A coupled acoustic-thermal-fluid model and numerical simulation of ultrasound vibration assisted friction surfacing

Based on comprehensive consideration the friction surfacing (FS) process, a new FS technology is presented by applying the ultrasonic vibration to substrate in front of the consumable rod. A coupled acoustic-thermal-fluid model is developed and the effects of ultrasonic vibration on temperature distribution and material flow behaviour during FS are investigated and discussed quantitatively. The numerical simulation results show that the ultrasound vibration has less effect on preheat and temperature distribution in the fusion zone, whereas it could effectively reduce material viscosity, increase flow velocity and expand the flow zone of plastic material. The contributions of this study can provide a new way for FS.