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<p>This study introduces a thermomechanically coupled Eulerian finite-element model enhanced with a modified Norton-based friction law to simulate friction stir additive manufacturing (FSAM) of dissimilar Al-Mg alloys. The proposed model accurately captures sliding-to-sticking transitions at the tool-workpiece interface, enabling stable, multilayer simulations of localized heat generation, plastic strain accumulation, and residual stress evolution. Peak temperature prediction reached 1310&#xa0;°C, and longitudinal residual stress peaked at 50 MPa, with validation with experimental data and published infrared thermography and XRD data showing an error of less than 4.4%. The model also predicted distortion reduction of 78.1% (from 16 to 3.5 mm) compared to traditional Coulomb-based FSW simulations. Simulated grain size decreased from 12.0 to 9.5 μm across layers due to cyclic re-heating, while Vickers hardness increased from 75 to 82 VHN, both in a good agreement with experimental EBSD and TEM trends. A process parameter sensitivity study across rotational speed (800-1500 rpm), traverse speed (1-3 mm/s), and axial force (3-6 kN) confirmed their nonlinear influence on thermal gradients and stress localization. To explore process optimization, a Box-Behnken design (BBD) was applied, revealing that combinations of ω = 1200 rpm, v = 1.0-1.5 mm/s, and <i>p</i> = 1.2 mm improve the ultimate tensile strength (UTS) from 225 to 271 MPa, and result in a 20.4% enhancement of yielding. These findings validate the model as a robust simulation tool for predictive design, parametric optimization, and future real-time control of FSAM processes involving dissimilar material systems.</p> Graphical abstract

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Enhanced Thermomechanical Modeling of Dissimilar Friction Stir Additive Manufacturing Using a Modified Eulerian-Based Friction Framework

  • 期刊论文

  • 发表日期：

    2025年8月11日

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  • Bahman Meyghani

摘要

This study introduces a thermomechanically coupled Eulerian finite-element model enhanced with a modified Norton-based friction law to simulate friction stir additive manufacturing (FSAM) of dissimilar Al-Mg alloys. The proposed model accurately captures sliding-to-sticking transitions at the tool-workpiece interface, enabling stable, multilayer simulations of localized heat generation, plastic strain accumulation, and residual stress evolution. Peak temperature prediction reached 1310 °C, and longitudinal residual stress peaked at 50 MPa, with validation with experimental data and published infrared thermography and XRD data showing an error of less than 4.4%. The model also predicted distortion reduction of 78.1% (from 16 to 3.5 mm) compared to traditional Coulomb-based FSW simulations. Simulated grain size decreased from 12.0 to 9.5 μm across layers due to cyclic re-heating, while Vickers hardness increased from 75 to 82 VHN, both in a good agreement with experimental EBSD and TEM trends. A process parameter sensitivity study across rotational speed (800-1500 rpm), traverse speed (1-3 mm/s), and axial force (3-6 kN) confirmed their nonlinear influence on thermal gradients and stress localization. To explore process optimization, a Box-Behnken design (BBD) was applied, revealing that combinations of ω = 1200 rpm, v = 1.0-1.5 mm/s, and p = 1.2 mm improve the ultimate tensile strength (UTS) from 225 to 271 MPa, and result in a 20.4% enhancement of yielding. These findings validate the model as a robust simulation tool for predictive design, parametric optimization, and future real-time control of FSAM processes involving dissimilar material systems.

Graphical abstract