AA 6061 is defined as the workpiece material and tool steel H13 is defined as the tool. Tool is tilted by 2 degrees toward the trailing edge during the assembly of the parts. Tool is modeled as a solid homogenous rigid body with a shoulder diameter of 16 mm and a cylindrical pin with a diameter of 5 mm, and a pin height of 2.5 mm pin. Void region is required to simulate the flash formation. The thickness of the workpiece (4.1 mm) is partitioned into two parts to define void surface and material assignment region each having thickness of 1 mm and 3.1 mm, respectively. Workpiece is defined as a three-dimensional Eulerian body with a dimension of 110 mm × 114 mm × 4.1 mm. In ABAQUS all parts are created in the part module. Numerical modeling methodologies for friction stir welding process 5.6.1 Geometric modeling and material model To improve the prediction accuracy, an average of seven predictions using seven different calibration curves were used (Fig. 1.22(b)).
By measuring the plasma line intensity ratios and comparing them with the calibration curve, the composition ratio of different elements can be obtained. Second-order polynomial fittings were used to form the calibration curves. When comparing the H13 tool steel spectral lines with the emission lines of pure chromium and pure iron, the chromium and iron lines are easily identified. Fig. 1.22(a) shows the calibration curves using two different chromium neutral atomic lines and two iron neutral atomic lines . During DMD of an H13 tool steel material, both chromium and iron atomic emission lines are observed.
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Therefore, real-time spectroscopic analysis can be used to predict composition by evaluating the generated plasma using optical emission spectroscopy further, a full spatial compositional evaluation of the manufactured products can be obtained.
Laser-aided direct metal deposition of metals and alloys 1.5.3.3 Composition sensorĭuring DMD, a plasma plume is generally a by-product because of the laser-induced plasma.
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