Abstract
Friction stir channelling (FSC) is a relatively new solid-state manufacturing technology able to produce conformal channels in a monolithic plate in a single step. During the FSC process the metal workpiece material is softened by the heat energy generated from dissipation during: plastic deformation, internal material flow and frictional work between the tool and the metal workpiece. The mechanical performance of a friction stirred channel aluminium alloy is affected by microstructure surrounding the channel. A new methodology that simulates a realistic 2D microstructure from experimental metallographic characterization and tensile tests was developed using the commercial software ABAQUS to study the mechanical behaviour of the friction stirred channel 5083-H111 aluminium alloy. Fourpoint bending tests were simulated and compared with experimental results. The RambergOsgood model was also adopted in the finite element analysis. It is seen from this investigation that microstructure can significantly affect the bending strength of friction stirred channel plates.
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