| Abstract Scope |
An overview of the residual stresses in cold-spray additive manufacturing will be given. Residual stresses in additive manufacturing are known to depend on deposition stress and on the mismatch in the coefficients of thermal expansion. The effects of the substrate fixturing conditions are suspected to contribute to the residual stresses but have not been investigated systematically. Voxel-by-voxel deposition simulations using the finite element method have been helpful in identifying previously unknown details of the residual stress distribution, but they are time-consuming to perform large-scale parametric studies. In this work, a closed-form solution for layer-by-layer additive manufacturing, extending the well-known Tsui-and-Cline method, is developed for a range of clamp conditions. This solution provides a clear view of the relationships between the deposit and substrate size, clamp conditions, deposition temperature, and residual stress state. Time permitting, experiments will be conducted and reported to verify the model. |