Numerical Simulation and Mechanism of the Effect of Resistance-assisted Heating on the Thermo-mechanical-flow Behavior of 316L-Cu Dissimilar Alloy during AFRD

XU Mingwang; ZHAO Jiyuan; PENG Baoying; DONG Qing; LIU Rui

doi:10.3969/j.issn.1674-6457.2026.07.019

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (7) : 207-219. DOI: 10.3969/j.issn.1674-6457.2026.07.019

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Numerical Simulation and Mechanism of the Effect of Resistance-assisted Heating on the Thermo-mechanical-flow Behavior of 316L-Cu Dissimilar Alloy during AFRD

XU Mingwang¹, ZHAO Jiyuan^2,*, PENG Baoying¹, DONG Qing³, LIU Rui¹

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Abstract

To solve the problems of insufficient interfacial heat input and poor material flow coordination caused by mismatch of thermophysical properties between 316L stainless steel and copper in rolling friction deposition additive manufacturing, the work aims to introduce resistance-assisted heating process to systematically explore its regulation mechanism on thermo-mechanical-flow behavior, so as to improve the forming quality and interfacial properties of dissimilar alloys fabricated by solid phase additive manufacturing. Based on Abaqus software, a three-dimensional thermal-mechanical-flow multi-field coupling numerical model coupled with Euler-Lagrange (CEL) method was established to simulate the AFRD process of 316L-Cu dissimilar alloy, and the reliability of the model was verified by preliminary experiments. The Johnson-Cook constitutive equation was used to describe the high temperature rheological behavior of the material. The process parameters such as auxiliary heating temperature (25-700 ℃), additive speed (180-300 mm/min) and tool head rotation speed (750-1 000 r/min) were systematically studied. The effect of auxiliary heat on temperature distribution, plastic zone expansion, material flow mode and interface mixing behavior was deeply revealed by tracing the material migration path with tracer particle method and combining with the analysis of equivalent plastic strain field. The resistance-assisted heating significantly improved the interfacial heat accumulation and material fluidity. Under the conditions of auxiliary heat temperature of 600 ℃, additive speed of 240 mm/min and rotation speed of 850 r/min, the peak temperature of the interface significantly increased from 722 ℃ under no auxiliary heat to 841 ℃, and the high temperature residence time was prolonged from 1.2 s to 2.5 s. The tracer particle analysis showed that the maximum migration distance of the material in the x direction of the additive direction increased from 10.95 mm to 11.46 mm, and the maximum migration distance in the z direction of the thickness direction increased from 2.31 mm to 2.63 mm. The flow ability of the material was improved in an all-round way, forming a wider and more uniform interface mixing zone. The equivalent plastic strain analysis further revealed that the auxiliary heat induced the strain localization phenomenon, which changed the high strain zone from a wide distribution to a concentrated narrow shear band. The maximum equivalent plastic strain value was reduced from 58.8 to 55.2 when there was no auxiliary heat, and the mode transitioned from wide and shallow forced deformation to narrow and deep efficient shear flow. Preliminary experimental verification showed that the simulation results were in good agreement with the experimental results in terms of macroscopic morphology and key dimensions. The resistance-assisted heating effectively coordinates the flow behavior of 316L-Cu dissimilar alloy in AFRD process by increasing heat input, promoting material softening and inducing strain localization, and solves the interface bonding problem caused by mismatch of thermophysical properties. The work clarifies the action chain of heat input-material softening-strain localization-coordinated flow, indicating that the interface bonding quality depends on not only the high average plastic strain, but also the optimal distribution and efficient utilization of deformation energy through thermo-mechanical synergy, providing an important theoretical basis and process optimization direction for high-performance solid phase additive manufacturing of dissimilar alloys.

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resistance-assisted heating / dissimilar alloys / rolling friction deposition additive manufacturing / thermo-mechanical-flow behavior / strain localization

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XU Mingwang, ZHAO Jiyuan, PENG Baoying, DONG Qing, LIU Rui. Numerical Simulation and Mechanism of the Effect of Resistance-assisted Heating on the Thermo-mechanical-flow Behavior of 316L-Cu Dissimilar Alloy during AFRD[J]. Journal of Netshape Forming Engineering. 2026, 18(7): 207-219 https://doi.org/10.3969/j.issn.1674-6457.2026.07.019

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