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Numan Habib

PhD Student

Project - Design and Development of an Additive Friction Stir Deposition Tool for Printing Solid State Recycled Aluminium

3D printing, also referred to as Additive Manufacturing (AM), is a fast-emerging technology that creates physical components from a 3D CAD model by successive addition of material. Metal AM is currently widely used in many industries, including aerospace, automobiles, and dental implants.  In metal AM, Additive Friction Stir Deposition (AFSD) has witnessed remarkable progress in the last decade because of its high build rate, simplicity of the process, and capability to produce metal components with high strength and fewer metallurgical defects. However, oxidation at the boundary layer is a major issue in utilising AFSD for recycled aluminium. Oxygen reacts with the deposited layer during the AFSD process, leading to micro-cracks and voids which affect the mechanical properties of the printed component. The main aim of this study is to break and mix a thin layer of Al2O3 on deposited layers to prevent micro-cracks and voids and enhance the mechanical properties. ANSYS® Fluent, UTM, Charpy impact testing and micro-hardness testing, EDS, SEM and CT scan will be used to optimise the tool and evaluate mechanical and microstructural properties. This research will open new possibilities for using the AFSD process in high-tech industries.

Research Areas and Interests

  • Additive Manufacturing
  • Thermo-fluids (Macro & Micro heat exchangers)
  • Materials and machining

Qualifications

  • MSc in Mechanical Engineering (Design and Manufacturing) – CECOS University, Pakistan, 2021.
  • BSc in Mechanical Engineering – CECOS University, Pakistan, 2016.

Supervisors

Contact

Numan Habib

School of Engineering
Email: n.habib@ecu.edu.au

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