Thermo-mechanical finite element analysis of the solid-state metal deposition via lateral friction surfacing

Lateral friction surfacing (LFS) is a novel variation of the friction surfacing (FS) process for solid-state fabrication of ultra-thin and smooth metal coatings. In the LFS technique, pressing the lateral side of a rotating rod against the substrate's surface generates frictional heat and plastic deformation, leading to the deposition of consumable material from the lateral surface of the rod onto the substrate. This study presents numerical analysis for such a complex coupled thermo-mechanical process to investigate the distribution of various variables such as temperatures, local pressure, stress, and strain throughout the consumable rod and substrate. A finite element model of the process was developed through ABAQUS/Explicit method to investigate the thermo-mechanical response of rod and substrate materials by incorporating various features such as process parameters, mechanical behaviors of materials, temperature-dependent material properties, and failure criteria. The finite element model was validated by conducting experimental analysis using the same materials and values of process parameters. The finite element simulation results were consistent with previous experiments and affirmed that process temperature is lower than in conventional FS and localized in a small area, which can reduce thermal impacts on the consumable rod and substrate materials. Although the majority of the frictional heat was transferred to the Al6061-T6 rod due to its higher thermal conductivity, it was revealed that the maximum process temperature occurred on the mild steel substrate. The results of the study demonstrate that selecting an appropriate dwellphase duration not only enhances the material's temperature to facilitate improved deposition but also ensures more consistent contact across all points along the rod's side, resulting in a uniform deposition.