Numerical and experimental study on the thermal process during additive friction stir deposition

Abstract

Additive friction stir deposition (AFSD) is a solid state coating process as well as a developing solid state additive manufacturing technology. AFSD has numerous advantages over friction surfacing coating technology. However, extensive research has demonstrated that a relationship between microstructure and mechanical properties exists at present. On the other hand, a few research focus on temperature field evolution.The temperature field during AFSD is examined in this paper using a combined experimental-numerical approach. According to characterizations of AFSD thermal process, AFSD was classified into friction preheating stages and steady deposition stages. The friction preheating model and the steady deposition heat model are both established. The experiment is carried out to confirm the temperature difference between the simulation and the experiment, where experimental and numerical results correspond well. The AFSD process parameters include rotational speed, feed speed, and deposition rate. The purpose of this research is to examine the effect of process parameters on heat input during the production of aluminum alloy coating by AFSD. The results shows that rotational speed is a critical element that influences heat input. Overall, the comparisons of experimental and numerical results show that the numerical model's accuracy is satisfactory, and the effect of process parameters on heat input was thoroughly investigated.