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<p>Wire arc additive manufacturing (WAAM) is an advanced and cost-effective technique for fabricating large-scale metal components; however, the process induces significant residual stress due to complex thermal cycles, leading to defects such as deformation and cracking. This study presents a generalized finite element analysis (FEA) model to investigate the temperature distribution and residual stresses evolution during the GTAW-based WAAM process. A thermo-mechanical explicit model was developed using Ansys software and validated experimentally using K-type thermocouples and X-ray diffraction (XRD) techniques. Additionally, detailed mechanical characterization, including tensile strength, impact strength, hardness, and electron backscatter diffraction (EBSD)-based microstructural analysis, was conducted. The numerical simulation demonstrated strong agreement with experimental results, with a maximum relative error of less than 8%. The findings reveal that WAAM-fabricated ER70S-6 components exhibit almost homogenous and isotropic mechanical properties throughout the build wall, indicating superior structural integrity.</p>

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Thermo-Mechanical Modeling and Experimental Validation of Residual Stresses in ER70S-6 Component Manufactured by WAAM Process

  • 期刊论文

  • 发表日期：

    2025年6月25日

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  • Deepak Kumar Gupta,
  • Rahul S. Mulik

摘要

Wire arc additive manufacturing (WAAM) is an advanced and cost-effective technique for fabricating large-scale metal components; however, the process induces significant residual stress due to complex thermal cycles, leading to defects such as deformation and cracking. This study presents a generalized finite element analysis (FEA) model to investigate the temperature distribution and residual stresses evolution during the GTAW-based WAAM process. A thermo-mechanical explicit model was developed using Ansys software and validated experimentally using K-type thermocouples and X-ray diffraction (XRD) techniques. Additionally, detailed mechanical characterization, including tensile strength, impact strength, hardness, and electron backscatter diffraction (EBSD)-based microstructural analysis, was conducted. The numerical simulation demonstrated strong agreement with experimental results, with a maximum relative error of less than 8%. The findings reveal that WAAM-fabricated ER70S-6 components exhibit almost homogenous and isotropic mechanical properties throughout the build wall, indicating superior structural integrity.