Measurement and modelling of residual stress in wire-feed additively manufactured titanium

ABSTRACT

Residual stresses were characterised in a wire-feed additively manufactured titanium alloy component. A numerical simulation based on the inherent strain method was used to model residual stresses arising from the manufacturing process. The contour method was used to experimentally determine the residual stress field. High tensile residual stresses were seen at and around the interface of the substrate and the deposited metal. Compressive residual stresses were present in the substrate and at the top of the deposit. The satisfactory correlation was achieved between the results from the numerical simulation and the contour method, except for the location of the root of the deposit. The effect of pre-heating the sample substrate on the residual stress distribution is also discussed.

KEYWORDS:

• Wire-feed additive manufacturing
• residual stress
• inherent strain-based method
• contour method
• titanium

Acknowledgements

The authors would like to thank Fred Carter and colleagues at Sciaky for providing the WFAM sample. The authors are also thankful to Steve Damms at The Institute for Advanced Manufacturing and Engineering, Coventry University, for his help with the WEDM. M. E. Fitzpatrick is grateful for funding from the Lloyd's Register Foundation, a charitable foundation helping to protect life and property by supporting engineering-related education, public engagement and the application of research.

Disclosure statement

No potential conflict of interest was reported by the authors.

ORCID

Bilal Ahmad http://orcid.org/0000-0003-0113-4169

Michael E. Fitzpatrick http://orcid.org/0000-0002-3618-6594

Hua Guo http://orcid.org/0000-0002-9691-9622