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<p>This study introduces a physics-based computational framework for additive friction stir deposition (AFSD) of Al6061-T6 using steady-state and transient computational fluid dynamics with conjugate heat transfer (CFD–CHT) modeling to capture the coupled thermo-mechanical process evolution. Unlike simplified thermal models that rely on prescribed heat sources, this presents a multi-domain CFD–CHT framework of the AFSD process that couples viscoplastic feedstock flow with heat conduction in the solid tool and substrate while directly resolving frictional heating, viscous dissipation, heat partitioning, and temperature-dependent material softening in a unified framework. The plasticized material is modeled using a shear-rate- and temperature-dependent non-Newtonian constitutive viscosity law, while frictional heat generation at the tool-feedstock and feedstock-substrate interfaces is described by the Coulomb friction law and implemented as a volumetric heat source through user-defined functions (UDFs). Simulations are conducted over tool rotational speeds of 15.8–52.35&#xa0;rad/s and feed rates of 0.00085–0.004&#xa0;m/s to assess process sensitivity. The results indicate that increasing rotational speed intensifies frictional and viscous heat generation, raises local temperature, reduces effective viscosity, and enhances material transport. Variations in feed rate influence thermal accumulation and flow localization, thereby affecting the spatiotemporal heat distribution within the deposition zone. Overall, the developed CFD–CHT framework advances AFSD process modeling by resolving the coupled interaction among frictional heating, viscous dissipation, heat partitioning, material softening, and solid-domain heat conduction. The model provides a predictive tool for identifying thermally stable processing conditions, improving thermal management, and reducing experimental trial-and-error during AFSD process optimization.</p>

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Thermo-mechanical process modeling of additive friction stir deposition

  • 期刊论文

  • 发表日期：

    2026年7月20日

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  • Gazi A. Raihan,
  • Uttam K. Chakravarty

摘要

This study introduces a physics-based computational framework for additive friction stir deposition (AFSD) of Al6061-T6 using steady-state and transient computational fluid dynamics with conjugate heat transfer (CFD–CHT) modeling to capture the coupled thermo-mechanical process evolution. Unlike simplified thermal models that rely on prescribed heat sources, this presents a multi-domain CFD–CHT framework of the AFSD process that couples viscoplastic feedstock flow with heat conduction in the solid tool and substrate while directly resolving frictional heating, viscous dissipation, heat partitioning, and temperature-dependent material softening in a unified framework. The plasticized material is modeled using a shear-rate- and temperature-dependent non-Newtonian constitutive viscosity law, while frictional heat generation at the tool-feedstock and feedstock-substrate interfaces is described by the Coulomb friction law and implemented as a volumetric heat source through user-defined functions (UDFs). Simulations are conducted over tool rotational speeds of 15.8–52.35 rad/s and feed rates of 0.00085–0.004 m/s to assess process sensitivity. The results indicate that increasing rotational speed intensifies frictional and viscous heat generation, raises local temperature, reduces effective viscosity, and enhances material transport. Variations in feed rate influence thermal accumulation and flow localization, thereby affecting the spatiotemporal heat distribution within the deposition zone. Overall, the developed CFD–CHT framework advances AFSD process modeling by resolving the coupled interaction among frictional heating, viscous dissipation, heat partitioning, material softening, and solid-domain heat conduction. The model provides a predictive tool for identifying thermally stable processing conditions, improving thermal management, and reducing experimental trial-and-error during AFSD process optimization.