A computationally efficient thermo-mechanical model with temporal acceleration for prediction of residual stresses and deformations in WAAM

ABSTRACT

The present paper introduces a novel temporal acceleration strategy for computationally efficient prediction of residual stresses and deformations in wire arc additive manufacturing (WAAM) components. It employs a semi-analytical approach, dividing temperature into the analytical and the complementary fields. The analytical field is obtained by a closed-form solution, and the complementary field is employed to solve the boundary conditions. A temporal acceleration factor for the heating period is applied. Meanwhile, the diffusion time in the analytical field is manipulated to guarantee accurate temperature prediction. Validation via WAAM experiments, including both a thin-wall structure and a practical engineering component with characteristic dimensions on the order of metres, indicates that the predicted stresses is 50 MPa lower than the experimental values. Moreover, the discrepancy of between the predicted deformations and the experimental measurements is less than 10%, demonstrating reasonable accuracy can be achieved with attractive computational efficiency.

KEYWORDS:

• Wire arc additive manufacturing
• process modelling
• thermo-mechanical model
• residual stresses and deformations

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability

The raw/processed data required to reproduce these findings is available from the corresponding authors on reasonable request.

Additional information

Funding

Y. Yang is sponsored by National Natural Science Foundation of China (Grant Number 52105421) and Guangdong Provincial Natural Science Foundation (Grant Number 2022A1515011621). Q. Li is sponsored by Beijing Nova Program (Grant Number 20230484294) and Young Elite Scientist Sponsorship Program by CAST (Grant Number 2019QNRC001).