Parametric study of residual stress formation in Wire and Arc Additive Manufacturing

A finite element model was created to simulate the Wire Arc Additive Manufacturing (WAAM) thermal and mechanical processes of Inconel 718 on a A36 steel substrate, as well as the effects of process parameters on Residual Stress (RS). The model was verified using temperature data obtained from three...

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Bibliographic Details
Published in:	Journal of manufacturing processes Vol. 75; pp. 863 - 876
Main Authors:	Abusalma, H., Eisazadeh, H., Hejripour, F., Bunn, J., Aidun, D.K.
Format:	Journal Article
Language:	English
Published:	United States Elsevier Ltd 01-03-2022 Society of Manufacturing Engineers; Elsevier
Subjects:	MATERIALS SCIENCE Neutron diffraction Numerical simulation Residual stress Wire Arc Additive Manufacturing (WAAM) Numerical simulation Wire Arc Additive Manufacturing (WAAM) Neutron diffraction Residual stress
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Summary:	A finite element model was created to simulate the Wire Arc Additive Manufacturing (WAAM) thermal and mechanical processes of Inconel 718 on a A36 steel substrate, as well as the effects of process parameters on Residual Stress (RS). The model was verified using temperature data obtained from three thermocouples attached to the upper surface of the build substrate and micro-strain measurements obtained from Neutron Diffraction (ND) measurement. The model was then used to study the effects of changing the torch travel speed and interlayer dwell time. The study found that travel speed has little effect on RS when maintaining the same heat input rate. As well, the interlayer dwell time has a strong effect on RS. Reducing the dwell time causes the stress profiles to become relatively uniform and a high-stress region extends deeper along the build direction. This study provides important insight into mechanical stresses inside large walls made by the WAAM method.
Bibliography:	USDOE Office of Science (SC), Basic Energy Sciences (BES) AC05-00OR22725
ISSN:	1526-6125 2212-4616
DOI:	10.1016/j.jmapro.2022.01.043