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Study of Friction Extrusion and Consolidation Xiao Li University of South Carolina University of South Carolina Scholar Commons Theses and Dissertations 6-30-2016 Study of Friction Extrusion and Consolidation Xiao Li University of South Carolina Follow this and additional works at: https://scholarcommons.sc.edu/etd Part of the Mechanical Engineering Commons Recommended Citation Li, X.(2016). Study of Friction Extrusion and Consolidation. (Doctoral dissertation). Retrieved from https://scholarcommons.sc.edu/ etd/3507 This Open Access Dissertation is brought to you by Scholar Commons. It has been accepted for inclusion in Theses and Dissertations by an authorized administrator of Scholar Commons. For more information, please contact [email protected]. STUDY OF FRICTION EXTRUSION AND CONSOLIDATION by Xiao Li Bachelor of Science Hohai University, 2008 Master of Science Hohai University, 2011 Submitted in Partial Fulfillment of the Requirements For the Degree of Doctor of Philosophy in Mechanical Engineering College of Engineering and Computing University of South Carolina 2016 Accepted by: Anthony P. Reynolds, Major Professor Michael Sutton, Committee Member Xiaomin Deng, Committee Member Joshua Tarbutton, Committee Member Paul Ziehl, Committee Member Lacy Ford, Senior Vice Provost and Dean of Graduate Studies © Copyright by Xiao Li, 2106 All Rights Reserved. ii DEDICATION To my Mom Ping, for giving me life To my wife Shanshan, for giving me love To my Oncoming daughter Aurora, for giving me hope iii ACKNOWLEDGMENTS This dissertation was made possible due to the masterly guidance of Dr. Anthony P. Reynolds. I was nourished profoundly from your erudite knowledge, dedication to work, optimistic attitude to life and spirit of always seek truth from facts. You set a good example of both researcher and experimentalist. Those countless brainstorm enlightens me to think critically and deeply, today and tomorrow. I can’t feel luckier to have you as my Ph.D. advisor. Dan, you are the best engineer and model plane maker in the world. Only your generous selfless help makes my experiments possible and I feel I owe you too much that can’t be expressed by words. I also gratitude to Dr. Wei Tang, who helped me get along with USC and living in Columbia. Your methodology and advises are still guiding me find the right path. I appreciate my committee members’ effort of helping me improve this dissertation and providing valuable suggestions for my research. To make my past five years unique, not only it is a course of pursuing doctor degree but also a wonderful journey of knowing friends come from all over the world. I am amazed by the transcultural communications between people who born in lands and cultures apart, who exchange thoughts with spark but respects as well. I sincerely thank all my group members, also my comrades and partners: Piyush, Rabby, Clinton, Joel, Hussein, Xiaomin, Hejun, Dawei, Ryan, Marie, Mathieu, Corbin, Ilana, Jeffery and many people who worked with me and help me in academic area or daily life. I miss the moments not only we can iv share our idea of research but also our feeling and attitude to the entire world. Love in advancing side, life in retreating side. All little drops of time shared with you come together as a priceless stream that will always flow in my mind. v ABSTRACT Friction extrusion and consolidation was invented by The Welding Institute (Cambridge, UK) in the early 1990’s. It is related to simple extrusion processes with the primary difference being that the extrusion die rotates about the extrusion axis and the die is required to impart substantial deformation to the initially, finely divided charge (like metal waste or chips) in order to consolidate it prior to extrusion. It can produce high quality wire and fully consolidated bulk material from low-cost precursors like metal chips or powders. The advantages lie in that it is a direct method to recycle metal chips or scraps and considered as more convenient, economical and “green” process when compared with conventional recycle processes involving melting and casting. This is a novel process believed to have huge potential for producing high quality wire products with customized chemical composition for fusion welding and additive manufacturing with relatively simpler devices and less time/labor/energy requirements. This dissertation work aims to develop insight understanding of the underlying physics of friction extrusion and consolidation processes and enable its use for a wide range of high value-added manufacturing applications, like additive manufacturing. The specific works are listed as follow: The thermal-mechanical progression of friction extrusion and consolidation process was studied experimentally and numerically. The deformation and material flow were revealed via a marker insert technique, thus, strain in friction extrusion vi wire is deduced. The relationship between control parameters (like extrusion/consolidation force and die rotational speed) and responses (like torque, extrusion rate, grain size and features of marker pattern etc.) were analyzed. Electron backscatter diffraction result showed that there is no strong texture preference in friction extruded aluminum wire. Using friction extruded aluminum alloy wire, wall samples were built via wire and arc additive manufacturing. Finite element simulation helped predict heat transfer and temperature field during the additive manufacturing process. Post-analysis indicates that good mechanical properties can be achieved if favorable thermal management was provided. vii TABLE OF CONTENTS Dedication .......................................................................................................................... iii Acknowledgments .............................................................................................................. iv Abstract .............................................................................................................................. vi List of Figures ..................................................................................................................... x List of Tables .................................................................................................................. xvii Chapter 1 Introduction and background ............................................................................. 1 1.1 Introduction ............................................................................................................... 1 1.2 Background of research and motivation ................................................................... 5 1.3 Dissertation Layout ................................................................................................... 8 Chapter 2 Literature review .............................................................................................. 10 2.1 General background ................................................................................................ 10 2.2 Friction stir process ................................................................................................. 11 viii 2.3 Conventional manufacturing methods .................................................................... 17 2.4 Wire based additive manufacturing ........................................................................ 25 Chapter 3 Friction Extrusion ............................................................................................. 30 3.1 Experimental and testing procedures ...................................................................... 30 3.2 Results and analyzes ............................................................................................... 50 3.3 Discussion and summary ...................................................................................... 103 Chapter 4 Friction consolidation ..................................................................................... 108 4.1 Aluminum chips consolidation ............................................................................. 108 4.2 ODS bead on plate ................................................................................................ 128 Chapter 5 Wire and arc additive manufacturing using friction extrusion wires ............. 136 5.1 Wire produce and wall sample build .................................................................... 137 5.2 Post-analysis ......................................................................................................... 142 5.3 Transient thermal modeling of wire and arc additive manufacturing ................... 152 5.4 Summary and discussions ..................................................................................... 161 Chapter 6 Conclusions and future work .......................................................................... 164 BIBLIOGRAPHY ........................................................................................................... 169 Appendix A - The mathematical method of curve fit with arbitrary order .................... 175 Appendix B - Matlab code for marker material pattern reconstruction .......................... 178 ix LIST OF FIGURES Figure 1.1 Schematic diagram of friction extrusion process .............................................. 2 Figure 2.1 Schematic diagram of friction stir welding ..................................................... 12 Figure 2.2 Conventional extrusion process ....................................................................... 20 Figure 3.1 Schematic diagram of friction extrusion die for 2.54mm wire ......................
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