Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel components
This research focusses on wire arc additive manufacturing (WAAM) of carbon steel components made of 3Dprint AM35 (grade S355) by cold metal transfer-based welding process. A finite element (FE) model is developed to simulate the deposition process, and the numerical results are rigorously validated...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-01-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127524009237 |
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| author | Xiongfeng Ruan Burak Karabulut Scott MacDonald Jelena Dobrić Barbara Rossi |
| author_facet | Xiongfeng Ruan Burak Karabulut Scott MacDonald Jelena Dobrić Barbara Rossi |
| author_sort | Xiongfeng Ruan |
| collection | DOAJ |
| description | This research focusses on wire arc additive manufacturing (WAAM) of carbon steel components made of 3Dprint AM35 (grade S355) by cold metal transfer-based welding process. A finite element (FE) model is developed to simulate the deposition process, and the numerical results are rigorously validated against experimental measurements, demonstrating that the temperature, deformation, and stress fields developing during the additive process can be reproduced accurately. The sensitivity of the FE model to ambient temperature, element activation strategies, alignment errors of thermocouples and strain gauges, and the use of a sequentially coupled approach is analysed. The effect of boundary conditions on the longitudinal and transverse residual stress patterns is studied, revealing that they are highly sensitive to the bolt pretension forces and substrate joining methods. However, they redistribute in a similar manner after the removal of the substrate. Guidance is provided to monitor the residual stress distribution in the fabricated component. |
| format | Article |
| id | doaj-art-06750f25f3f84f2b8d39f8966c372ae3 |
| institution | Kabale University |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj-art-06750f25f3f84f2b8d39f8966c372ae32025-01-09T06:12:22ZengElsevierMaterials & Design0264-12752025-01-01249113548Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel componentsXiongfeng Ruan0Burak Karabulut1Scott MacDonald2Jelena Dobrić3Barbara Rossi4KU Leuven, Faculty of Engineering Technology, Sint-Katelijne-Waver, Belgium; University of Oxford, Department of Engineering Science, Oxford, United Kingdom; Corresponding author.KU Leuven, Faculty of Engineering Technology, Sint-Katelijne-Waver, BelgiumWhittaker Engineering, Robotic Welding Engineering, Stonehaven, United KingdomUniversity of Belgrade, Faculty of Civil Engineering, Belgrade, SerbiaKU Leuven, Faculty of Engineering Technology, Sint-Katelijne-Waver, Belgium; University of Oxford, Department of Engineering Science, Oxford, United KingdomThis research focusses on wire arc additive manufacturing (WAAM) of carbon steel components made of 3Dprint AM35 (grade S355) by cold metal transfer-based welding process. A finite element (FE) model is developed to simulate the deposition process, and the numerical results are rigorously validated against experimental measurements, demonstrating that the temperature, deformation, and stress fields developing during the additive process can be reproduced accurately. The sensitivity of the FE model to ambient temperature, element activation strategies, alignment errors of thermocouples and strain gauges, and the use of a sequentially coupled approach is analysed. The effect of boundary conditions on the longitudinal and transverse residual stress patterns is studied, revealing that they are highly sensitive to the bolt pretension forces and substrate joining methods. However, they redistribute in a similar manner after the removal of the substrate. Guidance is provided to monitor the residual stress distribution in the fabricated component.http://www.sciencedirect.com/science/article/pii/S0264127524009237Wire arc additive manufacturing3Dprint AM35Numerical modellingResidual stress pattern |
| spellingShingle | Xiongfeng Ruan Burak Karabulut Scott MacDonald Jelena Dobrić Barbara Rossi Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel components Materials & Design Wire arc additive manufacturing 3Dprint AM35 Numerical modelling Residual stress pattern |
| title | Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel components |
| title_full | Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel components |
| title_fullStr | Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel components |
| title_full_unstemmed | Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel components |
| title_short | Effect of boundary conditions on residual stress in cold metal transfer-based wire arc additively manufactured steel components |
| title_sort | effect of boundary conditions on residual stress in cold metal transfer based wire arc additively manufactured steel components |
| topic | Wire arc additive manufacturing 3Dprint AM35 Numerical modelling Residual stress pattern |
| url | http://www.sciencedirect.com/science/article/pii/S0264127524009237 |
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