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<p>One of the propitious concepts in additive manufacturing is wire arc additive manufacturing&#xa0;(WAAM) as it can be used to fabricate customized parts with high deposition rates. This process consists of the deposition of wire on the substrate through a heat source via an electric arc. Path planning strategies and thermal management are important aspects as they can affect the accuracy of the part. The objective of the present work is to observe the temperature profile and heat flux distribution of the model throughout the welding cycle. The temperature profiles at different sections of the model are also presented. Moreover, transient structural analysis has also been performed by coupling with the thermal load to predict the mechanical behavior of the body to determine the deformation and thermal strain caused. In this study, a finite element model was developed and analyzed by transient thermal module in ANSYS 2021 R2 software through a Gaussian moving heat source. The materials used for the substrate and filler wire were AA 6061-T6 and Al 5183 respectively. It was found that the temperature of the deposited layer reached about 1380&#xa0;°C at the end of the deposition path. The temperature increased abruptly when the moving heat source passed at the turning edges along the deposition path. The total deformation was approximately 0.427&#xa0;mm. The minimum and maximum thermal strains were approximately 0.012 and 0.035, respectively. The strain energy was higher on the substrate than on the weld bead because of greater thermal strain.</p>

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Modeling and Thermal-Structural Transient Simulation of Al Alloy Processed by Wire Arc Additive Manufacturing Using Gaussian Moving Heat Source

  • 期刊论文

  • 发表日期：

    2025年7月2日

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  • Ipsit Mishra,
  • Rajeev Srivastava

摘要

One of the propitious concepts in additive manufacturing is wire arc additive manufacturing (WAAM) as it can be used to fabricate customized parts with high deposition rates. This process consists of the deposition of wire on the substrate through a heat source via an electric arc. Path planning strategies and thermal management are important aspects as they can affect the accuracy of the part. The objective of the present work is to observe the temperature profile and heat flux distribution of the model throughout the welding cycle. The temperature profiles at different sections of the model are also presented. Moreover, transient structural analysis has also been performed by coupling with the thermal load to predict the mechanical behavior of the body to determine the deformation and thermal strain caused. In this study, a finite element model was developed and analyzed by transient thermal module in ANSYS 2021 R2 software through a Gaussian moving heat source. The materials used for the substrate and filler wire were AA 6061-T6 and Al 5183 respectively. It was found that the temperature of the deposited layer reached about 1380 °C at the end of the deposition path. The temperature increased abruptly when the moving heat source passed at the turning edges along the deposition path. The total deformation was approximately 0.427 mm. The minimum and maximum thermal strains were approximately 0.012 and 0.035, respectively. The strain energy was higher on the substrate than on the weld bead because of greater thermal strain.