the smooth case. Experiments are performed where contact stiffness is measured simultaneously by both ultrasound and digital image correlation. The effect of normal and tangential loading upon the contact stiffness (normal and tangential) is investigated. Experimental evidence showing that ultrasound measures an ‘unloading’ stiffness while DIC measures a ‘loading’ stiffness is obtained for the case of tangential loading where the ‘DIC stiffness’ decreases with increasing tangential load whereas the ‘ultrasound stiffness’ remains approximately constant. On average, ultrasound gives magnitudes 3.5 and 2.5 times stiffer than the DIC results for the normal and tangential stiffness cases, respectively. The difference in magnitudes can largely be physically explained, and is relatively small considering the significant differences between the techniques. Therefore, both methods can claim to give valid measurements of contact stiffness – though each has its own limitations which are outlined herein.

Capillaries in tumours are often severely buckled (in a plane perpendicular to the axis) and / or chaotic in their direction. We develop a model of these phenomena using nonlinear solid mechanics. Our model focusses on the immediate surrounding of a capillary. The vessel and surrounding tissue are modelled as concentric annulii. The growth is dependent on the concentration of a nutrient (oxygen) diffusing from the vessel into the tumour interstitium. The stress is modelled using a multiplicative decomposition of the deformation gradient F=F_e F_g. The stress is determined by substituting the elastic deformation gradient F_e (which gives the deformation gradient from the hypothetical configuration to the current configuration) into a hyperelastic constitutive model as per classical solid mechanics. We use a Blatz-Ko model, parameterised using uniaxial compression experiments. The entire system is in quasi-static equilibrium, with the divergence of the stress tensor equal to zero. We determine the onset of buckling using a linear stability analysis. We then investigate the postbuckling behaviour by introducing higher order perturbations in the deformation and growth before using the Fredholm Alternative to obtain the magnitude of the buckle. Our results demonstrate that the growth-induced stresses are sufficient for the capillary to buckle in the absence of external loading and / or constraints. Planar buckling usually occurs after 2-5 times the cellular proliferation timescale. Buckles with axial variation almost always go unstable after planar buckles. Buckles of fine wavelength are initially preferred by the system, but over time buckles of large wavelength become energetically more favourable. The tumoural hoop stress T_{ThetaTheta} is the most invariant (Eulerian) variable at the time of buckling: it is typically of the order of the tumoural Young's Modulus when this occurs.

The core aim of this research project was to improve understanding of the effects of microstructure and crystallographic texture on the high strain rate plastic deformation behaviour of the industrially important Titanium alloy, Ti-6Al-4V. To facilitate this study, four rolled plates of Ti-6Al-4V, with varying thermo-mechanical processing histories, were provided by TIMET Corp., the world’s largest supplier of Titanium product. To determine the nature of each plate’s microstructure and the crystallographic texture of the dominant α phase, the four Ti-6Al-4V plates were microstructurally characterised using techniques such as optical microscopy and electron backscatter diffraction (EBSD). To determine the effects of the measured microstructures and textures on the strain rate dependent plastic deformation behaviour of the four Ti-6Al-4V plates, uniaxial compression and tension tests were carried out in the three orthogonal material orientations at quasi-static (10^-3 s^-1) and high strain rates (10^3 s^-1) using a standard electro-mechanical test device and split-Hopkinson pressure bars (SHPB), respectively. To provide further understanding of the effects of microstructure and texture on the plastic deformation behaviour of Ti-6Al-4V, this time under complex impact loading conditions, the classic Taylor impact experiment was adapted to include an optical measurement and geometry reconstruction technique. A novel experimental setup was designed that consists of an ultra-high speed camera and mirror arrangement, allowing the Taylor impact specimen to be viewed from multiple angles during the experiment. Using the previously mentioned optical measurement and geometry reconstruction technique, it was then possible to gain valuable, previously unobtainable, data on the deformation history of Taylor impact specimens in-situ, such as the major/minor axes of the anisotropically deforming elliptical specimen cross-sections as a function of time and axial position, true strain as a function of time and axial position, and the true strain rate as a function of axial position. The technique was verified by testing a specimen cut from the in-plane material orientation of a clock-rolled high purity Zirconium plate. The output measurements from a post-deformation image frame were compared with measurements of the recovered specimen made using a coordinate measurement machine (CMM), with analysis showing excellent agreement between the two techniques. The experiment was then carried out on specimens cut from the two orthogonal in-plane material orientations of one of the four Ti-6Al-4V plates. Analysis of the data from these experiments gave significant insight into the plastic deformation behaviour of macroscopically textured Ti-6Al-4V under complex impact loading. Recovered Ti-6Al-4V specimens from the outlined Taylor impact experiments were then sectioned along specific planes and microstructurally characterised using EBSD, with comparisons made between the pre and post-deformation microstructures. From this analysis, and the previously discussed geometry reconstruction technique, insight was gained into the effects of micro-texture on the general anisotropic plastic deformation behaviour of Ti-6Al- 4V plate materials and in particular the role of micro-texture on the formation of deformation twins. Finally, the understanding gained from these experiments, and a detailed review of the literature, was used to inform a novel, physically based material modelling framework, capable of capturing the effects of microstructure and texture on the strain rate and temperature dependent plastic deformation behaviour of Ti-6Al-4V. The model was implemented in the computational software package, MATLAB, and verified by comparison with the mechanical characterisation results from one of the Ti-6Al-4V plates. A number of frameworks are discussed for implementing the new Ti-6Al-4V model within finite element (FE) analysis software packages, such as ABAQUS, LS-DYNA and DEFORM. It is hoped that the new Ti-6Al-4V model can be used to optimise the design of Ti-6Al-4V components and structures for impact loading scenarios.

The primary aim of this research was to develop and improve the experimental method and data interpretation for strain measurements using diffraction methods to gain a better understanding of micromechanical deformation and anisotropy of lattice strain response. Substantial part of the research was devoted to the development of the laboratory high energy X-ray diffractometer (HEXameter) for bulk residual strain evaluation. White beam energy dispersive X-ray diffraction was chosen as the principal diffraction mode due to its extreme efficiency in utilising X-ray flux and its ability to capture large segments of diffraction patterns. The specimens that have been examined were real engineering components, mechanically deformed specimens and thermally treated specimens, ranging from dynamic in-situ measurements to ex-situ materials engineering. For the real engineering components, a wedge coupon from the trailing edge of a Ti64 wide fan blade and a turbine combustion casing were examined. Among the mechanically deformed specimens that have been measured were shot-peened steel plates, elasto-plastically bent bars of Mg alloy and cold expanded Al disks. Amongst the thermally deformed specimens, laser-formed steel plates, thermal spray coatings, a manual inert gas weld of Al plates, a friction stir weld of Al plates and Ni tubes and a quenched Ni superalloy cylinder used for strain tomography were studied. In-situ loading experiments have also been carried out, such as experiments on pointwise mapping of grain orientation and strain using the 3DXRD microscope at the ESRF and in-situ loading experiments on titanium alloy, rheo-diecast and high pressure diecast Mg alloy, IN718 Ni-base superalloy and Al2024 aluminium alloy. Experimental results from X-Ray diffraction and strain tomography were used to achieve a better understanding of the material properties. Some results were compared with polycrystal Finite Element model predictions. Amongst the most prominent research achievements are the development on the HEXameter laboratory instrument, including: (i) the development of special collimation systems for the detectors and the source tube; (ii) the development of a twin-detector setup (that allows for simultaneous determination of strain in two mutually orthogonal directions); (iii) improved alignment procedures for better performance; and (iv) the adaptation of instrumentation for efficient scanning of both large and small components, that included choosing and adapting translation devices, programming of the translation system and designing sample mounting procedures. In this research several approaches to data treatment were investigated. Quantitative phase analysis, single peak fitting (using custom Matlab routines and GSAS) and full pattern fitting (with individual pattern data refined by GSAS and batch refinement done by invoking GSAS via a Matlab routine) were applied. Different Matlab routines were written for specific experimental setups; and various analysis methods were selected and used for refinement depending on the requirements of the measurement results interpretation. 16 papers were published, ensuring that the results of this thesis are readily available to other researchers in the field.

L'application du procédé SLM est limitée par la difficulté à contrôler le procédé. Son application aux céramiques est particulièrement difficile en raison de leur faible absorption au laser et de leur faible résistance au choc thermique. La maîtrise de ce procédé nécessite une compréhension complète du transfert de chaleur, de la dynamique des fluides et de la mécanique des solides. Dans ce travail, nous proposons un modèle numérique pour la simulation du procédé SLM appliqué aux céramiques. Le modèle est développé à l'échelle du cordon et avec l'hypothèse d'un lit de poudre continu. Il est basé sur la méthode level set et l'homogénéisation multiphasique, avec laquelle nous sommes capables de suivre l'évolution de l'interface gaz/matière et les transformations de phase. La simulation dévelopée permet d'étudier l'influence des propriétés du matériau et des paramètres du procédé sur la température, la forme du bain liquide, la dynamique des fluides et la mécanique des solides. En dehors de la puissance du laser et de la vitesse de balayage, l'absorption du matériau est également importante pour la thermique et la forme du bain liquide. Avec la dynamique des fluides, la forme convexe du cordon est obtenue sous tension de surface. Les gouttelettes liquides se forment lors de la fusion de la poudre et créent une instabilité du bain. Ceci entraîne une irrégularité du cordon après solidification. L'effet Marangoni, provoqué par le gradient surfacique de la tension de surface, est étudié. Son influence sur la répartition de la température, la forme du bain liquide et la régularité du cordon est évoquée. Cet effet peut lisser la surface du cordon avec ∂γ/∂T négatif. En augmentant la vitesse de balayage, la surface du cordon devient plus irrégulière. L'effet de « balling » est reproduit avec une vitesse de balayage élevée. Cela peut être utile pour trouver le régime donnant une forme de cordon régulière étant données la puissance et la vitesse du laser. Le défaut de fissuration est délétère dans la fabrication additive. L'utilisation d'un laser auxiliaire peut aider à éviter ce défaut en diminuant la contrainte de traction maximale. Le mode de fonctionnement de ce laser auxiliaire reste un sujet intéressant à étudier et quelques pistes ont été données par les simulations présentées. Le modèle est validé par la comparaison de la forme du bain liquide avec des expériences dans différentes conditions de procédé. Les simulations peuvent également révéler la tendance de variation de la surface du cordon dans certains cas. Par la simulation de la déposition de cordons multiples, l'influence de taux de recouvrement sur la surface d'une couche, la température et l'évolution de contrainte est soulignée. / The application of SLM process is limited by the difficulty of process control. Its application to ceramics is especially challengeable due to their weak absorption to laser and weak resistance to thermal shock. The mastery of this process requires a full understanding of heat transfer, fluid dynamics in melt pool and solid mechanics. In this work, we propose a numerical model for the simulation of SLM process applied to ceramics. The model is developed at the track scale and with the assumption of continuous powder bed. It is based on level set method and multiphase homogenization, with which we are able to follow the evolution of gas/material interface and phase transformation. Simulations are performed to study the influence of material properties and process parameters on temperature, melt pool shape, fluid dynamics and solid mechanics. Apart from the laser power and scanning speed, material absorption is also found to be important to the thermal behavior and the melt pool shape. With the fluid dynamics, convex shape of track cross section is achieved under surface tension. Besides that, liquid droplets collapsing formed by the melting of powder create melt pool instability when falling, thus leading to track irregularity after solidification. The Marangoni effect, caused by surface tension gradient at gas/material interface, is investigated. Its influence on temperature distribution, melt pool shape and track regularity is recognized. One interesting finding is the smoothing effect of track surface with negative ∂γ/∂T. When combine surface tension with scanning speed, track surface becomes more irregular with the increase of scanning speed. The well-known balling effect is reproduced with high scanning speed. This can be helpful to find the regime for regular track shape with given laser power and scanning speed. Cracking defect is deleterious in additive manufacturing. The use of an auxiliary laser can help to avoid this defect by decreasing the maximum tensile stress. The process mode of this auxiliary laser remains an interesting subject to be studied and some guidelines have been given by the presented simulations. The model is validated by the comparison of melt pool shape with experiments under different process conditions. Simulations can also reveal the tendency of track surface variation for certain cases. By the application to multi-track deposition, the influence of hatch distance on layer surface, temperature and stress evolution is emphasized.

Le recours à des simulations numériques pour l’étude de l’influence des paramètres d’entrée (matériaux, chargements, conditions aux limites, géométrie, etc.) sur les différentes quantités d’intérêt en soudage (contraintes résiduelles, distorsion, etc.) s’avère trop long et coûteux vu l’aspect multi-paramétrique de ces simulations. Pour explorer des espaces paramétriques de grandes dimensions, avec des calculs moins coûteux, il parait opportun d’utiliser des approches de réduction de modèle. Dans ce travail, d’une façon a posteriori, une stratégie non-intrusive est développée pour construire les abaques dédiées aux études paramétriques du soudage. Dans une phase offline, une base de données (‘snapshots’) a été pré-calculée avec un choix optimal des paramètres d'entrée donnés par une approche multi-grille (dans l’espace des paramètres). Pour explorer d’autres valeurs de paramètres, une méthode d’interpolation basée sur la variété Grassmannienne est alors proposée pour adapter les bases réduites espace-temps issues de la méthode SVD. Cette méthode a été constatée plus performante que les méthodes d’interpolation standards, notamment en non-linéaire. Afin d’explorer des espaces paramétriques de grandes dimensions, une méthode de type décomposition tensorielle (i.e. HOPGD) a été également étudiée. Pour l’aspect d’optimalité de l’abaque, nous proposons une technique d’accélération de convergence pour la HOPGD et une approche ‘sparse grids’ qui permet d’échantillonner efficacement l’espace des paramètres. Finalement, les abaques optimaux de dimension jusqu’à 10 à précision contrôlée ont été construits pour différents types de paramètres (matériaux, chargements, géométrie) du procédé de soudage. / The use of standard numerical simulations for studies of the influence of input parameters (materials, loading, boundary conditions, geometry, etc.) on the quantities of interest in welding (residual stresses, distortion, etc.) proves to be too long and costly due to the multiparametric aspect of welding. In order to explore high-dimensional parametric spaces, with cheaper calculations, it seems to be appropriate to use model reduction approaches. In this work, in an a posteriori way, a non-intrusive strategy is developed to construct computational vademecum dedicated to parametric studies of welding. In an offline phase, a snapshots database is pre-computed with an optimal choice of input parameters given by a “multi-grids” approach (in parameter space). To explore other parameter values, an interpolation method based on Grassmann manifolds is proposed to adapt both the space and time reduced bases derived from the SVD. This method seems more efficient than standard interpolation methods, especially in non-linear cases. In order to explore highdimensional parametric spaces, a tensor decomposition method (i.e. HOPGD) has also been studied. For the optimality aspect of the computational vademecum, we propose a convergence acceleration technique for HOPGD and a “sparse grids” approach which allows efficient sampling of the parameter space. Finally, computational vademecums of dimension up to 10 with controlled accuracy have been constructed for different types of welding parameters (materials, loading, geometry).

Les Vibrations Induites par Frottement (FIV) sont un phénomène complexe qui surgit chaque fois deux surfaces subissent un glissement relatif. Pendant les dernières décennies, une quantité significative de œuvres expérimentales et numériques a traité des Vibrations Induites par Frottement, tandis que la simulation de l'excitation dynamique de contacts frictionnels a été toujours un vrai défi dans beaucoup de domaines de recherche industrielles. Dans ce cadre de recherche, ce travail est adressé à l'analyse des Vibrations Induites par Frottement, en développant des analyses en même temps expérimentales et numériques ; on propose une nouvelle approche numérique pour reproduire l'excitation dynamique locale du contact et son effet sur la réponse vibrationnel du système, sans augmentation significative des coûts de calcul. Le système mécanique, l'objet de l'analyse, est composé par deux poutres en acier en contact frictionnel dans un mouvement relatif ; la dynamique simple du système tient compte de la distinction entre la réponse de dynamique du système et l'excitation à haut débit venant du contact. Une campagne expérimentale paramétrique a été conduite pour analyser les effets de trois paramètres de contact principaux (la vitesse de glissement, la charge normale et la rugosité superficielle) sur la réponse du système vibrationnel, c'est-à-dire sur les vibrations induites. En parallèle, un modèle numérique a été mis en œuvre pour reproduire l'excitation dynamique locale du contact et son effet sur la réponse vibrationnel du système. Une nouvelle loi de friction a été présentée dans le modèle, proposant l'utilisation d'un terme provoquant une perturbation dans le coefficient de frottement pour simuler les effets de l'excitation au contact. Les inclusions de l'excitation dynamique locale, en raison des phénomènes de contact, par le terme de perturbation du coefficient de frottement, permettent de reproduire correctement les Vibrations Induites par Frottement sans présenter une représentation de la topographie superficielle réelle, qui a besoin d'un grand nombre d'éléments, économisant donc le temps de calcul. Des signaux différents pour le terme provoquant la perturbation ont été testés pour simuler correctement les vibrations mesurées. L'évolution du terme provoquant la perturbation récupérée par une méthode inverse a surligné les contributions spectrales différentes de l'excitation locale du contact. La comparaison entre les Vibrations Induites par Frottement mesurées et ceux simulés numériquement a montré une bonne corrélation, validant la loi de frottement proposée. Finalement, l'effet d'un changement de rugosité e de vitesse de glissement a été aussi simulé numériquement et corrélé avec les résultats expérimentaux. / Friction-Induced Vibrations (FIV) are a complex phenomenon which arises each time two surfaces undergo relative sliding. During the last decades, a significant amount of experimental and numerical works dealt with Friction-Induced Vibrations, while the simulation of the dynamic excitation from frictional contacts has always been a real challenge to face in many industrial research areas. In this research framework, this work is addressed to the investigation of the Friction-Induced Vibrations, carrying on at the same time experimental and numerical analyses; a new numerical approach is proposed to reproduce the local dynamic excitation from the contact and its effect on the vibrational response of the system, without significant increase of the computational time costs. The mechanical system, object of the investigation, is composed by two steel beams in frictional contact during relative motion; the simple dynamics of the system allows for distinguishing between the dynamics response of the system and the broadband excitation coming from the contact. A parametrical experimental campaign has been conducted to analyse the effects of three main contact parameters (the relative sliding velocity, the normal load and the surface roughness) on the system vibrational response, i.e. on the induced vibrations. In parallel, a numerical model has been implemented to reproduce the local dynamic excitation from the contact and its effect on the vibrational response of the system. A new friction law has been introduced in the model, proposing the use of a perturbative term in the friction coefficient in order to simulate the effects of the contact excitation. The inclusions of the local dynamic excitation, due to the contact phenomena, by the perturbation term of the friction coefficient allows to correctly reproduce the Friction-Induced Vibrations without introducing a representation of the real surface topography, which usually needs a large number of elements, saving then computational time. Different signals for the perturbative term have been tested to simulate correctly the measured vibrations. The evolution of the perturbative term recovered by an inverse method allowed for highlighting the different spectral contributions of the local excitation coming from the contact. The comparison between the measured Friction-Induced Vibrations and the ones simulated numerically showed good correlation, validating the proposed friction law. Finally, the effect in a change of the sliding velocity and surface roughness have been simulated numerically too and correlated with experimental results.

Cette thèse est consacrée au développement d'outils de simulation numérique permettant d'appréhender les phénomènes multi-physiques complexes (thermique, mécanique des solides, mécanique des fluides et sciences des matériaux) mis en jeu lors d'opérations de soudage TIG (Tungsten Inert Gas) de tôles minces de type 316L utilisées dans l'industrie agroalimentaire. La fusion locale des éléments à assembler par soudage présente en effet l'inconvénient d'induire des déformations locales importantes qui compliquent le montage des pièces. Un autre désavantage est l'apparition de contraintes résiduelles qui impactent la durabilité de la structure soudée. Afin de prédire ces déformations et contraintes pendant la phase de conception, en vue par exemple de les minimiser en jouant sur des paramètres tels que la vitesse d'exécution et l'intensité du courant de soudage, des outils numériques prédictifs ont été développés dans le cadre de ce travail.Un modèle éléments finis 3D de couplage entre la thermique et la mécanique, dans les domaines transitoire et nonlinéaire,a notamment été programmé en langage APDL (Ansys Parametric Design Language) à l'aide du logiciel multi-physique ANSYS. La source mobile de chaleur par soudage a été représentée par un profil Gaussien dont les paramètres ont été calibrés de manière à optimiser la forme géométrique du cordon. Pour ce faire, la surface de réponse d'un plan d'expérience factoriel a été utilisée. Les résultats numériques obtenus sont tout à fait satisfaisants puisque les paramètres de la source de chaleur gaussienne identifiés à l'aide du plan d'expérience factoriel permettent une reproduction fidèle de la géométrie du cordon. La comparaison entre les valeurs expérimentales et calculées de la déviation montre par ailleurs une bonne cohérence avec un écart relatif inférieur à 5%. Afin d'étudier la tension et la conductibilité électrique lors de l'amorçage et du maintien de l'arc de soudure, un modèle axisymétrique bidimensionnel de l'arc électrique a été réalisé en utilisant le logiciel FLUENT. La géométrie réelle des composantes de la torche telles que le diffuseur de gaz, la buse et l'électrode a été prise en compte. Lemodèle intègre un couplage fluide-structure dans lequel les équations électromagnétiques et thermiques sont résolues dans la cathode solide. Les équations supplémentaires régissant l'écoulement sont considérées dans le domaine gazeux où l'arc est généré. Pour le maintien de l'arc, ces équations, qui ont été programmées en langage C++, permettent de s'affranchir de la conductibilité artificielle souvent utilisée dans la littérature. Le modèle permet d'obtenir les champs de température du plasma, les chutes de tension à l'anode et à la cathode de l'appareil de soudage, la tension dans l'arc ainsi que le rendement de l'apport d'énergie. Les résultats numériques indiquent que la température et la vitesse d'écoulement du plasma augmentent avecl'intensité du courant et avec la distance inter électrode. Il en va de même pour le potentiel électrique mais avec une influence plus forte de la distance inter électrode. Enfin, le débit de gaz ne joue aucun rôle sur la température et sur le potentiel électrique. Il influe par contre sur la vitesse d'écoulement du plasma. Plus le débit est élevé, plus la vitesse d'écoulement du plasma est faible. / This thesis is dedicated to the development of numerical simulation tools allowing to understand complex multi-physics phenomena (thermal, solid mechanics, fluid mechanics and sciences materials) involved in TIG (Tungsten Inert Gas) welding operations of 316L thin plate used in the food industry. The local fusion of the elements to be assembled by welding has indeedthe disadvantage of inducing significant local deformations that complicate the assembly of parts. Another The disadvantage is the appearance of residual stresses that impact the durability of the welded structure. In order to predict these deformations and constraints during the design phase, for example in order to minimize them in playing on parameters such as the speed of execution and the intensity of the welding current, digital tools Predictors have been developed as part of this work.A model finite elements 3D of coupling between the thermal one and the mechanics, in the transient and nonlinear domains,was programmed in Ansys Parametric Design Language (APDL) using the software multi-physics ANSYS. The mobile source of heat by welding has been represented by a Gaussian profile whose parameters have been calibrated to optimize the geometric shape of the cord. To do this, the surface of Response of a factorial experiment plan was used. The numerical results obtained are quite satisfactory since the parameters of the Gaussian heat source identified using the factorial experiment planallow a faithful reproduction of the geometry of the cord. The comparison between the experimental values ​​and Calculated deviation also shows good consistency with a relative difference of less than 5%. In order to study the voltage and the electrical conductivity during the priming and the maintenance of the welding arc, a Two-dimensional axisymmetric model of the electric arc was realized using FLUENT software. Geometry actual torch components such as the gas diffuser, the nozzle and the electrode were taken into account. The model integrates a fluid-structure coupling in which the electromagnetic and thermal equations are resolved in the solid cathode. The additional equations governing the flow are considered in the gaseous domain where the arc is generated. For the maintenance of the arc, these equations, which have been programmed in C ++, make it possible to overcome the artificial conductivity often used in the literature. The model allows to obtain the plasma temperature fields, the voltage drops at the anode and at the cathode of the welding, the voltage in the arc as well as the efficiency of the energy input. Numerical results indicate that plasma temperature and flow velocity increase with the intensity of the current and with the inter-electrode distance. The same goes for the electric potential but with a stronger influence of the inter-electrode distance. Finally, the gas flow plays no role on the temperature and on the electric potential. It influences the speed of flow of the plasma. The higher the flow, the higher the Plasma flow rate is low.