On the thermo-mechanical loads and the resultant residual stresses in friction stir processing operations

In friction stir welding and processing both a thermal flux and a mechanical action are exerted on the material determining metallurgical evolutions, changes in the mechanical behaviour and a complex residual stress state. In the paper, the metallurgical changes are examined through numerical simulation and experiments to highlight and distinguish the effects of thermal and mechanical loadings. A particular focus is made on the residual stresses generated during the stir processing of AA7075-T6 aluminium blanks. The predictions of FE model are validated by experimental measurements. Lastly, this paper presents an in-process quenching of the processed blanks for improved mechanical properties and microstructure.