Darbe tiriami mažaanglio plieno S235J2 (LST EN 10025:2004) suvirintų siūlių pasikeitimai, plieną apvirinant skirtingais glaistytaisiais elektrodais ir suvirinimo režimais. Tyrimų metu buvo naudojami AV-23 ir AV-66 glaistytieji elektrodai bei keičiamas trumpojo jungimo srovės stipris. Nustatytas ryšys tarp metalo įvirinimo gylio, rumbelės aukščio, išlydytų lašų dydžio, išlydytų lašų kiekio, trumpojo jungimo trukmės ir trumpojo jungimo srovės dydžio. Gauti tyrimų rezultatai, nubraižyti priklausomybių grafikai ir pateiktos išvados. Darbą sudaro: įvadas, literatūros apžvalga, eksperimentuose naudojama įranga ir medžiagos, tyrimo metodika, tyrimų metu gauti rezultatai, grafikai, išvados, literatūra. Darbo apimtis: 83 p. teksto, 73 iliustr., 18 lent., 23 bibliografiniai šaltiniai. / In final work was analyzed the changes of seams properties of steel S235J2 (LST EN 10025:2004), produced by welding with different technology are discussed. Samples were welded by hand arc welding, using AV-23 and AV-66 welding electrodes. The welded seams were made by changing short-circuit current. The duration of weld depth, ridge height, metal drop size, metal drop frequency, short-circuit time and short-circuit current value are determinated. The results of the research are given in graphs, final conclusions are also written. Structure: the introduction, survey of the related literature, equipment and materials, description of the methodology, results of research, graphs of the results, conclutions, references. Thesis consist of: 83 p. text, 73 pictures, 18 tables, 23 bibliographical entries.

Tendo em vista a tendência mundial de se buscar a diminuição de peso de estruturas metálicas de veículos, o desenvolvimento de aços de resistência mecânica superior apresenta-se como um importante fator para a competitividade e sustentabilidade da indústria brasileira, além da segurança do usuário. No setor automobilístico, as reduções no peso e no consumo de combustível requerem não somente a pesquisa de novos aços, mas também a utilização de componentes híbridos, resultantes, entre outros, da união entre os aços austeníticos inovadores de alta liga e baixo custo (TRIP) e aços ferríticos comerciais (ARBL). Na presente dissertação foram investigadas as propriedades mecânicas microestruturais, antes e após o processo de soldagem TIG, dos aços TRIP e ARBL utilizados pela indústria automotiva. O principal objetivo do trabalho foi avaliar possíveis estruturas e modificações nas propriedades das juntas soldadas de acordo com parâmetros de soldagem pré-determinados. Primeiramente, verificaram-se as extensões da zona termicamente afetada dos corpos de prova soldados. Os perfis de microdureza indicaram que não houve uma alteração significativa de dureza na zona termicamente afetada do aço de efeito TRIP, enquanto que para o aço ARBL observa-se um considerável aumento. Os limites de escoamento determinados pelos ensaios de tração realizados permitiram a obtenção dos níveis de resistência mecânica das juntas soldadas. Através dos ensaios de microscopia eletrônica de varredura e microscopia ótica foi possível observar a influência do aporte térmico na zona termicamente afetada do aço ARBL. A análise de EDX nas juntas dissimilares permitiu observar a presença de zonas parcialmente diluídas na zona fundida do lado do metal de base ARBL, a caracterização da composição química nas interfaces entre os metais de base e o metal de solda e prever a microestrutura destas regiões. As fases presentes nos metais de base e na zona fundida foram caracterizadas também pela difração de raios x. Por meio da estereologia quantitativa caracterizou-se as fases presentes na zona fundida e determinou-se suas proporções em função do aporte térmico. / In view of the global trend of searching for the weight reduction of metal frames in vehicles, the development of superior mechanical resistance steels presents itself as an important factor for the competitiveness and sustainability of the Brazilian industry, as well as to user safety. In the automotive industry, the reductions in vehicle weight and fuel consumption not only require research of new types of steel but also the use of hybrid components, which result, amongst other things, between the union of austenitic innovative high alloy and low cost (TRIP) with commercial ferritic steels (HSLA). This dissertation analyses the microstructural mechanical properties before and after the TIG welding process, the TRIP steel, and HSLA used by the automotive industry. The main objective of this study was to evaluate possible phase changes in steel structures and transformation in the properties of the welded joints according to pre-determined welding parameters by analyzing extensions of the heat-affected and melted zones of welded specimens. The micro hardness profiles showed no significant changes in hardness in the heat affected HSLA steel, while the TRIP steel showed considerable increase. Additionally, the yield point determined by the traction tests performed, allowed the obtainment of the mechanical resistance levels of the welded joints. Through the tests of scanning electron and optical microscopy was observed the influence of heat input on heat affected zone of HSLA steel. EDX analysis allowed us to observe the presence of molten zones partially diluted in the side of the base metal HSLA, characterization of the chemical composition at the interface of the base metal and weld metal and predicting the microstructure in these regions. The phases present in the base metal and weld zone were characterized too by x-ray diffraction. By quantitative stereology characterized by the phases present in the weld zone and their proportions were determined as a function of heat input.

Friction Stir Welding (FSW) is a rapidly growing solid state welding process and has been a proven method for welding high strength aluminium alloys which were formerly not recommended for joining by conventional fusion welding methods. Based on the information acquired from previous studies, to obtain a defect free Friction Stir (FS) weld with suitable strength, three basic requirements need to be fulfilled (i) Filling of the cavity created behind the tool pin during its traverse and ensuring satisfactory contact of filled material with newly generated surface (on advancing side trailing edge of the pin) (ii) Disrupting and distributing the oxide layer at the initial weld interface (iii) Adequate level of mixing of both side material (Adjacent and Retreating side) in similar welding. In the case of dissimilar welding mixing is desired in controlled amount (to prevent or curtail formation of intermetallics) depending on material combination. Failure to achieve the first precondition results in void. Second and third precondition are interconnected for similar FSW as adequate mixing in weld helps in disruption and distribution of oxide layer at initial weld interface. Failure to achieve this, results in Joint Line Remnant (JLR). Metal to metal contact cannot be established due to the presence of JLR (aligned oxide particles) and subsequently initial interface is left unwelded which deteriorate the static and dynamic strength of friction stir welds. The problem aggravates while friction stir welding materials with tenacious contaminant layer. Therefore, appropriate stirring (which entails large deformation and mixing) of initial weld interface is essential for successful FS welds. Hence, process aspects assisting mixing of adjacent (Advancing and Retreating side) materials need to identified and studied, which are missing in former studies. Experiments are conducted with classical FS tool (possessing frustum shaped/tapered circular pin) to analyse the effect of welding parameters (tool rotation speed, traverse speed, plunge depth, tool tilt and tool position w.r.t initial interface) and tool runout by changing these parameters over a range. Tool rotation speed, traverse speed, plunge depth and tool position with initial interface are changed continuously and tool tilt and tool runout are changed in discrete steps. Tool geometry is considered to be a prime parameter controlling the magnitude of mixing, as interaction of rotating tool with initial abutting base metal interface makes the process mechanism complex, unlike other solid state welding process, namely forge welding, diffusion welding, friction welding, explosive welding, ultrasonic welding and roll bonding. Furthermore, due to asymmetric nature of material flow in FSW process, the material located in different locations with respect to the tool is subjected to different levels of deformation. For this purpose experiments have been carried out to analyse the effect of different tool geometrical aspects on level of mixing and material flow. On the other hand, visualizing flow and mixing in metals is debatable as insertion of marker material in the weld line can alter the nature of material flow in the weld due to different material flow characteristics of the base and marker materials and introduction of additional interfaces. Further, using dissimilar materials for flow studies cannot be considered for comparison with similar friction stir welds as their flow properties are different. Therefore, an alternate experimental strategy is devised in these studies using physical modelling approach which is effective and helps in identifying and quantifying mixing observed under different tooling and process conditions. In the present investigation, plasticine of primary colours is adopted and the hue attribute of colour is used to study and quantify intermixing. Yellow and Blue plasticine are placed on advancing and retreating sides respectively. The degree of mixing is indicated by the intensity of generated green. Digital images of the cross section in weld nugget region are taken. To obtain hue component of these digital images the RGB color-maps are converted to HSV color-maps. Overall, these studies help in formulating the guidelines which are useful during tool design, and administering the process to obtain a defect free well mixed welds. Based on the experimental results following conclusions are derived. 1. Following process aspects: tool geometry, interface offset, tool rotation and tool runout demonstrate a significant impact on material mixing and breaking and dispersion of initial interface in weld nugget. Tool tilt, plunge depth, tool traverse exhibit negligible effect on degree of mixing. 2. Increase in tool rotation speed (with other parameters fixed) improves mixing substantially but can be increased to a certain limit after which voids emerge due to loss of weld nugget material in the form of flash. 3. Reducing the weld pitch (i.e. increasing tool rotation speed for a given tool traverse speed) reduces the size of the weld nugget and vice versa. Tool traverse speed largely affects advancing side material and rotation speed affects retreating side material. Therefore, for higher weld pitch advancing side material (yellow plasticine) dominates the weld nugget, whereas for lower weld pitch retreating side material (blue plasticine) dominates the weld nugget. 4. The extended macro-structural feature commonly observed in FS welds occurs under influence of plunge depth. Consequently, this macro-structural feature serves as the demarcation point between shoulder affected and pin induced material flow in FS weld. 5. The degree of mixing and subsequent elimination of JLR, improves, when original interface is offset on the advancing side w.r.t tool axis for all the tools investigated in the present study. Triangular and square pin generate larger pin induced mixing which intensifies further with interface on advancing side, indicating tools with such profiles to possess larger safe zone with better mixing characteristics 6. At zero interface offset with all the process parameters fixed, tapered triangular and square pin profile tools produce welds with maximum mixing. For pins with faces, material is transported in lumps around the pin. The size of lump increases with lesser number of faces on pin. Material in the vicinity of the pin experiences spinning/whirling movement. The volume of material experiencing spinning in a single tool revolution depends on (a) weld-pitch (lesser volume of material for smaller weld pitch and vice versa) and (b) number of faces on the pin (lesser volume of material for greater number of faces and vice versa). Therefore, circular pin which can be considered to be made of infinite faces, spinning of material occurs at micro level for relatively smaller weld pitch. 7. For classical FS tool (tapered circular/frustum shape), there exists an optimum ratio (shoulder diameter/pin diameter) situated between 2.7 to 3.6 to produce void free well mixed welds. Tools with ratio of 2.7 and below possess a tendency to produce welds with void but with better mixing in weld region. Tools with ratio of 3.6 and above possess a tendency to produce void free welds but with poor mixing in weld region. Voids appear and grow under following circumstances (a) with increase in pin diameter (for a fixed shoulder diameter), (b) with decrease in shoulder diameter (for a fixed pin diameter), (c) with decrease in pin taper (for a fixed shoulder diameter and top diameter of pin). Pin length has no effect on void formation. However, it is obvious, length of root defect increases with decrease in pin length. The tooling guidelines established in this study through plasticine work can be extended to metallic friction stir welds of various thickness plates by proportionately increasing or decreasing the tool dimensions as long as they fall in the recommended range. 8. Smaller pin diameter tools exhibit higher optimum weld pitch (but with lower degree of mixing) when compared to larger pins (but with higher degree of mixing). Optimum weld pitch represents weld pitch resulting in void free welds. Consequently, tools with higher optimum weld pitch help in welding at a better rate. 9. Tool runout is replicated through tools with eccentric pins. It is interesting to note that, all the tools with pin eccentricities do not assist in mixing but tools with only certain eccentricities (0.3 and 0.6mm assisted in mixing in the present investigation). It implies that tool runout of certain values facilitate mixing in weld. On the other hand density of void increases with eccentricity of pin/tool runout. 10. In dissimilar FSW investigated with plasticine A, B, C and D possessing different flow stresses (flow stresses ascending in the order of A, B, C and D) and strain rate sensitivity of 0.24, 0.22, 0.19 and 0.18 respectively, following inferences are drawn (i) For combination A and B, weldability improves when plasticine B is on Advancing Side (AS) and A is on Retreating Side (RS). The level of mixing also improves when interface is on AS (w.r.t tool axis) for this handedness. On the contrary, severe discontinuities emerge when plasticine B is on RS and A is on AS, especially when interface is closer to the tool pin axis. (ii) For combination A and C, weldability improves when C is on AS and A is on RS. The level of mixing also enhances when interface is on AS (w.r.t tool axis) for this handedness. (iii) For combination A and D, joining is poor for both the handedness. However, nature of defect is different in both the combinations. Cracks are observed when A is located on AS and voids emerge when D is located on AS. On the other hand, placing A on AS results in weld thinning. (iv) For combination B and C, there is no appreciable change in terms of weldability and level of mixing. Both the handedness in this combination yielded fairly similar results. (v) For combination B and D, though discontinuities do not emerge with change in handedness, mixing in weld improves when B is on AS unlike to its location on RS. (vi) For combination C and D, there is no appreciable change in terms of defect formation and level of mixing with change in handedness. Both the handedness in this combination yield fairly similar results.

The application of hardfacing brings the reduction of the wear and therefore increases service life of components and reducing the maintenance shutdowns. This work aims to study the wear resistance of hardface applied by welding, by using the process FCAW (Flux- Cored Arc Welding) Self-Shield Double Wire. Three types of consumables were used (FeCrC, FeCrC+Ti and FeCrC + Nb) with diameter 1.6 mm in twelve coating conditions. The coating was applied by welding on a steel SAE 1020 with and without E308lSi buttering, with metal transfer mode in short circuit. It was compared the deposits made with each condition. It was constructed specimens for the evaluation of wear in the laboratory with Rubber Wheel according to ASTM G65-00. The wear evaluation was made via mass loss. It was also carried analysis hardness and microhardness of the coating microstructure. The best wear resistance results were obtained with the use of two wires electrode with the same composition (FeCrC + Ti). The presence of Ti in the coating has fewer cracks and improves wear resistance in this study. The conditions with buttering have not shown good results with respect to wear resistance of coatings. / A aplicação de revestimentos com o objetivo de reduzir o desgaste e, consequentemente os custos de manutenção, busca o incremento da vida em serviço dos componentes e na redução das paradas programadas. Uma correta seleção do material depositado permite, dentre outras coisas, transformarem elementos descartáveis por desgaste em bens de capital recuperável, aumentar a resistência e prover as superfícies susceptíveis ao desgaste de características e propriedades desejadas e, em geral, aumentar a eficiência do processo. Assim, o objetivo deste trabalho é avaliar a resistência ao desgaste abrasivo de revestimentos duros depositados em camada única através do processo de soldagem FCAW (Flux - Cored Arc Welding) Duplo Arame, com arame tubular auto protegido. Foram utilizados três tipos de consumíveis (FeCrC, FeCrC+Ti e FeCrC+Nb) de diâmetro 1,6 mm em doze condições de revestimento diferentes. O revestimento por soldagem foi aplicado sobre uma chapa de aço carbono SAE 1020 com e sem amanteigamento de liga E308LSi, utilizando-se o modo de transferência metálica por curto-circuito. Construiu-se corpos de prova para a avaliação do desgaste em laboratório com abrasômetro Roda de Borracha de acordo com a norma ASTM G65-00. A avaliação de desgaste foi feita via perda de massa. Foram realizadas também análise de dureza, microdureza e microestrutura dos revestimentos. Os melhores resultados de resistência ao desgaste foram obtidos com a utilização dos dois arames eletrodo de mesma composição (FeCrC+Ti - FeCrC+Ti). A presença do Ti no revestimento apresenta menor quantidade de trincas e melhora a resistência ao desgaste com o ensaio utilizado nesta pesquisa. As condições com amanteigamento não demonstraram bons resultados com relação a resistência ao desgaste dos revestimentos. / Mestre em Engenharia Mecânica

Compte tenu de l'importance de maintenir une qualité optimale des cordons de soudure et l'impossibilité d'assurer tout risque de manque de pénétration et de fusion par des contrôles non-destructifs, cette thèse permettra de développer une expertise et des outils numériques pour la simulation numérique tridimensionnelle des procédés de soudage par fusion afin de prédire la géométrie finale du cordon. Pour ce faire, on implémente une méthode de suivi d'interface afin d'améliorer la prise en compte des phénomènes thermophysiques au niveau des surfaces libres déformables. Cela permettra en outre de prendre en compte les forces agissant à la surface du bain métallique telles que la tension de surface, la gravité et la pression d'arc. Puis, il est envisagé d'améliorer l'estimation du transfert thermique entre l'arc et les pièces à assembler via un couplage instationnaire des modèles de plasma et de bain de fusion pour ainsi simuler de façon optimale la forme finale du cordon de soudure. Cette thèse permettra de traiter certaines applications industrielles spécifiques à EDF, en particulier les soudures d'étanchéité de faible épaisseur, permettant des études approfondies sur les opérations de réparations par soudage en corniche. / In order to ensure total safety during maintenance operations within nuclear power plants, it is mandatory to preserve the optimal quality of the internal weld beads. To this end, we use Computational Magnetohydrodynamics to simulate adjacent phenomena within the plasma and the weld pool in order to improve the knowledge of welding operating process. One of the difficulties is to take into account the effects induced by the thermal gradient and the variations of surfactant element concentrations on the weld pool surface known as the Marangoni effect. In order to take into account all the physical phenomena at the plasma / weld pool interface, we use an interface tracking method (Arbitrary Lagrangian-Eulerian) to improve the simulation of weld pool with free surfaces. Subsequently, it enables to capture more precisely the interfacial forces such as the Marangoni effect, the arc pressure and the gravity, and improve vertical welding simulation. Thus, this work is part of the development of a tridimensional unsteady two-way coupling in order to overcome the Gaussian boundary condition used to model the heat transfer from plasma torch towards the work piece surface. Ultimately, we could obtain an unified model for an optimal welding process simulation.

Τα κριτήρια σχεδιασμού στις σύγχρονες κατασκευές και κυρίως στην αεροναυπηγική και ναυπηγική βιομηχανία, στοχεύουν στην παραγωγή δομικών στοιχείων με μειωμένο βάρος και χαμηλότερο κόστος, ενώ ταυτόχρονα, απαιτείται να παρουσιάζουν υψηλότερες επιδόσεις και ικανοποιητική δομική ασφάλεια. Οι στόχοι αυτοί έχουν διαμορφώσει μια σχεδιαστική τάση η οποία οδηγεί στην αντικατάσταση των ‘παραδοσιακών’ διαφορικών δομών (differential structures) με ‘σύγχρονες’ ολοκληρωμένες δομές (integral structures). Η τάση αυτή βρίσκει εφαρμογή κατά κύριο λόγο στην αεροναυπηγική, όπου η μείωση του βάρους χωρίς υποβάθμιση της ασφαλούς λειτουργίας αποτελεί βασικό και μόνιμο στόχο. Η αυξημένη παραγωγή δομικών στοιχείων ολοκληρωμένων δομών έχει οδηγήσει σε συνεχή αύξηση της εφαρμογής διεργασιών συνένωσης με έμφαση στις προηγμένες διεργασίες συγκόλλησης. Οι διεργασίας συγκόλλησης οι οποίες, λόγω των πλεονεκτημάτων τους, βρίσκονται στην αιχμή της τεχνολογίας είναι η Συγκόλληση με Τριβή και Ανάμιξη (Friction Stir Welding – FSW) και η Συγκόλληση με Ακτίνα Λέιζερ (Laser Beam Welding – LBW). Η εφαρμογή συγκολλήσεων στην παραγωγή ολοκληρωμένων δομών έχει πολλά τεχνολογικά πλεονεκτήματα έναντι των άλλων τύπων σύνδεσης, ωστόσο, συνοδεύονται από την ανάπτυξη Παραμενουσών Τάσεων και στρεβλώσεων στο τελικό προϊόν, κάτι το οποίο, ανάλογα με την εφαρμογή, μπορεί να προκαλέσει σημαντικά προβλήματα. Συγκεκριμένα, οι στρεβλώσεις επηρεάζουν τη λειτουργικότητα του δομικού στοιχείου, αφού μεταβάλλουν την γεωμετρία του, ενώ οι παραμένουσες τάσεις, αναπροσαρμόζοντας το εσωτερικό εντατικό πεδίο, επιδρούν στη δομική τους ακεραιότητα. Όπως είναι γνωστό με κατάλληλη επιλογή των παραμέτρων της διεργασίας (π.χ. ταχύτητα συγκόλλησης, ισχύς κτλ) μπορεί να επιτευχθεί μείωση των αναπτυσσόμενων παραμενουσών τάσεων και στρεβλώσεων. Επίσης, τα τελευταία χρόνια έχει αποδειχθεί ότι η προσομοίωση μιας διεργασίας συγκόλλησης μπορεί να βοηθήσει σημαντικά στην επιλογή του βέλτιστου συνδυασμού των παραμέτρων της. Για το λόγο αυτό, μεγάλο μέρος της ερευνητικής δραστηριότητας στην περιοχή των προηγμένων διεργασιών συγκόλλησης έχει στραφεί προς την ανάπτυξη αξιόπιστων μεθοδολογιών προσομοίωσης, οι οποίες με δεδομένο (input data) τις παραμέτρους της διεργασίας μπορούν να δώσουν σαν αποτέλεσμα (output data) κρίσιμες απαντήσεις όσον αφορά στις τεχνολογικές ιδιότητες της συγκόλλησης. Βάσει των ανωτέρω, σκοπός της παρούσης διατριβής είναι η ανάπτυξη ολοκληρωμένων μεθόδων θερμομηχανικής προσομοίωσης των προηγμένων διεργασιών συγκόλλησης FSW και LBW με κύριο στόχο την πρόβλεψη των παραμενουσών τάσεων και των στρεβλώσεων καθώς και τη μελέτη της επίδρασης τους στη δομική ακεραιότητα των παραγόμενων δομικών στοιχείων. Ένα από τα σημαντικότερα και ίσως το κρισιμότερο στάδιο κατά την προσομοίωση μιας θερμομηχανικής διεργασίας είναι η εξομοίωση της θερμικής πηγής και ο υπολογισμός του θερμικού φορτίου, γιατί μια εσφαλμένη εκτίμηση του θερμικού φορτίου προκαλεί λανθασμένη πρόβλεψη της θερμοκρασιακής κατανομής και κατά συνέπεια εισάγει σφάλματα στον υπολογισμό των παραμενουσών τάσεων και των στρεβλώσεων. Στη βάση αυτή, τόσο για την περίπτωση της FSW όσο και για την LBW αναπτύχθηκαν μεθοδολογίες για τον προσδιορισμό των θερμικών πηγών τους και συνοδεύτηκαν από θερμικά μοντέλα για την πρόβλεψη του θερμοκρασιακού ιστορικού. Ακολούθως, το θερμοκρασιακό ιστορικό ασκείται υπό τη μορφή εξωτερικού φορτίου σε ένα θερμομηχανικό μοντέλο από όπου υπολογίζονται οι παραμένουσες τάσεις και οι στρεβλώσεις της διεργασίας. Τέλος, η εσωτερική εντατική κατάσταση του συγκολλημένου δομικού στοιχείου συνυπολογίζεται στο εντατικό πεδίο λόγω της φόρτισης λειτουργίας της κατασκευής και γίνεται πρόβλεψη των συντελεστών έντασης τάσης (Stress Intensity Factors - SIFs ) έτσι ώστε να εκτιμηθεί η επίδρασης της συγκόλλησης στη δομική ακεραιότητα. Τόσο το θερμομηχανικό όσο και το θραυστομηχανικό μοντέλο μπορούν να προσαρμοσθούν σε πολλούς διαφορετικούς τύπους σύνδεσης και ρηγμάτωσης, αντίστοιχα. / The design criteria in modern structures aim to the production of components with reduced weight and low cost, as well as, with higher performance and increased safety. The above goals lead to a tendency of replacing traditional differential structures with more modern integral structure, mainly in aeronautic sector where the weight and cost reduction, without decrease of safety, comprises the main target of the current research effort. The production of integral structures requires the adaptation of existing forming processes as well as the development and optimization of advanced welding processes. The most promising welding processes in aeronautics and maritime industries currently are the Friction Stir Welding–FSW and Laser Beam Welding-LBW. Despite of the many technological advantages of FSW and LBW process, their application in the production of integral structures leads to the development of Residual Stress (RS) and distortion fields which can cause significant problems. Specifically, distortions can effect on the components assembly, while, RS affect the structural integrity. However, an appropriate selection of process parameters can significantly reduce the RS and distortions levels. The usual way to optimize process parameters is experimental trial and error approach; recently, process simulation has been proven efficient, too. The present work aims to the development of efficient methodologies for the thermomechanical simulation of FSW and LBW processes in order to predict temperature history, as wells as RS and distortion fields. Consequently, the RS field is used for the determination of the welding effects on the structural integrity of the welded component. Generally, the reliability of a simulation methodology of any thermo-mechanical process, such as welding, is seriously affected by many parameters; two of them are very base, namely, the accurate determination of the heat input introduced to the material (thermal load) and the accurate representation of thermal and mechanical boundary conditions. As the boundary conditions determined by the welder and it is usually easy to transfer in a numerical model, one of the most difficult simulation issues is the appropriate determination of the heat input which will lead to an accurate prediction of the material temperature history. For this reason, one of the main objectives of the present work is to develop methodologies for the accurate thermal load calculation in both FSW and LBW processes. After the validation of the developed methodologies with respect to experimental measurements, the defined heat sources are used in global thermal models in order to predict the temperature histories which, thereinafter, are introduced in the thermo-mechanical models to predict the developed RS and distortion fields. Finally, the structural integrity of the welded component, under the effect of both RS field and service loading is studied; different possible ‘fracture scenarios’ are investigated based on the Stress Intensity Factor concept and the Elastic Fracture Mechanics principles.

Made available in DSpace on 2016-03-15T19:36:56Z (GMT). No. of bitstreams: 1 Nicolangelo Del Busso.pdf: 1564969 bytes, checksum: 09a254462846bd38848d90350375c6c6 (MD5) Previous issue date: 2016-02-01 / The present work investigates the possible changes that occur in the mechanical properties and microstructure of welded joints through the process of submerged arc in steel plates High Strength Low Alloy (HSLA) type API 5L X70, used in pipelines. These are usually constructed starting from calendered plates and welded through submerged arc process, forming 600 mm diameter pipes, with 12 m long. To reproduce faithfully the pipes manufacturing processes, for further characterization of test bodies were produced, welding plate supplied by USIMINAS, through the submerged arc welding, and withdrawing samples to perform the characterization of the regions of the weld metal (WM), the heat affected zone (HAZ) and the base metal (BM). Conventional tensile and Charpy V-Notch were performed to determine mechanical and impact properties of the tested materials, as well as macrograph tests and Optical microscopy (OM) and weld metal (WM), the heat affected zone (HAZ) and the base metal (BM). The metallographic examination showed banded microstructure consisting of polygonal ferrite, pearlite and bainite with small grain size. The results showed increased strength and hardness influenced by the presence of acicular ferrite. The fractography analysis after impact tests revealed ductile-brittle behavior. Impact tests were performed at temperatures of 0°C and -20°C, which exhibited significant toughness decrease, that is 260J to 202J for the BM, 106J to 81J for HAZ and 25J to 19J to the WM, while the Vickers hardness testing (HV10) was increased from the fusion zone to the base metal (194HV for WM, 202 HV for HAZ and 218 HV for BM). / O presente trabalho investiga as alterações que ocorrem nas propriedades mecânicas e na microestrutura em juntas soldadas por Arco Submerso, em chapas de aço ARBL (Alta Resistência e Baixa Liga) tipo API 5L X70, utilizadas em tubos de minerodutos. Estes são geralmente construídos a partir de chapas calandradas e soldadas de topo, pelo processo de Arco Submerso, formando tubos com diâmetro de cerca de 600mm, por 12 metros de comprimento. Objetivando reproduzir fidedignamente o processo de fabricação dos tubos, foram produzidos corpos de provas, soldando-se, pelo processo arco submerso, chapas fornecidas pela USIMINAS, e, destas foram retiradas amostras para se efetuar a caracterização das soldas, nas regiões da zona fundida (ZF), da zona termicamente afetada (ZTA), e do material base (MB). Foram efetuados os ensaios mecânicos de tração, dureza, dobramento e impacto, bem como a caracterização por macrografia e microscopias, ótica (MO) e de varredura (MEV). O exame metalográfico apresentou microestrutura bandeada, consistindo de ferrita poligonal, perlita e bainita com pequeno tamanho de grão. Os resultados obtidos mostraram o aumento da resistência mecânica e da dureza, influenciados pela presença de ferrita acicular. As análises fratográficas, após ensaios de impacto revelaram comportamento ductil-frágil. Os ensaios de impacto foram realizados às temperaturas de 0ºC e de -20ºC, onde apresentaram quedas significativas da tenacidade na região da solda, decrescendo da região do metal base (260J e 202J) para a zona termicamente afetada (106J e 81J) e para a zona fundida (25J e 19J), respectivamente, para 0ºC e -20ºC. Os resultados dos ensaios de dureza Vickers (HV10) apresentaram um ligeiro aumento da dureza, crescendo no sentido MB-ZTA-ZF (194 HV, 202 HV e 218 HV, respectivamente).

Bakgrund: Under de senaste decennierna har industriell logistik fått en allt viktigare roll för att ge företag konkurrensfördelar på den globala marknaden. För att uppnå ökad effektivitet i logistikfunktionen kan konfigurationen av ett internt materialförsörjningssystem ha en betydande inverkan på minimering av icke värdeadderande aktiviteter. Det finns flera principer för intern materialförsörjning, hur dessa appliceras har en signifikant påverkan i en industriell miljö. Valet mellan olika system kännetecknas av en överhängande komplexitet där tillverkningsindustrier byter fram och tillbaka flera gånger. Syfte: Syftet med studien är att föreslå ett ramverk för utveckling av interna materialförsörjningssystem gällande svetsprocess inom metallbearbetning. Genomförande: Studien är genomförd som en enfallsstudie på Hörle Automatic. Där studiens tillvägagångsätt har varit att identifiera icke värdeadderade aktiviteter i fallföretagets interna materialförsörjningssystem till svetsprocessen. För att därefter utveckla deras nuvarande system för att minimera identifierade aktiviteter. Utifrån detta har ett ramverk konstruerats som belyser faktor som ska tas i beaktning vid utveckling av ett internt materialförsörjningssystem. Empiriskt material har samlats in genom intervjuer, observationer, fokusgrupper och arkivmaterial. För att möjliggöra identifiering av icke värdeadderande aktiviteter har en processkartläggning upprättats. Fortsättningsvis har det genomförts tester gällande förslag på arbetssätt som utvecklats. Resultat/Diskussion: Ett ramverk har konstruerats som belyser elva olika faktorer som ska tas i beaktning vid utveckling av ett internt materialförsörjningsystem. Det är faktorer relaterade till produktionsvariation, detaljspecifikation, layout, leverantörer och kommunikation. Slutsats: Det har identifierats totalt 18 icke värdeadderande aktiviteter gällande Hörle Automatics interna materialförsörjningssystem till svetsprocessen. Utvecklingen av det interna materialförsörjningssystemet enligt förslag eliminerar en del icke värdeadderande aktiviteterna som identifierats. Resterande aktiviteter minskas genom utvecklingen av en materialförsörjningsprocess som möjliggör en ny layout och att mer kostnadseffektiv personal utför de icke värdeadderande aktiviteterna / Background: Over the past decades, industrial logistics has gained an increasingly important role in giving companies a competitive edge in the global market. To achieve increased efficiency in the logistics function, the configuration of an internal materials supply system may have a significant impact on minimizing non-value added activities. There are several principles for internal materials supply system, how these are applied have a great impact on it’s industrial environment. The choice between different systems is characterized by an complexity where manufacturing industries change back and forth several times. Purpose: The purpose of this study is to propose a framework for the development of internal materials supply systems in the welding process within metalworking. Methodology: This is a case study at Hörle Automatic. The study approach has been to identify non-value adding activities in the case company's internal materials supply system to the welding process. And after that develop their current system to minimize identified activities. Based on this, a framework has been designed to highlight the factors to be taken into account when developing an internal materials supply system. Empirical material has been collected through interviews, observations, focus groups and archival material. To enable identification of nonvalue-adding activities, a process mapping has been established. Furthermore, tests have been carried out regarding internal materials supply processes to strengthen the author's proposal. Result/Discussion: The result of the study is a framework including eleven factors that companies should take into account when developing an internal materials supply system. The framework involves factors regarding, production variation, item specification, layout, suppliers, and communication. Conclusion: A total of 18 non-value adding activities was identified regarding Hörle Automatic's internal materials supply system in their welding process. The development of the internal materials supply system as proposed eliminates some of the identified nonvalue-adding activities performed by welding operators. The remaining activities are reduced through a new layout and that usage of more cost-effective personnel.

Le travail présenté dans cette thèse concerne la modélisation et la commande robuste en force de robots manipulateurs industriels à articulations flexibles utilisés pour le procédé FSW. Afin de réduire les temps de calcul et l'occupation de la mémoire, une approche basée sur la méthode par intervalle est proposée en vue de la simplification des modèles dynamiques des robots industriels, et contribue à identifier les paramètres d'inertie qui sont négligeables. Des études de cas sur trois types de trajectoires de test et l’analyse des couples moteurs ont démontré l'efficacité et les bonnes performances de la méthode de simplification. Ensuite, la modélisation dynamique et l'identification des paramètres du procédé FSW ont été effectuées. Les paramètres des modèles linéaires et non-linéaires de forces axiales sont identifiés. Sur la base de la modélisation du procédé FSW qui considère simultanément la cinématique du système complet, le modèle de déplacement du robot rigide, les flexibilités des articulations et le modèle dynamique de la force axiale, un contrôleur robuste en force est obtenu par la méthode de réglage fréquentielle. En outre, un simulateur du procédé FSW robotique est développé et les résultats de simulation montrent les bonnes performances du contrôleur en force. L'oscillation de la force axiale dans le procédé FSW peut être simulée en utilisant un modèle de perturbation de la position verticale de référence. / The work presented in this thesis focuses on the modeling and robust force control of flexible joints industrial robot manipulators used for FSW process. In order to reduce computation time and memory occupation, a novel interval-based approach for dynamic model simplification of industrial robots is proposed, which applies to arbitrary trajectories of whole robot workspace and contributes to obtaining negligible inertia parameters. Cases studies have been carried out on three kinds of test trajectories and torques analysis of robot dynamic equation, demonstrating the effectiveness and good performance of the simplification method. Then, the dynamic modeling and identification of robotic FSW process is performed, and the parameters of linear and nonlinear dynamic axial force process models are identified by using the plunge depth and its derivative. On the basis of the modeling of robotic FSW process which simultaneously considers the complete kinematics, the rigid robot displacement model, the joint flexibility and the dynamic axial force process model, a robust force controller can be obtained by using the frequency response approach. Besides, a simulator of robotic FSW process is developed and simulation results show good performance of the force controller. The oscillation of axial force in FSW process can be simulated when a disturbance model of initial vertical reference position is proposed and used in the simulation.

Electromagnetic welding is an innovative, high-speed technology to manufacture mixed material joints. In this dissertation, an experimental-numerical method is presented to identify robust process windows of aluminum-copper and aluminum-steel compounds. The microstructural characteristics of these joints were investigated in detail. Moreover, an evaluation of the joint quality is presented and different numerical models were introduced for the simulation of macroscopic and microscopic effects. To improve the accuracy of the simulations, the strain rate sensitivity of the materials must be considered. For this purpose a high-speed setup for the identification of relevant viscoplastic material parameters, comprising an inverse evaluation strategy, was developed.