Page 40 - IJAMD-2-3

International Journal of AI for
Materials and Design Biomimetic ML for AFSD aluminum properties

Table 1. Material properties and typical applications of the alloys considered in the present work
Alloy Temper Tensile strength (MPa) Yield strength (MPa) Elongation (%) Density (g/cm ) Typical applications
3
AA2024 T3 427 – 483 324 – 393 10 – 25 2.78 Aircraft structures, rivets, and truck
wheels
AA5083 H116 283 – 303 193 – 214 16 – 22 2.66 Shipbuilding, pressure vessels,
cryogenic tanks
AA5086 H116 290 – 324 172 – 193 18 – 25 2.66 Marine applications, automotive body
panels
AA7075 T6 517 – 572 434 – 503 5 – 11 2.81 Aerospace components, bicycle frames,
and rock climbing equipment
AA6061 T6 310 276 10 – 18 2.7 Architectural applications, bicycle
frames, and automotive components

Figure 1. Schematic representation of the numerical modeling steps for the additive friction stir deposition process. The diagram consists of three main
sections: sequential step creation, interaction types, and loading conditions. The simulation begins with the substrate and initially deactivated deposited
layers. The model then incorporates element activation and various interaction types (mesh change, conversion, and radiation). Four distinct loading
conditions are applied: heat source, pressure, and shear forces in both the longitudinal and rotational directions.
coupled temperature–displacement analysis in this study, allow the model to depict the evolving geometry and
a coupled temperature–displacement step is utilized. thermal history of the build by activating different regions
This type of step allows for the simultaneous analysis layer by layer. Convection interactions are required to
of both thermal and structural behavior, capturing the model heat transfer between the deposited material, the
interaction between temperature changes and the resulting tool, and the surrounding environment. This is essential
deformations or stresses. Figure 1 illustrates the top layer for predicting cooling rates, temperature gradients, and
of the deposited material, where these steps are applied. possible defects such as distortions or residual stresses.
Within each step, parameters such as step duration, The loading parameters applied in Abaqus to simulate
loading conditions, boundary conditions, and the analysis the AFSD process – namely, the heat source, pressure,
procedure (e.g., static, dynamic, or explicit) can be specified shear longitude, and shear rotational – are all relevant
according to simulation requirements. and important for ensuring an accurate representation
To accurately simulate the complex physical processes of the process, as depicted in Figure 1. The heat source
involved in AFSD, three interaction types – model change, plays a critical role by generating the necessary thermal
convection, and radiation – must be created, as shown energy through friction between the rotating tool and the
in Figure 1. Model change interactions are essential for substrate. The friction heat softens the material, enabling
representing the additive nature of AFSD by simulating the its deposition. The downward force exerted by the tool
sequential deposition of material layers. These interactions is essential for consolidating the deposited material and

Volume 2 Issue 3 (2025) 34 doi: 10.36922/ijamd.5014