Novel process parameters based approach for reducing residual stresses in WAAM

Panicker, C.T. Justus; Surya, K. Rohit; Senthilkumar, V.

doi:10.1016/j.matpr.2022.03.025

Cited by 6 publications

(2 citation statements)

References 15 publications

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“…The effect of grain morphology on solidification residual stresses is of interest but considered beyond the scope of this article. Further details related to DED-arc can be found in [41][42][43] .…”

Section: Discussionmentioning

confidence: 99%

Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing

2023

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Bimetallic wire arc additive manufacturing (AM) has traditionally been limited to depositions characterized by single planar interfaces. This study demonstrates a more complex radial interface concept, with in situ mechanical interlocking and as-built properties suggesting a prestressed compressive effect. A 308 L stainless core is surrounded by a mild steel casing, incrementally maintaining the interface throughout the Z-direction. A small difference in the thermal expansion coefficient between these steels creates residual stresses at their interface. X-ray diffraction analysis confirms phase purity and microstructural characterization reveals columnar grain growth independent of layer transitions. Hardness values are consistent with thermal dissipation characteristics, and the compressive strength of the bimetallic structures shows a 33% to 42% improvement over monolithic controls. Our results demonstrate that biomimetic radial bimetallic variation is feasible with improved mechanical response over monolithic compositions, providing a basis for advanced structural design and implementation using arc-based metal AM.

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Section: Discussionmentioning

confidence: 99%

Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing

2023

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“…Welding metals is a process that includes heating and cooling cycles, which strongly influences chemical-metallurgical reactions in liquid metal, phase transformations, grain growth, and therefore final material mechanical properties [12]. To better understand the mechanisms taking place during WAAM and to minimize the costs of experimental investigations at the same time, a simulation approach is eagerly applied, where not only finite element models [11,[13][14][15][16][17], but also neural networks [16,18,19] or mathematical [20], recursive models [21] are increasingly used. However, to accurately simulate the final properties of the part obtained by the WAAM process, a realistic heat source shape and distribution is necessary [22].…”

Section: Introductionmentioning

confidence: 99%

Determination of welding heat source parameters for fem simulation based on temperature history and real bead shape

Szyndler

2023

Materials Research Proceedings

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Abstract. To improve process understanding and increase the numerical prediction quality of a wire arc additive manufacturing (WAAM) process, this paper focuses on determining the parameters of a numerical model that reproduces an experimental setup of a welding process, with particular attention given to the actual shape of the weld bead. The dimensions of the heat source (HS) model in a welding process are determined based on experimentally measured weld pool sizes as well as temperature history at selected points below and adjacent to a weld seam. The whole experimental setup is accurately reproduced within the Simufact.Welding software and an optimization procedure is applied to obtain the best possible agreement between experimental and numerical results. A validated numerical model with reliable parameters for two heat sources is later used to predict and observe material behavior during the WAAM process of more complex parts.

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