Thermo-mechanical analysis of Tailor-made functionally graded materials through Friction stir processing

Abstract

Motivated by the recent use of friction stirring in the manufacture of in-situ composites, a new additive manufacturing method for design and manufacture of tailor-made functionally graded composites is presented. A numerical analysis of Aluminium 6061 T6 alloy and SiC in-situ metal matrix was developed with Friction stir processing. Functionally graded material (FGM) possess gradual change in Composition and structure over the entire volume, which results in corresponding changes in its material properties. A geometrical model of Aluminium 6061 T6 alloy of thickness of 6 mm is generated. SiC nanoparticles is filled in the pre-drilled linear fashioned successively centre distance holes on aluminium base metal. Mori-Tanaka method and the rule of mixtures aid to determine the material properties of the model from the elementary constituents. A moving coordinate which produce heat input from both the tool shoulder and the tool pin is introduced to make modelling the moving tool easier. The temperature distribution of the FG plate was analysed across various regions of the path from material flow in addition to the evaluation of process efficiency by 3 dimensional finite element method using COMSOL multi-physics.