A computational and experimental approach to understanding material flow behavior during additive friction stir deposition (AFSD)

Stubblefield, G. G.; Fraser, Kirk; Robinson, T. W.; Zhu, Na; Kinser, R. P.; Tew, J. Z.; Cordle, B. T.; Jordon, J.B.; Allison, P. G.

doi:10.1007/s40571-023-00578-x

Cited by 10 publications

(9 citation statements)

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“…Moreover, the pressure from the filler material assists in increasing the temperature up to 1100 °C. This phenomenon shows up as a thermal interplay between the continuous layers during the additive manufacturing process [ 41 , 42 , 43 ].…”

Section: Resultsmentioning

confidence: 99%

“…It is notable that during the sticking condition some parts of the materials adhere to the tool. Providing the layers are added to each other, a larger heat zone at the workpiece is observed because of the preheating at the initial steps [ 42 , 43 , 44 , 45 ]. As with the previous layer, a sliding condition is also present far from the center of the workpiece.…”

Section: Resultsmentioning

confidence: 99%

“…In contrast, using the Eulerian model decreases the computational costs, and shows a similar pattern for the simulation. As can be seen, in order to optimize the model, the mesh sizes at the center of the workpiece are larger than at the sides [ 42 , 43 , 44 , 45 ].…”

Section: Resultsmentioning

confidence: 99%

“…Since the material at the center of the workpiece faces a disparity, its cooling rate is faster than the other parts. The most important reason for this disparity is the higher material velocity at the center of the workpiece that results in lower heat generation and a higher cooling rate [ 43 , 44 , 45 , 46 , 47 ]. In the cooling phase, this thermal behavior appears across the workpiece, and this causes larger rings (see Figure 6 ).…”

Section: Resultsmentioning

confidence: 99%

“…It should be noted that, near the tool, the sticking friction behavior is obtained while far from the tool the sliding behavior appears for the model; therefore, the friction model should be able to optimize the sliding and sticking conditions at a same time. Moreover, the pressure from the filler material assists in increasing the temperature up to 1100 • C. This phenomenon shows up as a thermal interplay between the continuous layers during the additive manufacturing process [41][42][43]. Figure 4 indicates the temperature distribution at the workpiece in the third la the process.…”

Section: Temperature At the Layersmentioning

confidence: 99%

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A Framework to Simulate Friction Stir Additive Manufacturing (FSAM) Using the Finite Element Method

Meyghani,

Teimouri

2024

Micromachines

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Defining an accurate friction model without having the mesh distortion in an optimized computational time has always been a significant challenge for modelling solid-state natural processes. The presented paper proposes an Eulerian frictional-based solid static model for the accurate modeling of sliding and sticking conditions for the friction stir additive manufacturing process (FSAM). For the frictional behavior, a modified friction model is proposed to investigate the sliding and sticking conditions during the process. The magnesium alloy is selected as the workpiece material and AZ31B-F is employed as the filler material. Two different subroutines, Dflux and Sfilm, are used in order to simulate the heat flux during the process. The convection and emission during the process are determined using the Goldak double ellipsoidal model. DC3D8 and C3D8R elements are employed as the thermal and mechanical models, respectively. The results indicated that the temperature sharply increased up to 870 °C in the first and the second layers. After that, the increasing rate becomes slower with a maxim temperature of 1310 °C. A linear cooling behavior is obtained at the cooling step. The stress results indicated that the tool and the filler material pressure play a significant role in increasing the stress at the center of the workpiece. On the sides of the workpiece, a peak stress is also obtained due to the clamping force. At the cooling phase for the center of the workpiece, the longitudinal residual stress of 5 MP and transverse residual stress of 7 MPa (compression) are achieved. The distortion of the workpiece is also investigated and a maximum value of 0.13 mm is obtained. To wrap up, it should be noted that by implementing an accurate sliding/sticking condition in a frictional based model, a more comprehensive investigation about frictional interactions and their influence on thermal and mechanical behavior can be carried out.

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Section: Resultsmentioning

confidence: 99%