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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing Modeling, Simulation and Artificial Intelligence
Presentation Title F-38: Simulation and Experimental Investigation of Dual-Side Deposition Strategy for Deformation Control in DED-Arc
Author(s) Shubham Agarwal, Neel Kamal Gupta, Henning Zeidler
On-Site Speaker (Planned) Neel Kamal Gupta
Abstract Scope This study presents a simulation-driven and experimentally validated investigation into deformation control in Directed Energy Deposition-Arc (DED-Arc) of aluminium alloys using a dual-side deposition strategy. Multi-layer welds on Al 6082 substrates with Al 4043 filler wire were modelled using Simufact Welding to assess Z-axis deformation. Aluminium’s high thermal conductivity and low melting point make it particularly susceptible to thermal distortion during deposition. The proposed dual-side approach involves flipping the substrate between layer sets, allowing for more balanced heat distribution and stress relief across the build. Simulation results indicated that alternating deposition sides every 2–3 layers reduced peak deformation by up to 64% compared to conventional single-sided builds. Experimental trials confirmed the trend, showing strong agreement with the numerical predictions. This dual-side strategy offers a scalable, practical solution for enhancing dimensional accuracy in WAAM processes, with direct applicability to large-format and structural aluminium components in aerospace and industrial manufacturing.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Aluminum, Other

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