About this Abstract |
| Meeting |
2025 AWS Professional Program
|
| Symposium
|
2025 AWS Professional Program
|
| Presentation Title |
Analysis of Residual Stress Evolution in Wire-DED: Influence of Phase Transformation Using Thermal Sensing and Finite Element Modeling |
| Author(s) |
Yousub Lee, Rangasayee Kannan, Miguel Hoffmann Rodriguez, Mario Rodriguez Parra, Wen Dong, Tom Feldhausen, Srdjan Simunovic |
| On-Site Speaker (Planned) |
Yousub Lee |
| Abstract Scope |
Advanced manufacturing techniques generate unique distributions of thermal and mechanical signatures leading to complex physical metallurgy interactions among the feedstock, process, microstructure, properties, and performance. These interactions consequently influence part deformation behavior. The multi-scale nature of these physical metallurgy interactions challenges conventional manufacturing and verification and validation approaches in areas such as process optimization, process planning, and high-quality component design. Modeling and simulation tools that predict and control these interactions are critical for efficiently optimizing advanced manufacturing processes and enhancing the quality and performance of large, complex components. The current research trend in predicting residual stress evolution in wire-DED necessitates a multidisciplinary approach integrating advanced in-situ sensing, modeling techniques, and an understanding of dynamic phase evolution. These efforts aim to improve the predictability and control of residual stress, thereby enhancing the structural integrity and performance of wire-DED components.
In this research, we focus on rationalizing the influence of phase transformation on residual stress evolution in various printing conditions of wire-DED. Two walls, one straight and one L-shaped, were printed with thermal sensors. Analysis of the voxelated infrared (IR) data showed that the martensite start (Ms) temperatures can be determined for all voxels by identifying the inflection points in each cooling curve. The Ms temperature was found to vary with voxel position corresponding to build height. These findings suggest that incorporating spatial variations in Ms temperature into thermo-mechanical simulations can improve the accuracy of residual stress predictions in the wire-DED parts. A wire-DED specific CCT diagram is generated using CALPHAD method to support enhanced phase transformation prediction and will be experimentally validated using the Gleeble test. Local heterogeneities in phase fractions will be characterized using SEM and EBSD to validate the finite element thermo-kinetic (phase evolution)–mechanical model. |
| Proceedings Inclusion? |
Undecided |