Mathematically Compensating for the Barrelling Effect Occurring During Compression Testing of Additive-Manufactured A20X Samples and Describing Friction with Validated Finite Element Models

This study examines the deformation behaviour of laser powder bed fusion-produced A20X aluminium alloy and its accurate representation using flow curve models that account for die–specimen friction. Tests across multiple strain rates at room temperature were conducted on a Gleeble 3800; force–displacement data were friction-corrected to derive constitutive flow curves. A mathematical model was developed to capture barrelling and its impact on the stress–strain response, yielding corrected stresses significantly lower than measured values and validating the correction. An equation linking key post-deformation geometric parameters to their mathematical representation correlated well with a calibrated 2D finite element model, which reliably predicted plastic strain and deformation. The model’s friction factors agreed with experimental data, enabling efficient determination of the friction coefficient. Microstructural analysis and micrographs supported the predicted plastic strain distributions. Together, the corrected experiments and validated simulations provide a robust description of A20X’s response and inform performance and application potential.