Mechanisms of FRAM toolhead enhancing material flow and grain refinement

IF 7.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

International Journal of Mechanical Sciences Pub Date : 2025-02-26 DOI:10.1016/j.ijmecsci.2025.110097

Yiyang Liu , Haibin Liu , Ruishan Xie , Ying Chen , Shujun Chen

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Abstract

Friction-rolling additive manufacturing (FRAM) is a solid-phase additive manufacturing technique that relies on tool-driven material deposition and interlayer bonding. However, the interfacial bonding and formation mechanisms induced by toolhead features are unclear. In this study, a three-dimensional thermomechanical coupled Eulerian–Lagrangian (CEL) model was developed by incorporating a damage constitutive model that reflected the friction between various toolhead features and the damaged material. This study systematically investigated the heat generation and material flow behavior around the toolhead with different features and evaluated their effects on the interfacial bonding and microstructure. The results showed that the groove feature enhanced material disruption in the forward region of the toolhead, thereby reducing the heat generated by friction and accelerating the overall accumulation of plastic deformation. This significantly increased the material capture ability and plasticized zone range. The material flow is influenced by the combined effects of shearing and extrusion around the toolhead, which subsequently affects the interface morphology. The groove features promote upward migration on the substrate surface, forming a mechanical interlocking structure at the interface. In addition, the groove features significantly enhanced recrystallization in the deposition layer, achieving a grain refinement of up to 80% of the base material size. These findings reveal the interaction mechanisms between toolheads and materials, which offer further insights into toolhead design and optimization.

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来源期刊

International Journal of Mechanical Sciences 工程技术-工程：机械

CiteScore

12.80

自引率

17.80%

发文量

769

审稿时长

19 days

期刊介绍： The International Journal of Mechanical Sciences (IJMS) serves as a global platform for the publication and dissemination of original research that contributes to a deeper scientific understanding of the fundamental disciplines within mechanical, civil, and material engineering. The primary focus of IJMS is to showcase innovative and ground-breaking work that utilizes analytical and computational modeling techniques, such as Finite Element Method (FEM), Boundary Element Method (BEM), and mesh-free methods, among others. These modeling methods are applied to diverse fields including rigid-body mechanics (e.g., dynamics, vibration, stability), structural mechanics, metal forming, advanced materials (e.g., metals, composites, cellular, smart) behavior and applications, impact mechanics, strain localization, and other nonlinear effects (e.g., large deflections, plasticity, fracture). Additionally, IJMS covers the realms of fluid mechanics (both external and internal flows), tribology, thermodynamics, and materials processing. These subjects collectively form the core of the journal's content. In summary, IJMS provides a prestigious platform for researchers to present their original contributions, shedding light on analytical and computational modeling methods in various areas of mechanical engineering, as well as exploring the behavior and application of advanced materials, fluid mechanics, thermodynamics, and materials processing.