Abstract
Wire + arc additive manufacturing components contain significant residual stresses, which manifest in distortion. High-pressure rolling was applied to each layer of a linear Ti–6Al–4V wire + arc additive manufacturing component in between deposition passes. In rolled specimens, out-of-plane distortion was more than halved; a change in the deposits' geometry due to plastic deformation was observed and process repeatability was increased. The Contour method of residual stresses measurements showed that although the specimens still exhibited tensile stresses (up to 500 MPa), their magnitude was reduced by 60%, particularly at the interface between deposit and substrate. The results were validated with neutron diffraction measurements, which were in good agreement away from the baseplate.This paper is part of a Themed Issue on Measurement, modelling and mitigation of residual stress.
Highlights
Wire+arc additive manufacturing (WAAM) is a technique which utilises arc-welding processes, in combination with wire feeding, for additive manufacturing (AM) purposes.[1]
Tungsten inert gas or plasma processes can be used for titanium, aluminium and refractory metals;[2,3,4] and metal inert gas welding for aluminium and steel.[5,6,7]
Benefits of this AM technique include high deposition rates and lower cost of deposition compared to powder-based processes, greatly reduced lead times, and potentially limitless part size.[1]
Summary
Wire+arc additive manufacturing (WAAM) is a technique which utilises arc-welding processes, in combination with wire feeding, for additive manufacturing (AM) purposes.[1] Tungsten inert gas or plasma processes can be used for titanium, aluminium and refractory metals;[2,3,4] and metal inert gas welding for aluminium and steel.[5,6,7] Benefits of this AM technique include high deposition rates and lower cost of deposition compared to powder-based processes, greatly reduced lead times, and potentially limitless part size.[1]. WAAM components are affected by residual stress and distortion.[8] These two issues threaten to undermine the adoption of AM in industry; numerous projects are targeting their mitigation. When applied to the toes of a Global mechanical tensioning involves tensile loading of the weld;[11],[12] it could be done either during the welding process (in situ global mechanical tensioning (GMT))
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