Measurement and Mitigation of Residual Stress in Wire-Arc Additive Manufacturing: A Review of Macro-Scale Continuum Modelling Approach

2020 ◽  
Author(s):  
Shekhar Srivastava ◽  
Rajiv Kumar Garg ◽  
Vishal S. Sharma ◽  
Anish Sachdeva
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Macro Scale ◽  
Continuum Modelling ◽  
Wire Arc Additive Manufacturing ◽  
Modelling Approach

Multi-physics continuum modelling approaches for metal powder additive manufacturing: a review

2020 ◽  
Vol 26 (4) ◽  
pp. 737-764 ◽  
Author(s):  
Shekhar Srivastava ◽  
Rajiv Kumar Garg ◽  
Vishal S. Sharma ◽  
Noe Gaudencio Alba-Baena ◽  
Anish Sachdeva ◽  
...  
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Powder Layer ◽  
Extensive Review ◽  
Content Type ◽  
Continuum Modelling ◽  
Mechanical Modelling ◽  
Mitigation Techniques ◽  
Am Processes ◽  
Modelling Approach

Purpose This paper aims to present a systematic approach in the literature survey related to metal additive manufacturing (AM) processes and its multi-physics continuum modelling approach for its better understanding. Design/methodology/approach A systematic review of the literature available in the area of continuum modelling practices adopted for the powder bed fusion (PBF) AM processes for the deposition of powder layer over the substrate along with quantification of residual stress and distortion. Discrete element method (DEM) and finite element method (FEM) approaches have been reviewed for the deposition of powder layer and thermo-mechanical modelling, respectively. Further, thermo-mechanical modelling adopted for the PBF AM process have been discussed in detail with its constituents. Finally, on the basis of prediction through thermo-mechanical models and experimental validation, distortion mitigation/minimisation techniques applied in PBF AM processes have been reviewed to provide a future direction in the field. Findings The findings of this paper are the future directions for the implementation and modification of the continuum modelling approaches applied to PBF AM processes. On the basis of the extensive review in the domain, gaps are recommended for future work for the betterment of modelling approach. Research limitations/implications This paper is limited to review only the modelling approach adopted by the PBF AM processes, i.e. modelling techniques (DEM approach) used for the deposition of powder layer and macro-models at process scale for the prediction of residual stress and distortion in the component. Modelling of microstructure and grain growth has not been included in this paper. Originality/value This paper presents an extensive review of the FEM approach adopted for the prediction of residual stress and distortion in the PBF AM processes which sets the platform for the development of distortion mitigation techniques. An extensive review of distortion mitigation techniques has been presented in the last section of the paper, which has not been reviewed yet.

Numerical simulation of the influence of the idle time on residual stress of walls deposited by wire + arc additive manufacturing

2020 ◽  
Vol 20 (2020) ◽  
pp. 412-413
Author(s):  
Francisco Werley Cipriano Farias ◽  
Augusto Veríssimo Passos ◽  
Victor Hugo Pereira Moraes E Oliveira ◽  
João da Cruz Payão Filho ◽  
Diego Russo Juliano ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Additive Manufacturing ◽  
Idle Time ◽  
Wire Arc Additive Manufacturing

scholarly journals Residual Stress Modeling with Phase Transformation for Wire Arc Additive Manufacturing of B91 Steel

JOM ◽  
2020 ◽  
Vol 72 (12) ◽  
pp. 4178-4186
Author(s):  
Xavier Jimenez ◽  
Wen Dong ◽  
Santanu Paul ◽  
Michael A. Klecka ◽  
Albert C. To
Keyword(s):  
Residual Stress ◽  
Phase Transformation ◽  
Additive Manufacturing ◽  
Stress Modeling ◽  
Wire Arc Additive Manufacturing ◽  
Residual Stress Modeling

scholarly journals Residual Stress and Microstructure of a Ti-6Al-4V Wire Arc Additive Manufacturing Hybrid Demonstrator

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 701
Author(s):  
Tatiana Mishurova ◽  
Benjamin Sydow ◽  
Tobias Thiede ◽  
Irina Sizova ◽  
Alexander Ulbricht ◽  
...  
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Structural Integrity ◽  
Hybrid Approach ◽  
Aerospace Applications ◽  
Machined Parts ◽  
Functional Features ◽  
Tool Set ◽  
Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) features high deposition rates and, thus, allows production of large components that are relevant for aerospace applications. However, a lot of aerospace parts are currently produced by forging or machining alone to ensure fast production and to obtain good mechanical properties; the use of these conventional process routes causes high tooling and material costs. A hybrid approach (a combination of forging and WAAM) allows making production more efficient. In this fashion, further structural or functional features can be built in any direction without using additional tools for every part. By using a combination of forging basic geometries with one tool set and adding the functional features by means of WAAM, the tool costs and material waste can be reduced compared to either completely forged or machined parts. One of the factors influencing the structural integrity of additively manufactured parts are (high) residual stresses, generated during the build process. In this study, the triaxial residual stress profiles in a hybrid WAAM part are reported, as determined by neutron diffraction. The analysis is complemented by microstructural investigations, showing a gradient of microstructure (shape and size of grains) along the part height. The highest residual stresses were found in the transition zone (between WAAM and forged part). The total stress range showed to be lower than expected for WAAM components. This could be explained by the thermal history of the component.

Residual stress distributions in thick specimens excavated from a large circular wire+arc additive manufacturing mockup

2020 ◽  
Vol 56 ◽  
pp. 474-481
Author(s):  
Chuan Liu ◽  
Changhua Lin ◽  
Jianfei Wang ◽  
Jianxin Wang ◽  
Lianju Yan ◽  
...  
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Stress Distributions ◽  
Wire Arc Additive Manufacturing

scholarly journals Effect of Phase Transformations on Scanning Strategy in WAAM Fabrication

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7871
Author(s):  
Muhammad Hassaan Ali ◽  
You Sung Han
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Phase Transformations ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Stress Generation ◽  
Temperature History ◽  
History Of ◽  
Wire Arc Additive Manufacturing

Due to its high production rates and low cost as compared to other metal additive manufacturing processes, wire arc additive manufacturing (WAAM) has become an emerging technology in the manufacturing industry. However, the residual stress generation and part distortion hinder its widespread adoption because of the complex thermal build-histories of WAAM parts. One of the ways to alleviate this problem is to consider the effects of scan strategies as it directly influences the thermal history of the built part. Since WAAM itself is an evolved welding process and even though it is evident from welding studies that phase transformations directly affect the residual stresses in welded parts, it remains unclear how the consideration of phase transformations for different scan strategies will affect the residual stresses and distortions in the WAAMed parts. A FEM study has been performed to elucidate the effects of phase transformations on residual stresses and the distortion for different deposition patterns. The current findings highlight that for the fabrication of low-carbon martensitic steels: The consideration of phase transformations for line-type discontinuous patterns (alternate and raster) do not significantly affect the residual stresses. Consideration of phase transformations significantly affects residual stresses for continuous patterns (zigzag, in–out and out–in). To accurately simulate complex patterns, phase transformations should be considered because the patterns directly influence the temperature history of the built part and will thus affect the phase transformations, the residual stresses and the warpage. During the fabrication of WAAM parts, whenever possible, discontinuous line scanning patterns should be considered as they provide the part with uniform residual stress and distortion. The alternate line pattern has been found to be the most consistent overall pattern.

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