Session: 13-13-01: Simulations of Material Modeling and Behavior Analysis for MEMS Applications

Paper Number: 146030

146030 - Fracture Analysis of Additive Friction-Stir Deposited Non-Ferrous and Ferrous Alloys 

In the rapidly evolving domain of metal 3D printing, solid-state additive manufacturing (AM) techniques have emerged as a significant innovation in terms of efficiency, environmental impact, and material properties when compared to the conventional methods. Additive Friction Stir Deposition (AFSD) distinguishes itself as a promising solid-state AM technique due to its potential in fabricating high-strength and full-density non-ferrous and ferrous alloys with superior mechanical properties. AFSD unlocks new possibilities for the repair and production of crucial parts across diverse industries. This study presents a comprehensive analysis of fatigue crack growth and fracture behavior of non-ferrous (AA6061-T6) and ferrous (SS316) alloy specimens processed by the AFSD technique. Experiments are carried out for standard specimens for tensile and fracture properties using universal material testing machine and image processing technology with the modified compact tension specimens (MCTS). Standard specimens are fixed at one end and increasing tensile load is applied on the other end to assess the tensile strength. The fracture analysis is carried out in the same machine with tensile cyclic loads. The crack propagation trajectory is observed with respect to time and experimental data is plotted to determine the Paris Law constants for the AFSD-processed specimens. Current study sheds light on the advanced capabilities of the Separating Morphing Adaptive Remeshing Technology (SMART) tool in ANSYS software, while the numerical model predicts crack propagation trajectories and fatigue crack growth under constant amplitude loading in the same 3D model of MCTS. The stress intensity factor, crack extension, stress, and deformation contours have been presented from the numerical models to compare with the experimental data. A crucial element of this research involves the comparison of the mechanical integrity of specimens produced by the AFSD method with that of traditional base alloys. The analysis encompasses both tensile and fracture properties, providing insights into the relative improvements in mechanical properties offered by the AFSD process. The finite element models developed for the tensile and fracture behavior simulations have demonstrated a high level of precision in predicting tensile strength and crack trajectories, thus emphasizing the dependability of these methods in evaluating the durability and resilience of AFSD produced parts. Moreover, the present investigation examines the diverse aspects impacting the progression of cracks in AFSD processed parts. The study is further extended by comparing the properties of SS316 alloy with that of the aluminum 6061-T6 alloy. Current study provides insight into the fatigue crack growth and fracture properties of the AFSD-produced non-ferrous and ferrous alloys while addressing the promising potential of these materials for high-strength structural and repair applications. 

Presenting Author: M Shafiqur Rahman Louisiana Tech University

Presenting Author Biography: Dr. M Shafiqur Rahman is an Assistant Professor in the Department of Mechanical Engineering at Louisiana Tech University (LaTech), Ruston, LA. Before joining LaTech as a faculty, he was a Postdoctoral Fellow in Civil Engineering Department at Johns Hopkins University, Baltimore, MD. He pursued his Ph.D. and M.S. in Mechanical Engineering from the University of New Orleans, New Orleans, LA, in 2020 and 2016, respectively, and served there as a faculty in Mechanical Engineering. His area of research covers additive manufacturing/3D printing, solid mechanics, computational fluid dynamics, heat transfer, and machine learning. Dr. Rahman is passionate about research-based teaching, supervising students, promoting diversity, and learning new things that come across in our day-to-day life.

Authors:

Chowdhury Sadid Alam Louisiana Tech University
Abyaz Abid Louisiana Tech University
Radif Uddin Ahmed Louisiana Tech University
M Shafiqur Rahman Louisiana Tech University