Page 41 - IJAMD-2-3

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

ensuring a strong bond with the substrate. In addition, in the 11-direction (typically aligned with the build
pressure influences both the material flow and the shape direction in AFSD), allowing for the assessment of residual
of the deposited bead. Shear longitude refers to the shear stresses caused by thermal and mechanical loads. Plastic
force acting in the direction of the tool’s travel. This force strain (PEEQ) is a scalar measure of plastic deformation
plays an important role in material transport, mixing, and that complements AC YIELD in identifying regions where
the formation of the characteristic AFSD microstructure. the material may fail or undergo significant changes in
In contrast, shear rotational refers to the circumferential properties. LE, representing logarithmic strain, is used
shear force generated around the tool. It contributes to to analyze material behavior under large deformations,
material flow, stirring, and the development of the final which are common in AFSD due to elevated temperatures
part geometry. and severe plastic deformation. HFL, the heat flux vector,
Figure 2 displays the predicted outcomes of the AFSD indicates both the direction and magnitude of heat flow
simulations. One key parameter, AC YIELD, represents during AFSD, encompassing conduction, convection,
the accumulated equivalent plastic strain at the end of each and radiation. Understanding heat flux patterns is
increment. This parameter is crucial for understanding essential for optimizing process parameters and cooling
the extent of plastic deformation during the AFSD process strategies. The present work focused on the deposition
and helps identify regions susceptible to material failure of similar alloy layers onto a substrate of a similar alloy.
due to excessive strain. It also supports the optimization The input parameters for these simulations included the
of process parameters to achieve desired material elastic modulus of the alloys (GPa), specific heat (J/kg·K),
properties. Gradient of Temperature (GRADT), the spatial shear translation (n), shear rotational (N·m), and heat
temperature gradient, reveals temperature distribution source (W/m³). These parameters were carefully selected
and heat flow within the material during AFSD. Sharp to represent the key physical properties and process
temperature gradients can induce thermal stresses and conditions influencing the AFSD process, as summarized
affect the microstructure and mechanical properties of the in Table 2. The primary output parameters analyzed
final part. NT11 represents the normal stress component were the von Mises stress (MPa) and logarithmic strain

Figure 2. Visualization of predicted outcomes from the additive friction stir deposition numerical simulations, including accumulated equivalent plastic
strain (AC YIELD), temperature gradient (GRADT), von Mises stress (NT11), and logarithmic strain (LE). These parameters are essential for assessing
material properties and the overall performance of the deposited structures.

Volume 2 Issue 3 (2025) 35 doi: 10.36922/ijamd.5014