About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Additive Manufacturing of Metals: Multiscale and Non-Equilibrium Solidification Fundamentals
|
| Presentation Title |
Active Thermal Management for Residual Stress Control and Microstructural Refinement in Wire-Arc Direct Energy Deposition (W-DED) |
| Author(s) |
aleksander Angel Aleman, Tyler Dolmetsch, Sohail Mohammed, Tanaji Paul, Arvind Agarwal |
| On-Site Speaker (Planned) |
aleksander Angel Aleman |
| Abstract Scope |
Thermal gradients inherent in the W-DED process often result in dimensional distortion and residual stress accumulation. To mitigate these limitations and induce beneficial internal stresses, this study introduces an actively controlled thermal management system. The system employs a combination of water cooling, resistance heating, and localized induction heating to precisely regulate temperature in real time. Experimental trials on mild steel demonstrated that constant active cooling enhanced thermal control, resulting in a 24% increase in bead height across five deposited layers. Microstructural analysis revealed a significant refinement under constant cooling, and highest microhardness of 231.3 HV, compared to 201.0 HV in the uncontrolled baseline. Among the controlled temperature conditions, the 100 °C sample exhibited a finer microstructure and higher hardness than the 200 °C condition. Thermal penetration depth varied notably with substrate temperature. These findings indicate that precise thermal regulation not only minimizes excessive heat accumulation but also optimizes microstructural characteristics. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Iron and Steel, Aluminum |