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<p>Restoration of historical components has become an increasingly important topic in recent years, driven by the growing use of additive manufacturing (AM) technologies. However, the tendency of these methods to introduce significant residual stresses in restored components remains insufficiently understood, potentially hindering the reliable utilization of such parts. In light of this, this article compares the residual stress distribution in pedals manufactured using selective laser melting (SLM) method and wire arc additive manufacturing (WAAM) method. This article compares residual stress distributions in pedals manufactured using selective laser melting (SLM) method and wire arc additive manufacturing (WAAM) method. Semi-destructive hole drilling method (HDM) and destructive sectioning method are employed for residual stress investigation. Finite Element Analysis (FEA) software (Ansys Workbench and Simufact Additive) is used for simulating residual stress distribution in the metal 3D-printed components. The obtained data helps in understanding how residual stresses are distributed in the parts produced using these two technologies. The results from physical tests indicate that the pedal manufactured using the WAAM method retains significantly fewer residual stresses than its SLM counterpart, primarily due to the temperature condition in the manufacturing process. During the WAAM deposition, there is a tempering effect on the previous layers, which reduces residual stresses in the weldment. This study thus highlights the advantages and disadvantages of both methods in the context of residual stresses and practical applications.&#xa0;</p>

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Comparative analysis of residual stress distributions in a braking pedal from a historical motorbike manufactured via selective laser melting and wire arc additive manufacturing

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年4月28日

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  • Lukáš Kudrna,
  • František Fojtík,
  • Jindřich Kozák,
  • Petra Váňová,
  • Quoc-Phu Ma,
  • Jiří Hajnyš,
  • Roman Potrok,
  • Jakub Měsíček

摘要

Restoration of historical components has become an increasingly important topic in recent years, driven by the growing use of additive manufacturing (AM) technologies. However, the tendency of these methods to introduce significant residual stresses in restored components remains insufficiently understood, potentially hindering the reliable utilization of such parts. In light of this, this article compares the residual stress distribution in pedals manufactured using selective laser melting (SLM) method and wire arc additive manufacturing (WAAM) method. This article compares residual stress distributions in pedals manufactured using selective laser melting (SLM) method and wire arc additive manufacturing (WAAM) method. Semi-destructive hole drilling method (HDM) and destructive sectioning method are employed for residual stress investigation. Finite Element Analysis (FEA) software (Ansys Workbench and Simufact Additive) is used for simulating residual stress distribution in the metal 3D-printed components. The obtained data helps in understanding how residual stresses are distributed in the parts produced using these two technologies. The results from physical tests indicate that the pedal manufactured using the WAAM method retains significantly fewer residual stresses than its SLM counterpart, primarily due to the temperature condition in the manufacturing process. During the WAAM deposition, there is a tempering effect on the previous layers, which reduces residual stresses in the weldment. This study thus highlights the advantages and disadvantages of both methods in the context of residual stresses and practical applications.