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 dwell-phase 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.

中文翻译：

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横向摩擦堆焊固态金属沉积的热机械有限元分析

横向摩擦堆焊 (LFS) 是摩擦堆焊 (FS) 工艺的一种新颖变体，用于固态制造超薄且光滑的金属涂层。在LFS技术中，将旋转杆的侧面压在基板表面上会产生摩擦热和塑性变形，导致消耗材料从杆的侧面沉积到基板上。这项研究对这种复杂的耦合热机械过程进行了数值分析，以研究整个自耗棒和基材中各种变量的分布，例如温度、局部压力、应力和应变。通过 ABAQUS/Explicit 方法开发了该过程的有限元模型，通过结合工艺参数、材料的机械行为、温度相关的材料特性和失效准则等各种特征来研究棒材和基材材料的热机械响应。通过使用相同的材​​料和工艺参数值进行实验分析来验证有限元模型。有限元模拟结果与之前的实验一致，并证实工艺温度低于传统FS并且集中在一个小区域，这可以减少对自耗棒和基材材料的热影响。尽管由于 Al6061-T6 棒的导热性较高，大部分摩擦热都转移到了该棒上，但研究表明，最高工艺温度出现在低碳钢基材上。研究结果表明，选择适当的停留阶段持续时间不仅可以提高材料的温度以促进改善沉积，而且还可以确保沿棒侧面的所有点之间的接触更加一致，从而实现均匀的沉积。