Date of Award


Degree Type


Degree Name


Degree Program

Engineering and Applied Science - Mechanical


Mechanical Engineering

Major Professor

Dr. Uttam Chakravarty

Second Advisor

Dr. Paul J Schilling

Third Advisor

Dr. David Hui


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.


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Available for download on Saturday, December 16, 2023