Outcomes FSE

FSE

ALICE aims to develop an FEM formulation for the analysis of FSE; therefore, a numerical model for the researched Friction Stir Extrusion process was developed using the DEFORM3D^TM software, a Lagrangian implicit code tailored for metal forming processes. 

The model has been refined using experimental temperature measurements obtained with a thermocouple placed on the symmetry axis at the base of the die chamber.

Using the DT, the geometry of the tool was optimized by analyzing the deformation patterns to ensure the tool possessed the most favorable mechanical properties. Indeed, for the application of these wires in deposition processes, they must exhibit high ductility, tensile strength, and consistent density.

Once the numerical model was calibrated, it was utilized to study the optimal geometry of the tool. Specifically, the inclination angle of the tool was varied from 0° to 10° to achieve enhanced heating and consequently improved deformation, directing the plasticized material toward the extrusion die.

The best process parameters were found to be 500 rpm and 21 kN which present the variables of temperature, effective strain, and effective strain rate.