About this Abstract |
| Meeting |
2025 AWS Professional Program
|
| Symposium
|
2025 AWS Professional Program
|
| Presentation Title |
Towards Expediating Residual Stress and Distortion Calculations for Part Scale Wire Arc Directed Energy Deposition Considering an Initial Stress |
| Author(s) |
Kajal Khan, Amitava De |
| On-Site Speaker (Planned) |
Amitava De |
| Abstract Scope |
INTRODUCTION: Wire arc directed energy deposition (DED-Arc) is increasingly utilized for manufacturing three-dimensional components by melting and depositing filler wire across overlapping tracks and successive layers resulting high residual stress and distortion. Routine finite element method based heat transfer and stress analyses are often computationally unrealistic. We present here a recourse to calculate residual stress and distortion for part scale DED-Arc considering an initial stress field for a deposited layer.
TECHNICAL APPROACH: A novel approach is developed to compute residual stress and distortion in part-scale DED-Arc that incorporates layer-by-layer melting and cool down but ignores the transient temperature history. The discrepancy in computed stress field due to the neglect of temperature history is adjusted based on an input initial stress tensor, determined using back-of-the-envelope relations and experimental results from literature for a range of DED-Arc conditions.
RESULT AND DISCUSSION: The proposed model is validated against experimentally measured residual stress and distortion for DED-Arc of diverse alloys with a discrepancy well within 20%. Compared to full-fidelity track-by-track heat transfer and stress analysis, the computational time and memory requirements of the proposed model are reduced by 2-3 orders of magnitude, thereby, significantly enhancing the efficiency while maintaining predictive accuracy.
CONCLUSION : An easy-to-use numerical modelling framework is proposed for a fast and reliable calculation of full-field residual stress and distortion at part scale DED-Arc. The model is easy to implement without the need for numerous small-scale tedious numerical experiments and associated experimental validations. Amongst several on-going efforts for feasible and expedited calculations of residual stress and distortion in part-scale DED-Arc, the proposed initial stress based numerical modelling stands unique by the ease of its adaptability to the diverse range of parametric conditions and deposit geometry. |
| Proceedings Inclusion? |
Undecided |