Prediction of Temperature Distribution Using Coupled Eulerian-Lagrangian (CEL) Finite Element Modelling of Plunging Stage During Additive Friction Stir Deposition

Abstract A friction-based additive manufacturing technique called Additive Friction Stir Deposition (AFSD) produces metallic solid objects with lower residual stresses, free from hot-cracking, less porosity, and other defects than traditional fusion-based additive manufacturing. In this work, the thermo-mechanical deformation behavior of the AFSD process during the plunging stage is studied using a Coupled Eulerian-Lagrangian (CEL) finite element simulation framework. The model considers the substrate as an aluminum alloy (AL6061-T6) and the rigid tool as an H13 steel. The study envisaged that the model is suitable for predicting the temperature distribution of the substrate material at any location. The model establishes a physics-based relation between thermal evolution and phenomenological parameters such as the rotational speed of the tool, frictional contact, and plastic dissipation during the AFSD process. The model accounts for the complex interaction between tool, substrate, and process parameters. The developed model provides significant insights for process optimization and control. The study is the first step towards modeling the complete AFSD process in a finite element model framework.