The qualitative analysis of warpage on residual stresses in wire arc additive manufacturing

Additive manufacturing (AM) is a fabrication method of parts and components, layer by layer, using a suitable high-density heat source. This process concedes to the user in fabricating the parts or components directly from a digital file. The application of high heat energy and a complex thermal cycle led to residual stresses during the fabrication. Generally, the top layer of the walls experiences tensile stresses, and this stress field provides a suitable environment for crack propagation in the components. The cracks inside the components deteriorate the functional life and quality of products. ER70S-6 commonly used welding wire as feedstock materials in wire arc additive manufacturing (WAAM) for structural application. Generally, maximum tensile stresses in the layers are limited to yield strength. These stresses cause bending distortion in the assembly, leading to warpage. The warpage and hardness have a direct relation with residual stresses. The compressive stresses in the parts have more hardness than the parts with a tensile residual stress field. The assembly warped due to the redistribution of the stress field. This article proposes a new deposition technique for reducing residual stresses in the in-situ condition. In addition, this novel deposition technique shall use to conduct a qualitative analysis of mitigation staregy for warpage in situ-state. Copyright (C) 2022 Elsevier Ltd. All rights reserved.