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

Abusalma, Hisham; Eisazadeh, Hamid; Hejripour Rafsanjani, Fatemah; Bunn, Jeffrey R.; Aidun, Daryush K.

doi:10.1016/j.jmapro.2022.01.043

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

Journal Article · 31 January 2022 · Journal of Manufacturing Processes

DOI: https://doi.org/10.1016/j.jmapro.2022.01.043 · OSTI ID:1888941

Abusalma, Hisham ^[1]; Eisazadeh, Hamid ^[1]; Hejripour Rafsanjani, Fatemah ^[2];

^[3]; Aidun, Daryush K. ^[4]

Old Dominion Univ., Norfolk, VA (United States)
Binghamton Univ., NY (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Clarkson Univ., Potsdam, NY (United States)

Here, 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.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1888941

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Vol. 75; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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