Numerical Simulation of Friction Stir Additive Manufacturing of 2195 Aluminum Alloy

Author of the article:SU Yu1,2, LI Wenya1,2, YANG Xiawei1,2, ZOU Yangfan1,2, SHEN Zhikang3 , WU Dong1,2, CHU Qiang4

Author's Workplace：1. School of Materials Science and Engineering, Northwestern Polytechnical University, Xi'an 710072, China; 2. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072, China; 3. College of Engineering and Technology, Southwest University, Chongqing 400715, China; 4. Xi'an Aerospace Engine Co., Ltd., Xi'an 710100, China

Key Words：friction stir additive manufacturing; high-strength aluminum alloy; numerical simulation; temperature field; rheological behavior

Abstract：High-strength aluminum alloys have been widely used in aerospace manufacturing field, due to their advantages of lightweight and high strength. The friction stir additive manufacturing (FSAM) technology provides a potential application prospect for integrated manufacturing forming for high-strength aluminum alloys, which will further improve the service performance of complex components. In this study, a 3D finite element model of the 2195 aluminum alloy was established in the FSAM process by numerical simulation, based on the coupled Eulerian-Lagrangian (CEL) algorithm. The distribution of temperature field, flow field and strain field in the FSAM process were analyzed, which can provide a theoretical basis for studying the forming characteristics and material rheological behavior of FSAM workpieces, and provide guidance for improving the forming quality of high-strength aluminum alloys.