About this Abstract |
| Meeting |
2025 AWS Professional Program
|
| Symposium
|
2025 AWS Professional Program
|
| Presentation Title |
Probing Residual Stress and Distortion in Wire Arc Directed Energy Deposition Using a Convective Heat Transport Assisted Thermomechanical Model |
| Author(s) |
Wei Zhang, Diljit P K, Aryan Fnu, Amitava De |
| On-Site Speaker (Planned) |
Amitava De |
| Abstract Scope |
INTRODUCTION: The residual stress and distortion during wire arc directed energy deposition (DED-Arc) is routinely evaluated by numerical models that require an input of the deposit profile in advance and limits the usability of these models. We present here a novel pathway to compute the actual deposit profile using a comprehensive heat transfer and fluid flow model, and undertake a sequential heat transfer and mechanical analysis to compute the residual stress and distortion resulting a self-consistent framework. The proposed approach is tested rigorously for DED-Arc of thin wall and blocks for diverse filler wire alloys.
TECHNICAL APROACH: A heat transfer and fluid flow model is used first to simulate DED-Arc with filler wire deposition, and compute the deposit profile by using the volume of fluid method. The computed deposit profile is next used to constitute the solution domain for a sequential heat conduction and thermomechanical stress analysis thereby alleviating the need for simplified assumptions of the deposit profile. The reduced computational demand for a heat conduction analysis in comparison to a heat transfer and fluid flow model allows the consideration of a near part-scale geometry for the analysis of residual stress and distortion.
RESULTS AND DISCUSSIONS: The heat transfer and fluid flow model could simulate DED-Arc of thin wall and block structure for diverse conditions in small deposit volumes. The computed deposit profile for a given condition is used to construct the solution domain for the subsequent heat transfer and thermomechanical analysis notably in a near part-scale deposit volume. The computed residual stress and distortion are found to be much closer to the corresponding experimentally measured results. The overall scheme is tested rigorously for multiple DED-Arc conditions in the literature.
CONCLUSION: The proposed scheme offers a self-consistent, fundamental and substantive route to compute residual stress and distortion in part-scale DED-Arc. |
| Proceedings Inclusion? |
Undecided |