Enabling solid state metal recycling with new numerical techniques

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This project performs modelling to help develop an additive metal manufacturing process that makes use of scrap as input feed. It will develop new understanding of the key physical aspects of friction stir additive manufacturing and build a new efficient yet accurate continuum thermo-mechanical model for its simulation. This technology will enable metal deposition at rates an order of magnitude greater than conventional powder additive manufacturing methods. The new computational approach will be used to create processing and design maps. The work will facilitate greater use of high metal scrap and pave the way for more robust supply chains and new business models with application in automotive, mining, aerospace and military sectors.