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Thermo-mechanical analysis of Wire and Arc Additive Layer Manufacturing process on large multi-layer parts

By J. Ding, Paul A. Colegrove, Jorn Mehnen, Supriyo Ganguly, P. M. Sequeira Almeida, F. Wang and Stewart W. Williams


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

Topics: Additive Layer Manufacturing Thermo-mechanical analysis Lagrangian model Eulerian model Residual stress Distortion
Publisher: Elsevier Science B.V., Amsterdam.
Year: 2011
DOI identifier: 10.1016/j.commatsci.2011.06.023
OAI identifier:
Provided by: Cranfield CERES

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