Work

Thermo-mechanical response of aluminum alloy in the additive friction-stir deposition process

Year: 2024

Type: article

Abstract: Additive Friction Stir Deposition (AFSD) is an emerging solid-state additive manufacturing (AM) technique that creates fully dense metallic structures with equiaxed fine microstructures. The feedstock material is plasticized via frictional heating and deposited in the solid state. Due to the complex multi-physics nature of the process, an in-depth understanding of the interplay between material flow, temperature variations, and stress distribution within the deposited layers under various process parameters is crucial for achieving desired outcomes. This study focuses on the development of a distinctive computational model that employs a coupled Eulerian-Lagrangian (CEL) finite element methodology to analyze the thermo-mechanical response of the AA6061-T6 alloy in the AFSD process. By incorporating essential AFSD process variables namely, tool rotation speed, tool traverse speed, and material deposition rate, the model can accurately forecast the flow of material, temperature fluctuations, and stress distribution across different operational settings. The CEL model is validated by comparing its results (e.g., peak temperature) with the experimental data and published computational results for the same combination of process parameters, giving the maximum errors of 8 % and 2.8 %, respectively. Through the utilization of this proposed model, a practical and efficient means of predicting process results is established, enabling the identification of optimal conditions for material depositions within the AFSD process in a rapid and cost-effective manner. Ultimately, this advancement contributes to the progression of solid-state AM techniques by streamlining the process with multifunctionality and a variety of material selections.

Source: Additive Manufacturing Letters

DOI: 10.1016/j.addlet.2024.100263

Authors: Chowdhury Sadid Alam, Vahid Karami, Shengmin Guo, M Shafiqur Rahman

Institutions: Louisiana Tech University, Amirkabir University of Technology, Louisiana State University

Language: English

Topic: Advanced Welding Techniques Analysis

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $1,250

Funders: National Science Foundation, Louisiana Board of Regents