| Abstract | In this study, a combined computational and experimental particle tracking investigation was performed for a solid-state additive manufacturing and repair process, Additive Friction Stir Deposition (AFSD). Specifically, smoothed particle hydrodynamics (SPH) simulations of AFSD were conducted in-order to elucidate deposition mechanics. The particle tracking of the SPH AFSD simulations was validated using experimental depositions of two feedstock varieties, including anodized AA6061-T6 feedstock to track external particles and AA6061-T6 copper wire core feedstock to track internal particles, to represent flow behavior from different regions of the feedstock. The X-Ray computed tomography (CT) experimental results revealed that the anodized oxides on the outside of the feedstock flowed to the retreating side, whereas the copper wire in the center of the feedstock migrated to the advancing side. Particle tracking results from the SPH simulations showed that, in general, particle movement is limited to directly beneath the feedstock. The rotational, radial, and traverse flow interactions visualized by AFSD simulations explained the advancing and retreating side biases experienced by the internal copper wire and surface oxides on the anodized feedstock. This work demonstrates the ability to predict AFSD material distributions, which has a significant impact on as-deposited material quality. |
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