About this Abstract |
| Meeting |
TMS Specialty Congress 2026
|
| Symposium
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World Congress on Reproducibility, Qualification, and Standards Development of Additive Manufacturing and Beyond (RQSD 2026)
|
| Presentation Title |
FEA Thermal-History-Guided Correlation of Spatial Geometry Evolution and Layer-Resolved Heterogeneity in Robotic CMT-Based WAAM of AA2319 Al–Cu Alloy |
| Author(s) |
Deepak Kumar, Sunil Jha |
| On-Site Speaker (Planned) |
Deepak Kumar |
| Abstract Scope |
Wire Arc Additive Manufacturing (WAAM) of Al–Cu alloys offers a promising route for fabricating high–strength aerospace structures. However, spatial variability in geometry and properties remains a key challenge to reproducibility. In this work, a FEA thermal-history-guided framework is extended to establish a quantitative correlation between spatially varying thermal cycles and build-height-dependent geometric evolution in robotic CMT-WAAM of AA2319. Three-dimensional transient thermal simulations incorporating a Goldak double-ellipsoidal heat source and layer-wise activation predict systematic increases in peak temperature, interpass baseline temperature, and the number of layers experiencing temperatures above the eutectic threshold with increasing build height. Experimental measurements reveal corresponding increases in lateral material flow and progressive bead width expansion along wall height. The results demonstrate that cumulative thermal exposure governs melt pool stability and geometric consistency in WAAM AA2319. This study provides fundamental insight into thermal-driven geometry variation and establishes a foundation for reproducible geometry control in WAAM process design. |
| Proceedings Inclusion? |
Undecided |