Wire and Arc Additive Layer Manufacturing (WAALM) is gaining increasing
popularity as the process allows the production of large custom-made metal
workpieces with high deposition rates. The high power input of the welding
process, causes significant residual stress and distortion of the workpiece.
This paper describes the thermo-mechanical behaviour of the multi-layer wall
structure made by the WAALM process. A 3D thermo-elastic–plastic transient model
and a model based on an advanced steady-state thermal analysis are employed in
this study. This modelling approach shows a significant advantage with respect
to the computational time. The temperature simulations and distortion
predictions are verified by comparing with the experimental results from thermo-
couples and laser scanners, while the residual stresses are verified with the
neutron diffraction strain scanner ENGIN-X. The stress across the deposited wall
is found uniform with very little influence of the preceding layers on the
following layers. The stress redistributed after unclamping with a much lower
value at the top of the wall than at the interface due to the bending distortion
of the samp
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