Modeling of Solid-State Materials Consolidation Repair Process for Static Strength and Fatigue Life Predictions

The present corrosion repair requirement specified by Navy is to restore the component’s previously un-corroded remaining useful life, while maintaining acceptable static strength capability. To meet these requirements, an extensive testing matrix has to be established to ensure a sufficient level of safety margin for a repaired system, not mentioning that the conventional corrosion repair methods could be costly and labor intensive. The additive friction stir deposition (AFSD) integrates the friction stir principle with a robust material feeding mechanism to enable the site-specific deposition along with the metallurgical bond formation. In Phase I, the research team will develop a thermal/metallurgical/mechanical analytical tool for AFSD enabled repair of aluminum structures under static loading. A multiphysics modeling approach will be constructed to simulate the temperature, material flow, and the resulting microstructure evolution. The temperature- and microstructure-dependent properties will be generated via a digital material library. An accumulative plastic strain driven damage initiation and propagation model will be applied for static failure prediction of AFSD repaired samples. Verification and validation of the multiphysics tool will be performed using the in-situ and ex-situ measurement data.