| Abstract Scope |
The estimation of thermomechanical residual stress and distortion part-scale during fusion welding and metal additive manufacturing has by far remained a challenge due to immense computational demand, yet these predictions are needed to help prevent failures, enhance dimensional consistency, and improve manufacturing reliability. Several analytical and finite element method based numerical modelling attempts are presented in the literature to handle part-scale residual stress and distortion simulation in fusion welding and metal additive manufacturing. These modelling strategies are driven primarily by a trade-off between the computational tractability, which is achieved by means of simplifying assumptions, and the overall reliability of the full-field estimations. Although attempts are made to undertake the model simplifying assumptions based on mechanics based principles, the nature of evolution of the residual stress and distortion in part-scale is complex and has precluded a fit-for-all generalizations. As a result, many of these modelling approaches are successful but depend on calibration based on reliable experimental results. This work will present a broad overview of some of the recently reported analytical and numerical modelling strategies, and their competitive computational successes for fast, full-field estimations of residual stress and distortion in fusion welding and metal additive manufacturing. |