About this Abstract |
| Meeting |
2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Symposium
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2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
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| Presentation Title |
Build-Plate-Free Wire-Arc Direct Energy Deposition: Neutron Diffraction and Computational Study |
| Author(s) |
Aslan Nasirov, Wen Dong, Christopher Fancher, Bhagya Prabhune, Jerry Anzalone, Russel Stein, Srdjan Simunovic, Andrzej Nycz, Yousub Lee |
| On-Site Speaker (Planned) |
Aslan Nasirov |
| Abstract Scope |
Wire-arc Direct Energy Deposition (Wire-arc DED) enables efficient fabrication of large metallic components because of its high deposition rate and high material efficiency but relies on a build plate to constrain deformation during printing. Build-plate-free (“freeform”) approach provides greater geometric flexibility but introduces additional challenges in predicting and controlling residual stresses. This study proposes a simulation framework for predicting residual strain in freeform wire-arc DED and validates the predictions using neutron diffraction measurements. Three wall parts were investigated: (i) an as-deposited wall using conventional 3-axis deposition, (ii) a wall after build-plate removal, and (iii) a 5-axis freeform wall. Residual strains were measured at ORNL’s neutron facility, High Flux Isotope Reactor (HFIR). Sequentially coupled thermo-mechanical finite element simulations, modeling the deposition process, captured the measured residual strain trends for all three walls and demonstrated the capability of the modeling approach to predict residual strain evolution in freeform Wire-arc DED. |
| Proceedings Inclusion? |
Undecided |