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An element birth and death approach using commercially available Ansys Additive directed energy deposition feature is adapted to the modelingModeling of Additive Friction Stir DepositionAdditive friction stir deposition (AFSD) of AA 7075-T6 material. Experimental data are collected by inserting thermocouples into the part during deposition to gather temperature histories at various locations in the build. These data were then compared to the simulation model for validation, where reasonable agreement was seen with the experiment, after a period of model adjustment, where appropriate boundary conditions were refined in order to better match those that occurred during the experiment. The current effort aims to enable manufacturers to predict thermal histories, final part shape, and residual stresses in AFSD-fabricated parts. If successful, this advancement will help to speed the development of AFSD as a manufacturing process, potentially leading to broader industrial adoption and innovation.

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Simulation of the Additive Friction Stir Deposition Process Using a Directed Energy Deposition Approach

  • 会议论文

  • 发表日期：

    2025年

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  • Joseph Broadhead,
  • Michael Miles,
  • Yuri Hovanski,
  • Hengfeng Gu,
  • Alaa Olleak,
  • Courtney Pennington

摘要

An element birth and death approach using commercially available Ansys Additive directed energy deposition feature is adapted to the modelingModeling of Additive Friction Stir DepositionAdditive friction stir deposition (AFSD) of AA 7075-T6 material. Experimental data are collected by inserting thermocouples into the part during deposition to gather temperature histories at various locations in the build. These data were then compared to the simulation model for validation, where reasonable agreement was seen with the experiment, after a period of model adjustment, where appropriate boundary conditions were refined in order to better match those that occurred during the experiment. The current effort aims to enable manufacturers to predict thermal histories, final part shape, and residual stresses in AFSD-fabricated parts. If successful, this advancement will help to speed the development of AFSD as a manufacturing process, potentially leading to broader industrial adoption and innovation.