Date of Award

12-2022

Degree Type

Thesis-Restricted

Degree Name

M.S.E.

Degree Program

Engineering and Applied Science - Mechanical

Department

Mechanical Engineering

Major Professor

Dr. Uttam Chakravarty

Second Advisor

Dr. Paul J Schilling

Third Advisor

Dr. David Hui

Abstract

Additive friction stir deposition (AFSD) is a novel metal additive manufacturing (AM) process that enables fast, scalable manufacturing of metal and alloys by utilizing friction stirring and metal feeding processes together. Thermo-mechanical process optimization during the AFSD process is very critical for ensuring better quality control, improved microstructure, and desired thermo-mechanical properties. In this study, the numerical models based on computational fluid dynamics are developed to investigate spatial thermal and flow behaviors such as temperature evolution, wall heat flux, material velocity, pressure distribution, etc. in the metal printing of Ti6Al4V alloy via the AFSD process. The material conversation law with a steady state flow is applied where the heat generation is measured in considering stacking/ slipping conditions. To measure the temperature evolution, the steady state conservation of energy equation is formulated where viscous dissipation is implemented due to plasticity. The numerical results show the material deposition as a highly viscous flow where the temperature evolution is optimized around 20% below the melting temperature. Similarly, wall heat flux, material velocity, pressure distribution, etc. are exhibited with varying process conditions. Finally, the numerical model is validated with the published literature and the convergence study is performed for reducing the numerical cost.

Rights

The University of New Orleans and its agents retain the non-exclusive license to archive and make accessible this dissertation or thesis in whole or in part in all forms of media, now or hereafter known. The author retains all other ownership rights to the copyright of the thesis or dissertation.

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