About this Abstract |
| Meeting |
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
|
| Symposium
|
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
|
| Presentation Title |
Deformation Control in Wire Arc Additive Manufacturing via a Secondary Heat Source |
| Author(s) |
Conor Savage, Tao Liu, Chinedum Okwudire |
| On-Site Speaker (Planned) |
Conor Savage |
| Abstract Scope |
Wire Arc Additive Manufacturing (WAAM) often suffers from significant deformation due to non-uniform cooling and large thermal gradients, particularly in cantilevered or overhanging structures. Mitigating such deformation remains a major challenge. In this work, we propose a physics-based, feedforward control strategy that utilizes a secondary heat source to locally modify the thermal field during fabrication. Instead of relying on complex numerical models or full analytical solutions, a simplified three-bar thermo-mechanical model is developed to capture the essential relationship between thermal gradients and structural deformation. This reduced-order model enables rapid prediction of deformation and guides the optimization of secondary heating strategies. By locally adjusting cooling rates and thermal gradients during fabrication, effective deformation control becomes feasible. Finite element simulations are conducted to validate the predictions of the simplified model. The results demonstrate that targeted secondary heating, informed by a physics-based reduced-order model, can improve distortion control in WAAM. |
| Proceedings Inclusion? |
Planned: Post-meeting proceedings |