Research on Temperature Field and Stress Evolution of 2319 Aluminum Alloy in Wire and Arc Additive Manufacturing

Athermal elastic plastic finite element method (FEM) for the wire and arc additive manufacturing (WAAM) of 2319 aluminum alloy was established. The instantaneous temperature field and the temperature gradient near fusion line were calculated, and the effects of processing parameters on the temperature field of melting pool were analyzed. The distribution rules of temperature field under different processing parameters were investigated, it was found that the increase in current and the decrease in substrate movement speed would cause the temperature gradient to increase. On the basis of temperature field calculation, the evolution and distribution rules of residual stress in WAAM were investigated by thermal elastic plastic finite element method. In the case of single⁃layer deposition, the longitudinal stress in the substrate was compressive stress, the inside of the deposited layer suffered tensile stress. The longitudinal stress was close to the von Mises stress in value; the maximum stress was in the middle part of the deposited layer. The stress distributions of the deposition layer under different processing parameters were investigated, and it was found that increasing the substrate moving speed could reduce the von Mises stress and longitudinal stress inside the deposition layer, while the current would increase the von Mises stress and longitudinal stress. Combined with the temperature field results, it could be found that the residual stress was positively associated with the temperature gradient in the molten pool. © 2023 Cailiao Daobaoshe/ Materials Review. All rights reserved.