About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
In-Situ Monitoring and Control of Solidification & Deformation Processes in Metal Additive Manufacturing
|
| Presentation Title |
Tailoring Phase Transformation and Residual Stress in Wire-DED via Thermal Sensing and Multiphysics Modeling |
| Author(s) |
Yousub Lee, Rangasayee Kannan, Miguel Hoffmann Rodriguez, Mario Rodriguez Parra, Wen Dong, Thomas Feldhausen, Srdjan Simunovic |
| On-Site Speaker (Planned) |
Yousub Lee |
| Abstract Scope |
Advanced manufacturing techniques involve complex interactions among the heat source, material, and geometry, leading to distinct thermal, metallurgical, and mechanical behavior. These interactions influence material properties and challenge traditional process optimization, planning, and real-time certification. We integrate in-situ sensing, modeling, and phase transformation analysis to improve process control and part quality. In this study, straight and L-shaped walls were printed using wire-based directed energy deposition (DED) with embedded thermal sensors. A shift in martensite starting temperature along the build direction (220 °C to 330 °C) was captured using voxelated infrared (IR) data and its effects on microstructure, hardness, and residual stress were investigated. Phase evolution and local heterogeneity were predicted using a metallurgical model and validated through SEM and EBSD. A wire-DED-specific CCT diagram generated using CALPHAD and Gleeble tests supports improved predictions of phase transformation and residual stress. Process tailoring will be demonstrated by controlling martensite temperature shift and interpass temperature. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Modeling and Simulation, Phase Transformations |