Elucidating the influence of temperature and strain rate on the mechanics of AFS-D through a combined experimental and computational approach

Stubblefield, G. G.; Fraser, Kirk; Iderstine, D. Van; Mujahid, S.; Rhee, Hongjoo; Jordon, J.B.; Allison, P. G.

doi:10.1016/j.jmatprotec.2022.117593

Cited by 25 publications

(4 citation statements)

References 24 publications

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“…Setpoints, such as the desired temperature, and other properties, such as frictional force and heat capacity, change the base settings for control; thus investigations of varying control settings for different materials are warranted. For this work, we have selected aluminum alloy 6061 as the deposition material because its properties are well understood based on previous work [19,36,37].…”

Section: Process Descriptionmentioning

confidence: 99%

“…Additionally, a wide variety of materials-such as aluminum alloys [24][25][26][27][28], magnesium alloys [29,30], copper [31,32], Inconel [33,34], and titanium alloys [35]-can be used in AFSD. While modeling and simulation of AFSD focus on the accurate representation of atomistic or continuum phenomena underlying the process [13,36,37], accurate real-time process prediction and underlying analytical process dynamics for AFSD remain outstanding issues. With respect to automation, temperature control [38][39][40] and force control [10,41] have been successfully applied to FSW.…”

Section: Introductionmentioning

confidence: 99%

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Closed-Loop Temperature and Force Control of Additive Friction Stir Deposition

Merritt

Williams

Allison

et al. 2022

JMMP

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Additive Friction Stir Deposition (AFSD) is a recent innovation in non-beam-based metal additive manufacturing that achieves layer-by-layer deposition while avoiding the solid-to-liquid phase transformation. AFSD presents numerous benefits over other forms of fusion-based additive manufacturing, such as high-strength mechanical bonding, joining of dissimilar alloys, and high deposition rates. To improve, automate, and ensure the quality, uniformity, and consistency of the AFSD process, it is necessary to control the temperature at the interaction zone and the force applied to the consumable feedstock during deposition. In this paper, real-time temperature and force feedback are achieved by embedding thermocouples into the nonconsumable machine tool-shoulder and estimating the applied force from the motor current of the linear actuator driving the feedstock. Subsequently, temperature and force controllers are developed for the AFSD process, ensuring that the temperature at the interaction zone and the force applied to the feedstock track desired command values. The temperature and force controllers were evaluated separately and together on setpoints and time-varying trajectories. For combined temperature and force control with setpoints selected at a temperature of 420 °C and a force of 2669 N, the average temperature and force tracking errors are 5.4 ± 6.5 °C (1.4 ± 1.6%) and 140.1 ± 213.5 N (5.2 ± 8.0%), respectively.

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Section: Process Descriptionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Closed-Loop Temperature and Force Control of Additive Friction Stir Deposition

Merritt

Williams

Allison

et al. 2022

JMMP

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“…One of the greatest advantages of AFSD is depositing fully dense as-printed parts [6]. Solidification-induced porosity and hot tearing or hot cracking are not an issue, because the AFSD is a solid-state process [7]. AFSD also eliminates defects that are induced by melting processes, such as a lack of infusion and spatter ejection [6].…”

Section: Introductionmentioning

confidence: 99%

The Effects of Layer Thickness on the Mechanical Properties of Additive Friction Stir Deposition-Fabricated Aluminum Alloy 6061 Parts

Ghadimi,

Talachian,

Ding

et al. 2024

Metals

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Solid-state additive friction stir deposition (AFSD) is a thermomechanical-based additive manufacturing technique. For this study, AFSD was utilized to produce aluminum alloy 6061 (AA6061) blocks with varying layer thicknesses (1 mm, 2 mm, and 3 mm). The mechanical properties were assessed through uniaxial tensile tests and Vickers microhardness measurement, and statistical analysis was employed to investigate differences among data groups. The results revealed that the deposition layer thickness influences tensile properties in the building (Z) direction, while the properties in the X and Y directions showed minor differences across the three AFSD blocks. Furthermore, variations in tensile properties were observed depending on the sample orientation in the AFSD blocks and its depth-wise position in the part in the building direction. The microhardness values decreased non-linearly along the building direction, spread across the width of the part’s cross-section, and highlighted that the deposition layer thickness significantly affects this property. The 1 mm block exhibited lower average microhardness values than the 2 mm and 3 mm blocks. The temperature histories and dynamic heat treatment are influenced by the deposition layer thickness and depend on the location of the point being studied in the part, resulting in variations in the microstructure and mechanical properties along the building direction and across the part’s width.

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“…Nonetheless, there are some exceptions. For example, the Smoothed Particle-Hydrodynamics (SPH) has already been extensively used to simulate the friction stir extrusion (FSE), a novel solid-phase processing technique that consolidates and extrudes metal powders (and other kinds of raw materials) into high-performance parts (Li et al, 2022a(Li et al, , 2022b, the additive friction stir deposition (AFS-D) (Stubblefield et al, 2021;Stubblefield et al, 2022), the laser fusion additive manufacturing (Russell et al, 2018), the selective laser melting process (Qiu et al, 2021), which uses a laser to heat metal or alloy powders that melt and solidify into metal parts or melt pool simulations in laser powder bed fusion (LPBF) (L€ uthi et al, 2023). This work investigates the advantages of using the Radial Point Interpolation Method (RPIM) (Wang and Liu, 2002) in the simulation of the viscoplastic extrusion process that occurs in the FFF but already eyes the future modelling of the full FFF process using the same meshless method.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of the extrusion process of viscoplastic materials using a radial point interpolation method

Rodrigues,

Belinha,

Natal Jorge

2023

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PurposeFused Filament Fabrication (FFF) is an extrusion-based manufacturing process using fused thermoplastics. Despite its low cost, the FFF is not extensively used in high-value industrial sectors mainly due to parts' anisotropy (related to the deposition strategy) and residual stresses (caused by successive heating cycles). Thus, this study aims to investigate the process improvement and the optimization of the printed parts.Design/methodology/approachIn this work, a meshless technique – the Radial Point Interpolation Method (RPIM) – is used to numerically simulate the viscoplastic extrusion process – the initial phase of the FFF. Unlike the FEM, in meshless methods, there is no pre-established relationship between the nodes so the nodal mesh will not face mesh distortions and the discretization can easily be modified by adding or removing nodes from the initial nodal mesh. The accuracy of the obtained results highlights the importance of using meshless techniques in this field.FindingsMeshless methods show particular relevance in this topic since the nodes can be distributed to match the layer-by-layer growing condition of the printing process.Originality/valueUsing the flow formulation combined with the heat transfer formulation presented here for the first time within an in-house RPIM code, an algorithm is proposed, implemented and validated for benchmark examples.

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Elucidating the influence of temperature and strain rate on the mechanics of AFS-D through a combined experimental and computational approach

Cited by 25 publications

References 24 publications

Closed-Loop Temperature and Force Control of Additive Friction Stir Deposition

Closed-Loop Temperature and Force Control of Additive Friction Stir Deposition

The Effects of Layer Thickness on the Mechanical Properties of Additive Friction Stir Deposition-Fabricated Aluminum Alloy 6061 Parts

Numerical simulation of the extrusion process of viscoplastic materials using a radial point interpolation method

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