Resumo O presente trabalho tem como objetivo obter uma ferramenta computacional para estimar os principais parâmetros do processo FSSW para a indústria de construção naval, utilizando uma abordagem em dois estágios, usando os Métodos de Volumes finitos e Elementos Finitos em domínios com simetria de revolução. Soldas experimentais foram realizadas em duas placas de liga de alumínio AA6082 com 3mm de espessura. Da comparação entre os resultados numéricos e experimentais, as temperaturas máximas de 423°C estiveram próximas às reportadas pela literatura. Porém, as medidas experimentais foram afetadas pela posição dos termopares embutidos no suporte de aço, medindo valores máximos inferiores, de 302°C. Os campos de velocidades circunferenciais e suas zonas de altos gradientes foram coincidentes com a zona de mistura revelada no ataque metalográfico. A técnica, não obstante, foi bem sucedida apesar das simplificações adotadas.

Abstract The main goal of the present work is to obtain a computational tool for the shipbuilding industry to estimate the main parameters of the FSSW process, by means of a two phase approach using the Finite Volume Method and the Finite Element Method on a two dimensional domain with symmetry of revolution. Experimental weldments were done on two 3mm thick overlapping plates of AA6082 Aluminum alloy. Upon comparison between numerical and experimental results, the contact conditions were well chosen and the maximum temperatures of 423°C were close to those reported in literature. Nevertheless, the experimental measurements were affected by the position of the thermocouples, into the backing steel plate, resulting in lower maxima of 302°C. Circumferential velocity fields and their high gradients zones were coincident with the mixing zone, revealed in the metallurgical attack. The technique was considered successful despite its simplifications.

ABSTRACT Friction stir spot welding (FSSW) is a novel process of metal joining. In the present work, the authors analysed the possibility of using this process to solve current problems in shipbuilding industry regarding small vessels by replacing the current arc welding techniques with the aforementioned process. Numerical simulation was carried out by the multiple purpose solver framework for Finite Element Method with a novel modelling approach. The problem was solved using a coupled mechanics system of equations in an axisymmetric continuum where material velocities were calculated in three dimensions, coupled with pressure and thermal fields. The heat source was calculated as a consequence of internal friction dissipation only. Two boundary conditions were analysed, adiabatic and with heat dissipation. Experimental welding tests were performed using a milling machine. Comparison between numerical modelling results and experimental FSSW testing results was done and analysed in detail.

O processo denominado "Friction Stir Welding" (FSW) é um método de soldagem desenvolvido pelo "The Welding Institute" (TWI) na Inglaterra em 1991. O equipamento de soldagem consiste de uma ferramenta que gira e avança ao longo da interface entre duas chapas fixas. A junção é produzida pelo calor gerado por fricção o qual causa o amolecimento de ambos os componentes atingindo uma condição visco-plástica e também pelo escoamento resultante entre as laminas a ser unidas. A modelagem numérica do processo pode fornecer uma predição real das principais variáveis do processo, reduzindo o número de testes experimentais, acelerando, portanto os processos de projeto ao mesmo tempo em que reduz custos e permite a otimização das variáveis tecnológicas envolvidas. Neste trabalho, o processo de soldagem por fricção é modelado empregando um programa de propósito geral baseado no método dos elementos finitos, procurando reproduzir a distribuição térmica e o correspondente escoamento de massa. Os resultados numéricos térmicos são comparados com distribuições termográficas experimentais e os resultados numéricos de escoamento de massa são comparados com aqueles obtidos a partir de técnicas experimentais de visualização, atingindo uma concordância aceitável.

The process of Friction Stir Welding (FSW) is a welding method developed by the "The Welding Institute" (TWI) of England in 1991. The welding equipment consists of a tool that rotates and progresses along the joint of two restrained sheets. The joint is produced by frictional heating which causes the softening of both components into a viscous-plastic condition and also by the resultant flow between the sheets to be joined. Numerical Modeling of the process can provide realistic prediction of the main variables of the process, reducing the number of experimental tests, thus accelerating the design processes while reducing costs and optimizing the involved technological variables. In this study the friction stir welding process is modeled using a general purpose finite element based program, reproducing the material thermal map and the corresponding mass flow. Numerical thermal results are compared against experimental thermographic maps and numerical material flow results are compared with material flow visualization techniques, with acceptable concordance.

The present work is aimed to simulate the Friction Stir Welding process as a three-dimensional thermally coupled viscoplastic flow. A Finite Element technique is employed, within the context of a general purpose FEM framework, to provide the temperature distributions and the patterns of plastic flow for the material involved in the welded joints. The computational tool presented here may be of great relevance for technologist seeking to set the process control variables, as they are intended to obtain suitable material properties that yield the adequate on service response of the structural components.

A mathematical pultrusion model of a thermosetting matrix composite is presented. The energy balance was solved by Finite Elements techniques using a program developed for this purpose. This model is applied to describe the temperature and resin conversion profiles along the die. This study was developed considering different pulling velocity, die temperature, different composite and different sections die. The model outcomes are verified through comparison with the experimental results reported in the literature.