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Abstract <p>The gas metal arc-wire direct energy deposition (DED) process is best suited for producing large-scale parts, reduced material waste, and better deposition rates than other AM processes. One of the key challenges of arc-wire DED-made components is related to the thermally induced residual stresses and distortion. The temperature gradient is caused mainly due to localized heat input, and an accumulation of excessive heat in the fabricated part often leads to undesirable failures, such as poor dimensional tolerances due to the generation of residual stresses and degradation of mechanical properties. Therefore, it is crucial to understand the influencing factors that impact the generation and distribution of residual stress in arc-wire DED-made components. The present study employs a finite element analysis based on the physically derived instantaneous heat source model to simulate the evolution of residual stress and distortion during the aluminium alloy 4047 filler material deposition on aluminium alloy (A1050, A6060) substrates. This work examined numerical investigations on three different substrates: a block (Case I), a large plate (Case II), and a small plate (Case III) that simulate the various use case scenarios of employing arc-wire DED processes for repair and additive manufacturing. The numerical results were validated with experimentally measured results. The thermo-mechanical simulation based on the proposed approach predicted the peak temperature with a mean relative error of 3.3%, 4.8%, and 3.4% for the three cases, respectively. Furthermore, the magnitude and variation trend of the residual stress and distortion in Case III are reasonably accurate with the experimental results. The simulated results from the proposed approach show the significance of the physically derived instantaneous arc power and heat source process parameters, along with the definite boundary conditions, in accurately predicting distortion and residual stresses of arc-wire DED-processed parts.</p> Graphical abstract <p></p>

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Physically derived instantaneous modelling of complex current-voltage waveform-controlled arc-wire DED process—residual stress and distortion analysis

  • 期刊论文

  • 发表日期：

    2025年4月23日

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  • Pradeep Nagaraj,
  • Saravana Kumar Gurunathan,
  • Murugaiyan Amirthalingam

摘要

Abstract

The gas metal arc-wire direct energy deposition (DED) process is best suited for producing large-scale parts, reduced material waste, and better deposition rates than other AM processes. One of the key challenges of arc-wire DED-made components is related to the thermally induced residual stresses and distortion. The temperature gradient is caused mainly due to localized heat input, and an accumulation of excessive heat in the fabricated part often leads to undesirable failures, such as poor dimensional tolerances due to the generation of residual stresses and degradation of mechanical properties. Therefore, it is crucial to understand the influencing factors that impact the generation and distribution of residual stress in arc-wire DED-made components. The present study employs a finite element analysis based on the physically derived instantaneous heat source model to simulate the evolution of residual stress and distortion during the aluminium alloy 4047 filler material deposition on aluminium alloy (A1050, A6060) substrates. This work examined numerical investigations on three different substrates: a block (Case I), a large plate (Case II), and a small plate (Case III) that simulate the various use case scenarios of employing arc-wire DED processes for repair and additive manufacturing. The numerical results were validated with experimentally measured results. The thermo-mechanical simulation based on the proposed approach predicted the peak temperature with a mean relative error of 3.3%, 4.8%, and 3.4% for the three cases, respectively. Furthermore, the magnitude and variation trend of the residual stress and distortion in Case III are reasonably accurate with the experimental results. The simulated results from the proposed approach show the significance of the physically derived instantaneous arc power and heat source process parameters, along with the definite boundary conditions, in accurately predicting distortion and residual stresses of arc-wire DED-processed parts.

Graphical abstract